Installing all-wheel final drive

Fig 1: Overview Of Front-Axle Final Drive

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CAUTION: Risk of damage to ATF lines and pressure line for power steering.

→ Protect ATF lines with water hose or similar.

→ The servo line must not be crushed or stretched.

Information

A second fitter is required for removing/installing the four-wheel final drive.

Swivel left flange of final drive in over the front-axle carrier.
Rotate drive flange upwards and install final drive through the front-axle carrier.

Fig 2: Installing All-Wheel Final Drive
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Insert right drive shaft into output flange and place final drive into the mounts on the front-axle carrier.

Fig 3: Installing All-Wheel Final Drive
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Fit left drive shaft by lifting the final drive output flange.

Fig 4: Fitting Left Drive Shaft
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Information
- The front right fastening screw for the four-wheel final drive -left arrow- can only be screwed in with the front-axle carrier lowered.
  
  Fig 5: Locating VAG Bolts
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Insert fastening screws -arrows- for all-wheel final drive and screw for drive flange.

Fig 6: Locating VAG Bolts
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Information
- Supports 1, 4 and 7 must be fitted to the unit lifting platform.
Raise front-axle carrier with unit lifting platform until it is touching the body. Connect vent line at the same time.
Information
- For details of tightening torques for running gear parts, see → WM 4000TW Tightening torques for front axle .
Screw in bolts -arrows- on front-axle carrier.

Fig 7: Locating Front-Axle Carrier Bolts
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Screw in bolt -arrow- connecting spring strut to trailing arm.

Fig 8: Locating Connecting Spring Strut To Trailing Arm Bolt
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Fit holders -arrow- for coolant pipes to the body.

Fig 9: Locating Coolant Pipe Holder
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Engage servo line in the three holders -arrows- on the front-axle carrier.

Fig 10: Locating Servo Line Holders
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Screw servo line holders -arrow- on to air-conditioning compressor and clip in the line.

Fig 11: Locating Air-Conditioning Compressor Holder
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Information
- Screws which are tightened with a torque angle must be replaced with new ones.
Tighten fastening screw for all-wheel final drive. → Initial tightening: 90 Nm (67 ft lbs.) → Final tightening: 90°
Information
- For details of tightening torques for running gear parts, see → WM 4000TW Tightening torques for front axle .
Screw in drive shaft screws.
Connect steering column to steering gear. Screw in new screw.

Fig 12: Locating Steering Column Mounting
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Install cover plate on the steering.

Fig 13: Locating Steering Cover Plate Mounting Bolts
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Connect Servotronic plug to the steering gear.
Remove special tool spring compressor VW 552 from the spring strut.

Fig 14: Locating Installation Position Of Spring Compressor
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Screw in plastic nuts -arrows- on front right wheel housing liner.

Fig 15: Locating Wheel Housing Liner Mount
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Remove steering-wheel holder -figure- .

Fig 16: Supporting Steering Wheel Using Holder
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Information
- For details of tightening torques for running gear parts, see → WM 4000TW Tightening torques for front axle .
Tighten bolts -arrows- on front-axle carrier.

Fig 17: Locating Front-Axle Carrier Bolts
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