Front Final Drive

Special tools and workshop equipment required

Engine support bridge10-222 A
Spindle10-222 A/10
Supports10-222 A/19
Engine Sling2024 A with Bracket2024 A/1
Engine/transmission jackV.A.G 1383 A
BracketT10014
Counterhold toolT10172 with adaptersT10172/6
Engine Support Basic SetT40091
Engine Support Supplement SetT40093

Removing

-- On vehicles with air suspension, activate vehicle lifting mode. Refer to VEHICLE LIFT MODE .

-- Remove left and right front wheel housing liners. Refer to FRONT WHEEL HOUSING LINERS, REMOVING AND INSTALLING .

Vehicles with 4.2L FSI engine:

-- Remove left and right air filter housing. Refer to [For engine(s) BHK] Removal and Installation .

Vehicles with TDI engine:

-- Remove air filter housing. Refer to [For engine(s) CNRB] Removal and Installation .

All:

-- Remove both front wheels.

-- Remove screws and remove front -1- and rear -2- noise insulation.

Fig 1: Identifying Front/Rear Noise Insulation

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-- Remove noise insulation bracket -arrows-.

Fig 2: Identifying Bracket For Noise Insulation

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-- Remove left and right coupling rods from stabilizer bar -arrow-.

Fig 3: Identifying Nut -Arrows- Securing Coupling Rod

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

Fig 4: Identifying Heat Shield Bolts -Arrows- And Shield

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-- Check whether there is a factory marking (colored marking) on front driveshaft and at driveshaft flange. If not, identify position of driveshaft CV joint -arrow A- to driveshaft flange at front final drive -arrow B- with paint.

Fig 5: Identifying Mark On Driveshaft Flange & Front Final Drive

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-- Remove bolts -1- at front final drive/front driveshaft connection.

Fig 6: Identifying Removal Of Bolts -1- From Front Output Drive/Front Driveshaft Connection

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-- Use counterhold toolT10172 with the adaptersT10172/6 to do this.

-- Slide front driveshaft together with transfer case; CV joints can be moved axially.

-- Remove drive axle from front final drive. Refer to DRIVE AXLE .

-- Disconnect electrical connector -arrow- at steering gear.

Fig 7: Identifying Electrical Connector And Heat Shield

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

Fig 8: Identifying Universal Joint Bolt

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CAUTION:

Only disconnect universal joint from steering gear if front wheels are in straight-ahead position.
Do not change steering wheel position and steering gear position any more.

-- Remove universal joint bolt -B-..

-- Press universal joint off of steering gear.

Vehicles with TDI engine:

Fig 9: Identifying Bracket For Hydraulic Lines & Pressure Line And Return Line

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-- Remove hydraulic line bracket bolt -1-.

-- Remove hydraulic lines -2- from steering gear.

Vehicles with 4.2L FSI engine:

-- Disengage power steering hydraulic line from bracket at left of engine.

All:

-- Remove nuts and bolts on refrigerant lines retaining clamp -arrows-.

Fig 10: Identifying Coolant Line Retaining Clamp Nuts And Bolts -Arrows-

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NOTE:

When connections are loosened, coolant lines may be moved aside slightly to position the Supports10-222 A/19 on the longmembers.

Vehicles with 4.2L FSI engine:

-- Remove rear engine cover -arrows-.

Fig 11: Pulling Rear Engine Cover

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-- Remove front engine cover -arrows-.

Fig 12: Identifying Front Engine Cover, Electrical Connector, And Left Air Guide Hose

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-- Position Engine Support Bridge10-222 A with Adapters10-222 A/22 and ConnectorsT40091/3 on bolted fender flanges.

Fig 13: Identifying 10 - 222 A With 10 - 222 A /22 And T40091/3

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-- Install additional Engine Support Bridge10-222 A parts as illustrated. Position Supports10-222 A/19 on notches in longmembers.

Fig 14: Engaging 10 - 222 A /10 In Rear Engine Lifting Eyes

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-- Engage hooks on both short Spindles10-222 A/10 at engine lifting eyes.

-- Slide SupportT40091/2 with both SlidesT40093/5 into both SupportsT40093/4.

Fig 15: Sliding T40091/2 With Both Slides T40093/5 Into Both T40093/4

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-- Install long spindles from Engine Support Bridge10-222 A and engage spindle hooks at both front engine lifting eyes.

CAUTION:

Secure SupportT40091/2 with ConnectorT40093/4 pins and splints.

-- Raise engine slightly by tensioning all spindles evenly in order to achieve even weight distribution.

Vehicles with 3.0L TDI engine:

-- Carefully pull engine cover -arrows- off 4 retaining pins one after the other.

Fig 16: Removing Engine Cover From Retaining Pins In Succession

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NOTE:

Before removing ribbed belt, identify running direction with chalk or felt-tip pen. Reversed running direction on a used ribbed belt can lead to destruction.

Fig 17: Rotate The Belt Tensioner In The -Direction Of The Arrow

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-- To release tension from ribbed belt, swing tensioner in direction of -arrow-. Use a lever with TORX 60 socket to do this.

-- Remove ribbed belt from tensioning roller.

-- Remove bolts -arrows- and remove ribbed belt tensioner.

Fig 18: Identifying Bolt -1 And 2- To Ribbed Belt Tensioning Element

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-- Install Engine SupportT10014 in ribbed belt tensioner securing holes.

Fig 19: Identifying Engine Support T10014

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-- Position Engine Support Bridge10-222 A with ConnectorsT40091/3 and 2 spindles on bolted fender flanges.

Fig 20: Identifying Engine Support Bridge 10-222A And Movable Joints T40091/3

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Spindles are at front.

-- Engage both spindles at both engine rear lifting eyes.

-- Install additional Engine Support Bridge10-222 A parts as illustrated. Position Supports10-222 A/19 on notches in longmembers.

Fig 21: Identifying Rail With Holes T40091/2, Mounts T40093/5 And Movable Joints T40093/4

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-- Slide SupportT40091/2 with SlideT40093/5 into both ConnectorsT40093/4.

CAUTION:

Secure SupportT40091/2 with ConnectorT40093/4 pins and splints.

-- Remove Engine Sling2024 A eyes.

Fig 22: Identifying Engine Sling 2024A And Bracket 2024A/1

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-- Re-insert bolts -1- in middle engine sling hole and secure with a spring clip.

-- Engage engine sling pins in front engine support bridge spindle.

-- Install Bracket2024 A/1 at left side of engine sling.

-- Engage Engine Sling2024 A at right front engine lifting eye and at Engine SupportT10014.

CAUTION:

Mounting hooks and connecting pins on engine sling must be secured with plug connectors -arrows-.

-- Raise engine slightly by tensioning all spindles evenly in order to achieve even weight distribution.

All:

-- Position Engine/Transmission JackV.A.G 1383 A at bottom of subframe and lay wooden support -A- under subframe and wooden support -B- under front final drive.

Fig 23: Placing Engine/Transmission Jack V.A.G 1383 A With Universal Transmission Adapter 1359/2 Under Subframe And Lightly Press Against It

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CAUTION:

Transmission bracket bolts -1- and engine bracket bolts -3- must not be removed for the following steps.

Fig 24: Identifying Bolts -4- And Engine Carrier Bolts -3-

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CAUTION:

To avoid axle alignment later, subframe must be secured with Locating PinsT10300.

-- Secure subframe with Locating PinsT10300. Refer to SUBFRAME, SECURING .

-- With subframe supported, remove bolts -4-.

-- Lower subframe with front final drive by dimension -a- using Engine/Transmission JackV.A.G 1383 A.

Fig 25: Lifting Engine/Transmission Subassembly Using Scissor Lift Platform VAS 6131 Until Dimension Is Reached

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Dimension -a- = 200 mm.

NOTE:

If necessary, pull subframe down slightly.

-- Remove threaded connections -1 to 3- for front final drive -A- /subframe -B-.

Fig 26: Identifying Removal/Installation Of Bolts With Nuts For Front Final Drive On Subframe

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NOTE:

A 2nd technician is needed to remove the front final drive.

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

Fig 27: Identifying Removal Of Front Final Drive Toward Rear Between Subframe And Engine/Transmission

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-- Put left driveshaft up.

-- Have 2nd technician remove front final drive from mounts in subframe while guiding right driveshaft out of flange shaft.

-- Raise front final drive over steering gear and guide it back and out.

-- Refer to FRONT FINAL DRIVE .

Install in reverse order, paying attention to the following:

NOTE:

A 2nd technician is needed to insert front final drive in subframe mounts.

-- Install threaded connections -1 to 3- for front final drive -A- /subframe -B-.

Fig 28: Identifying Removal/Installation Of Bolts With Nuts For Front Final Drive On Subframe

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-- Install subframe. Refer to SUBFRAME, REMOVING AND INSTALLING .

-- Attach front driveshaft to front final drive. Refer to FRONT DRIVESHAFT .

-- If equipped, fasten right heat shield to front final drive with locking fluidD 154 100 A1 -arrows-.

Fig 29: Identifying Heat Shield Bolts -Arrows- And Shield

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-- Install universal joint on steering gear. Refer to STEERING GEAR .

-- Install hydraulic lines at steering gear. Refer to STEERING GEAR .

-- Attach coupling rods to stabilizer at left and right. Refer to SUBFRAME, STABILIZER BAR AND COUPLING ROD .

Vehicles with 3.0L TDI engine:

-- Install ribbed belt tensioner. Refer to [For engine(s) BAR] Removal and Installation .

All:

-- On vehicles with air suspension, deactivate the lift mode. Refer to VEHICLE LIFT MODE .

Tightening Specifications

NOTE:

The torque specifications apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts.

Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.

Do not use degreased parts.

Tolerance for torque specification ± 15%.

Component		Nm
Bolts/nuts	M6	9
	M8	20
	M10	40
	M12	65
Except for the following:
Front final drive to subframe		90 + 90° ¹⁾²⁾
¹⁾ Replace bolts. ²⁾ 90° correspond to a quarter turn.