Assembly Sequence

Assembly sequence, 01V, 5 SPD. A/T (AWD)

Special tools, testers and auxiliary items required:

^ Adapters 3139/3
^ Alignment fixture 4W dr. shaft 3298
^ Alignment fixture 4W dr. shaft 3405
^ Torque wrench 550 Nm V.A.G. 1331
^ Torque wrench 40-200 NM V.A.G. 1332
^ Hex bolt M10x10010.9

Special tools, testers and auxiliary items required

Brake pedal depressor V.A.G. 1869/2:

Propshaft, removing and installing

Removing
^ Before removing, mark the positions of all parts in relation to each other. Re-install in the same position otherwise imbalance will be excessive, the bearings could be damaged causing rumbling noises.
^ Do not bend propshaft, only store and move when fully extended.
^ A twin pillar vehicle hoist should be used when working on the propshaft.
^ Remove rear part of exhaust system.





^ Remove heat shield - A - from vehicle floor.
^ Remove shielding plate - B - - arrows -.
^ Check whether there is a marking (colored marking) on propshaft and at flange/propshaft at rear final drive.





^ If this marking is not present, then mark in color the position of propshaft flange - arrow A - to rear final drive - arrow B -.

Vehicles with threaded hole in facing side of rear final drive





^ Screw hex bolt M10x10010.9 - 3 - into rear final drive.
^ To loosen bolts - 1 - for propshaft at front and rear, counterhold using a lever - 2 -.
^ Remove the three upper bolts on each propshaft constant velocity joint.

Vehicles without threaded hole in facing side of rear final drive
^ Lower vehicle.





^ Insert brake pedal depressor V.A.G. 1869/2.
^ Operate brake pedal using brake pedal depressor V.A.G. 1869/2.
^ Raise vehicle.
^ Remove lower three mounting bolts for each propshaft constant velocity joint.
^ Lower vehicle.
^ Remove brake pedal depressor V.A.G. 1869/2.
^ Raise vehicle.
^ Rotate both rear wheels in one direction and then rotate propshaft 12 (180°) additional turn.
^ Lower vehicle.
^ Insert brake pedal depressor V.A.G. 1869/2.
^ Engage the brake pedal using the brake pedal loading device.
^ Raise vehicle.

Continued for all vehicles

Propshaft with nominal dimension 60 mm at front and rear

When attaching and removing assembly tool, do not damage propshaft protective coating.

^ Do not set alignment fixture 4W dr. shaft 3405 on balance plates.





^ Attach alignment fixture 4W dr. shaft 3405 and tighten plastic nuts.

Propshaft with nominal dimension 60 mm at front and 70 mm at rear

When attaching and removing assembly tool, do not damage propshaft protective coating.

^ Do not set alignment fixture 4W dr. shaft 3298 on balance plates.





^ Attach alignment fixture 4W dr. shaft 3298 with adapters 3139/3 and tighten plastic nuts.

Propshaft with nominal dimension 60 mm at front and 65 mm at rear

When attaching and removing assembly tool, do not damage propshaft protective coating.





The reduced diameter - arrow - can be disregarded.

^ Do not set alignment fixture 4W dr. shaft 3298 on balance plates.
^ Attach alignment fixture 4W dr. shaft 3298 with adapters 3139/3 and tighten plastic nuts.

Continued for all vehicles
^ Remove the three remaining bolts from the front and rear constant velocity joints.





^ Remove securing nuts - arrows - for intermediate bearing and remove propshaft using alignment fixture.

Installing
Installation is performed in the reverse order of removal. Pay attention to the following:

Always replace securing bolts for propshaft.

^ Always remove any remaining locking fluid from thread bores in flanged shafts for transmission propshaft and for rear final drive. Cleaning can be performed using a thread tap.

Otherwise, the securing bolts can shear while screwing in.





^ Make sure that the markings on flange for propshaft - arrow A - and for transmission/rear final drive - arrow B - line up.

If a new propshaft is installed and the factory marking on the rear final flanged shaft is no longer visible, check radial run out at flange/propshaft.

^ Remove seals for propshaft at transmission/rear final flanged shaft.
^ Clean flange for transmission/rear final drive.

Sealing surface must be free of grease.

^ Pull off protective foil and apply seal.

Vehicles with threaded hole in facing side of rear final drive





^ Screw hex bolt M10x10010.9 - 3 - into rear final drive.
^ To tighten bolts - 1 - for propshaft at front and rear, counterhold using a lever - 2 -
^ Bolt intermediate bearing for propshaft firmly to body.
^ Remove alignment fixture.

Vehicles without threaded hole in facing side of rear final drive
^ Tighten lower three mounting bolts for each propshaft constant velocity joint.
^ Bolt intermediate bearing for propshaft firmly to body.
^ Remove alignment fixture.
^ Lower vehicle.





^ Remove brake pedal depressor V.A.G. 1869/2.
^ Raise vehicle.
^ Rotate both rear wheels in one direction and then rotate propshaft 12 (180°) additional turn.
^ Lower vehicle.
^ Operate brake pedal using brake pedal depressor V.A.G. 1869/2.
^ Raise vehicle.
^ Tighten lower three mounting bolts for each propshaft constant velocity joint.

Continued for all vehicles





^ Bolt shielding plate - B - firmly to transmission - arrows - to 25 Nm.
^ Install heat shield - A - to vehicle floor.
^ Install rear part of exhaust system.