Universal Joint: Service and Repair

Rear Flexible Disc

• Beginning 07.07 a one piece driveshaft, which can no longer be separated in the center, is being installed.

Special tools, testers and auxiliary items required

• Torque wrench (V.A.G 1331)

• Torque wrench (V.A.G 1332)

• Engine and transmission jack (V.A.G 1383 A ) with universal transmission adapter (V.A.G 1359/2 )

Removing

• A twin post hoist should be used when working on the driveshaft.

• Before removing, mark the positions of all parts in relation to each other. Reinstall in the same position otherwise imbalance will be excessive, the bearings could be damaged causing rumbling noises.

• Do not kink the driveshaft, only store and move when fully extended.

- Remove the tunnel brace.

- Detach rear muffler on retaining loops and remove rear part of exhaust system.

- Remove the heat shield - arrows - below the driveshaft.





- Support the driveshaft in the area of the rear driveshaft tube with the engine and transmission jack (V.A.G 1383 A) and a block of wood - A -.

- Secure driveshaft against falling down with strap from the universal transmission support (V.A.G 1359/2).

- Check whether there is a marking (colored dot) on the driveshaft and rear final drive flange - arrows -. If not, mark the position of the driveshaft flexible disc to the rear final drive flange - arrows -.





- Remove rear driveshaft flexible disc bolts - arrows - from the rear final drive.





- Remove the driveshaft intermediate bearing bolts - arrows - from the vehicle.





- Remove the rear driveshaft from the rear final drive flange.

• If the rear driveshaft tube cannot be removed from the centering pins, remove the pendulum support from the transmission. To do this, remove bolts - 2 - and - 3 - and press the engine transmission assembly forward slightly toward the front end.





• Do not tilt the driveshaft when removing, pull off from centering pin in a horizontal position. Sealing ring in centering bushing - arrow - must not be damaged.





• Flexible disc and vibration dampener cannot be separated from each other.

Remove the rear flexible disc bolts - arrows - and disc from the rear driveshaft tube.





Installing

Install in reverse sequence; note the following points:

• Sealing rings in the driveshaft flanges - arrow - must not be damaged when removing and installing.





• Replace driveshaft if damaged.

• Do not tip rear driveshaft tube, push horizontally onto centering pins.

• Install all driveshaft parts marked in relation to each other in same position when reinstalling.

Location of flexible disc with vibration damper:





• Brace on outer diameter - arrows - faces away from driveshaft tube.

• Three projecting sleeves each on the rear final drive flange engage in the driveshaft flexible disc mounting holes.

- Install the driveshaft flexible disc to the rear final drive flange so the markings - arrows - align.





Install the Intermediate Bearing without Tension

• Tightening specifications, refer to => [ Tightening Specifications ] .

- Align the intermediate bearing in its elongated holes so the driveshaft or bearing is not under stress.

- Tighten intermediate bearing after tightening driveshaft.

- If the pendulum support has been removed, install it on the transmission with new bolts - 2 - and - 3 -.





- Install the exhaust system and align it without tension.

• If droning noises are audible while driving, do the following:

• Remove balance nut and balance washer - arrows -.





• Then, if necessary, remove driveshaft flexible disc from rear final drive flange and rotate one hole and reinstall.

• If droning noises are still heard, driveshaft must be bolted on again, offset by one more hole.

Tightening Specifications