Installing Front Drive Shaft

→ Wear personal protective gear.

→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).

Information 

• All screws and bolts on the axle must be tightened in vehicle position. Vehicle position means: vehicle resting on its wheels, or the wheel suspension is lifted with a universal jack  . -Dimension X from lower edge of wing to center of axle corresponds to vehicle position  . For the current height values, please refer to the adjustment values for suspension alignment → 4495TW ADJUSTMENT VALUES FOR SUSPENSION ALIGNMENT .
  Fig 1: Adjusting Dimension X Lower Edge Of Wing To Centre Of Axle

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• Visually inspect all parts  .
• Replace self-locking nuts  .
• Replace all expansion screws (screws fitted using torque angle tightening procedure)  .
• Use correct tightening torques and torque angle  . → 4X00IN TIGHTENING TORQUES FOR FRONT AXLE

Information 

• The spring strut screws are under tension. Carefully lever out the lower spring strut connection. Use a suitable lift with a rubber base  .
• Make sure not to damage the brake cover plate  .
  Fig 2: Adjusting Spring Strut Support

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Information 

• The pictures shown in this document may differ from the original  .

1. Grease the toothing with a little Optimoly TA aluminum paste and fit the drive shaft into the wheel bearing housing. When doing this, press the inner joint together tightly.

   One mechanic must carefully pull the upper wheel bearing housing out and turn the steering.

   The second mechanic must carefully insert the drive shaft.

   Information 

   • The drive shaft must be pulled in as far as it will go using the fitting tool T10206  .
     Fig 3: Identifying Fitting Tool T10206

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2. Pull the drive shaft into the wheel bearing housing.
3. Fit inner section of drive shaft on the transmission flange.
4. Fit fastening screws -1-  for securing drive shaft to transmission. → 4X00IN TIGHTENING TORQUES FOR FRONT AXLE
   Fig 4: Identifying Screws Of Drive Shaft To Transmission

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5. Grease the mounting-face ring of the axle nut with a little Optimoly TA aluminum paste. Fit the axle nuts to prevent the shaft from slipping out.
6. Counter with a screwdriver 9546  when tightening the ball joints if necessary.
7. Fit tie rod on the wheel bearing housing. → Installing Tie Rod
8. Fit ball joint of the upper trailing arm on the wheel bearing housing. → 401519 REMOVING AND INSTALLING UPPER TRAILING ARM (STEEL SPRINGS) 
9. Use a suitable jack -4-  to raise the trailing arm and remove spring tensioner VW 552 -1-  from the upper trailing arm -2-  .
   Fig 5: Securing Upper Trailing Arm

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10. Raise the axle support -1-  as far as required until the fastening screw -2-  slides easily through the spring strut -3-  and axle support.

    Tighten fastening screw. → Installing Lower Trailing Arm 

    Fig 6: Adjusting Spring Strut Threaded Joint

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11. Fit the brake disc. → Installing Front Brake Disc
12. Fit the brake calliper. → Installing Front Brake Calliper
13. Plug in electric plug connection -1-  for the speed sensor on the wheel bearing housing -A-  and lock it -a-  .
    Fig 7: Locating Electric Plug Connection For Speed Sensor

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14. Fit the holders -1, 2-  for the hydraulic lines on the wheel bearing housing -3-  .
    Fig 8: Identifying Mounting For Hydraulic Lines

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