3.0L TDI

Front Final Drive

Special tools, testers and auxiliary items required

• Engine Support Bridge (10 - 222 A)

• Adapter (10 - 222 A /22)

• Lifting Tackle (3033)

• Hose Clamps Up to 25 mm Dia. (3094)

• Engine-/Gearbox Jack (V.A.G 1383 A)

• Engine Bung Set (VAS 6122)

Removing

Do not remove the bolts for the transmission support - 1 - or the bolts for the engine support - 3 - when performing the following work.








- Activate the vehicle lift mode in vehicles with air suspension.

- Remove the left and right front wheel housing liners..

- Remove both front wheels.






- Remove the bolts and the front - 1 - and rear - 2 - noise insulation.

- Remove the noise insulation bracket - arrows -.






- If equipped, remove the heat shield - arrows - on the right side from the front final drive.






- Remove the front driveshaft. Refer to => [ Front Driveshaft ] Front Driveshaft.

- Disconnect the drive axle from the front final drive.

- Disconnect the connector - arrow - from the steering gear.






- Remove the heat shield - A - from the steering gear.






• Only remove universal joint from steering gear with front wheels in straight ahead position.

• Do not change steering wheel position and steering gear position.

- Remove the bolt - B - for the universal joint.

- Press the universal joint off of the steering gear.

- Free up the coolant hoses - arrow -.






- Remove the left and right hood seal - 1 - - arrow -.






Vehicles Equipped with a 3.0L TDI Engine:

- Mount the (10 - 222 A) on the fender bolting edges, as illustrated.






• The spindles for the (3033) are in the back.

- Attach the spindle carabiner hooks to the rear engine lifting eyes.

- Tension the engine slightly so that all of the spindles are exert an even pull in order to achieve a balanced weight distribution.

• Place a cloth under the separation point to catch any hydraulic fluid dripping out.

- Remove the hydraulic hose - 1 - for power steering pump hydraulic hose (3094).






- Remove the bolts - 2 - and remove the hydraulic lines from the power steering pump.

- Close the open lines and connections with clean plugs taken from the (VAS 6122).

- Place the (V.A.G 1383 A) underneath the subframe.






Do not remove the bolts for the transmission support - 1 - or the bolts for the engine support - 3 - when performing the following work.








In order to avoid having to align the axles later on, the subframe must be secured using the locating pins (T10300).

- Use the (T10300) to secure the subframe.

- With the subframe supported, remove the bolts - 2 - and - 4 - diagonally in stages.

- Lower the subframe and front final drive using the (V.A.G 1383 A) by dimension - a -.






• Dimension - a - = 200 mm.

• If necessary, pull the subframe down a little bit, and in some cases it maybe necessary to remove the subframe.

- Remove the threaded connectors - 1, 2, 3 - that connect to the front final drive - A -/subframe - B -.






• A second technician is required for removing the front final drive.

Remove the front final drive - 1 - between the subframe and engine/transmission assembly toward the rear as follows:






- Secure the left drive axle up high enough so that it is out of the way.

- Together with the second technician, remove the front final drive from its mounts on the subframe by guiding the drives axle on the right side out of the flange shaft.

- Lift the front final drive up over the steering gear and guide it out the rear.

Installing

Install in reverse order of removal. Note the following:

• Tightening specifications, refer to => [ Front Final Drive Overview ] Front Final Drive Overview.

• A second technician is required for installing the front final drive into the subframe mounts.

- Install the threaded connectors - 1, 2, 3 - that connect to the front final drive - A -/subframe - B -.






- Use the (V.A.G 1383 A) to position the subframe and align the longitudinal members according to the markings that were made during removal.






- Tighten the subframe bolts, engine support and transmission support only to tightening specification, do not continue tightening past this specification (do not tighten down bolts until the alignment has been carried out).

Do not drive the vehicle in this condition.

- Bolt the front driveshaft to the front final drive. Refer to => [ Front Driveshaft ] Front Driveshaft.

- Install the universal joint on the steering gear.

- Install the coupling rods.

- Install the power steering hydraulic line.

- Fill the power steering fluid reservoir with hydraulic fluid before the engine is started for the first time.

- Install the front wheels.

- Carry out an axle alignment.

Danger of an accident occurring if bolted connections are loose.

• After the axle alignment has been carried out, bring the subframe bolts to final specification.

- Deactivate the vehicle lift mode using a vehicle with air suspension.