Driveshaft, Installing

Install in reverse order of removal. Note the following:

• Tightening specifications. Refer to OVERVIEW - DRIVESHAFT .

• Remove any old, dry high-temperature grease from the CV joint and the driveshaft flange. Fill with the exact same amount of new high temperature grease.
• The M8 bolts threaded hole in the flange shaft on the rear final drive must be cleaned of locking fluid residue. They can be cleaned with a thread tap. If the threads are not clean, the bolts will break off when they are being installed.
• Always replace the bolts for the driveshaft and the three backing plates.
• Wipe the splines on the all-wheel drive clutch output shaft with a towel before installing the driveshaft. The splines are not lubricated.
• Replace the clamps -1- for the driveshaft boot -2-.

-- First mount the driveshaft on the transmission.

• Maximum bend angle when positioning: 10°.
• After the driveshaft is inserted approximately 50 mm into the all-wheel drive clutch output shaft, turn the driveshaft slightly to make sure that the all-wheel drive clutch output shaft splines are meshed into the inner splines of the driveshaft.
• Push the driveshaft all the way onto the splines of the all-wheel drive clutch output shaft.

-- Attach the driveshaft intermediate bearing to the body so that it is free of tension -arrows-.

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-- Replace the driveshaft flange seal for the driveshaft.

-- Position the driveshaft on the rear final drive while paying attention to the installation position:

• The marks on the driveshaft -arrow A- and on the rear final drive -arrow B- must line up.
• Maximum difference between the markings: 30°.

-- Install all six driveshaft bolts -1- by hand two to three turns.

• Tighten the driveshaft bolts -1- according to the tightening sequence. Refer to Figure.

-- Line up the clamp -1- for the driveshaft boot with the retainers -2- and then tighten the clamp using for example the Hose Clamp Pliers :V.A.G 1275A  .

Tip:

• In order to position the Hose Clip Pliers :V.A.G 1275A  correctly, move the driveshaft a little toward the rear.

-- Tighten the heat shield -1- to the transmission -arrows-.

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-- Install the heat shield -1-. Refer to COMPONENT LOCATION OVERVIEW - HEAT SHIELD .

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-- Install the exhaust system and align it without tension. Refer to OVERVIEW - MUFFLER (4 CYL) , or OVERVIEW - MUFFLER (6 CYL) .

-- Install the crossmember -1-. Refer to TUNNEL BRACE, REMOVING AND INSTALLING .

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