Front Final Drive
Front Final Drive
Special tools, testers and auxiliary items required
• Tensioner Hooks (VW 552)
• Spindle (10-222 A/11)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Bits (T10099)
Removing
- Loosen the wheel bolts.
- Lift the vehicle.
- Remove the front wheels.
- Remove the left and right front wheel housing liners.
- If the vehicle has air spring dampers installed, loosen the connection for the air line - 1 - and let the air out. Retighten the connection to specification.
- Install the tensioner hooks (VW 552) in the upper opening in the wheel housing - arrow A - on both sides of the vehicle and into the upper control arm - arrow B -.
- Lightly tension the control arm so that the ball stud in the ball joint does not get damaged.
- Remove the noise insulation underneath the engine and transmission.
- Remove the underbody trim under the front final drive, if equipped.
- Remove the bracket for the noise insulation.
- Remove the front driveshaft. Refer to => [ Front Driveshaft ] Front Driveshaft.
- Remove the heat shield bolts - arrows - and heat shield from the front final drive.
- Remove the right and left drive axles. Use the bit (T10099/1) to loosen the bolts.
- Remove the 2 steering gear heat shield bolts and shield - A - from the steering gear, if equipped.
- Remove the universal joint to steering gear bolt - B - and then remove the universal joint from the steering gear.
- Remove the coolant pipes - 1 - from the left longitudinal member, if equipped. Remove the nut - arrow A - and the bracket - arrow B -.
With a V6 TDI Engine:
- Remove the pressure line - 1 - from the bracket on the cylinder head in order to loosen the bolt - arrow -.
Tightening specification: 20 Nm
Continuation for all Vehicles:
- Install the spindle (10-222 A/11) into the lifting eyes - arrow - on the subframe on both the left and right sides of the vehicle.
- Insert a block of wood - A -, approximately 300 mm long, into the spindle (10-222 A/11) bracket.
- The bracket must face toward the rear.
- Tighten the wing nuts on the spindle. While doing this, the wood blocks must be supported on the subframe - B -.
- Mount a floor jack to the engine-/gearbox jack (V.A.G 1383 A).
- Position the engine-/gearbox jack (V.A.G 1383 A) under the subframe and lightly press against it.
A Wood block
- Remove one of the rear bolts - arrow - for the subframe.
- Secure the subframe.
- Remove the subframe bolts - arrows -.
- Remove the left and right coupling rods - 1 - from the stabilizer bar.
- Remove the threaded connection on the air spring damper or the strut from the lower control arm. Lower the subframe approximately 50 mm using the spindle (10-222 A/11) in the - direction of the arrow - to remove the bolt - 2 -.
- Install two M14 x 1.5 x 90 bolts - 3 -, for example bolts (N 104 281 01) , to secure the subframe to the underbody on the left and right sides.
- Remove the engine-/gearbox jack (V.A.G 1383 A) from under the subframe.
- Place the engine-/gearbox jack (V.A.G 1383 A) along with the universal transmission support (1359/2) under the subframe and press against it lightly. Place the wood blocks - A and B - underneath the subframe - A - and under the front final drive - B -.
- Secure the subframe using the belt from the universal transmission support (V.A.G 1359/2).
- Remove the spindle (10-222 A/11) from the subframe.
- Carefully lower the subframe and the front final drive to approximately 200 mm - a -.
- Measure dimension - a - between the body and the bolting surface on the subframe.
- Remove the bolts and the nuts - 1 through 3 - that attach the front final drive - A - to the subframe - B -.
A second technician will be needed in order to remove the front final drive.
- Remove the front final drive - 1 - toward the rear between the subframe and the engine/transmission:
- Tie up the left drive axle first.
- The second technician can then remove the front final drive from the mounts inside the subframe.
- Guide the right drive axle out of the flange shaft.
- Lift the front final drive over the steering gear and guide it out toward the rear.
Installing
Installation is performed in the reverse order of removal while observing the following:
A second technician will be needed to install the front final drive back into the mounts on the subframe.
- Install the bolts and nuts - 1 through 3 - that connect the front final drive - A - to the subframe - B -.
- Attach the drive axles to the flange shafts.
- Install the front driveshaft. Refer to => [ Front Driveshaft ] Front Driveshaft.
- Remove the tensioner hooks (VW 552).
- Install the left and right front wheel housing liners..
- Check the front final drive gear oil level, add as necessary. Refer to => [ Front Final Drive Gear Oil Level, Checking ] Front Final Drive Gear Oil Level, Checking.
- Install the underbody trim under the front final drive, if equipped.
- Install the front wheels.
- Perform a vehicle alignment after the installation is complete.