Rear Final Drive

Short Description

-- Prior to removal, print out a diagnostic protocol. Send back the removed final drive with the protocol in usual manner.

Before raising the vehicle, two holes must be made in the luggage compartment floor. The locations for drilling are marked "at the factory". These holes allow access to the final drive/subframe bolts located below.

The pendulum support is unbolted from the transmission at the front. The stabilizer bar is removed, the drive axles are disconnected from the final drive. Electrical connections and ventilation lines are disconnect from the final drive.

The rear section of the exhaust system is removed. Remove the driveshaft from the final drive, move it to the top and secure it there.

The final drive is lowered using the engine-/gearbox jack downward, diagonally in the direction of travel.

Removing

Special tools and workshop equipment required

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
Tensioning Strap T10038
Hand Drill
Stepped Drill Bit or Cone Drill Bit
Protective Eyewear

-- Raise the floor covering in the luggage compartment.

-- Remove the spare wheel.

Now, you have access to the marks -1- in the luggage compartment floor.

Fig 1: Identifying Luggage Compartment Floor Marks

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The -arrow- points in the direction of travel.

-- Drill 2 holes -1- on the marks to 26 mm -a-. Remove any drill shavings while drilling, if possible.

Fig 2: Identifying Luggage Compartment Floor Holes

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-- Deburr the holes and remove any shavings carefully.

Reestablish the corrosion protection with the materials specified by the manufacturer. Refer to Body Collision Repair.

-- Loosen and remove both bolts -1-.

Fig 3: Identifying Luggage Compartment Floor Holes

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You must replace these bolts later.

-- Lift the vehicle.

-- Remove the stabilizer bar. Refer to Removal and Installation .

-- Support the front exhaust pipe -A- using the tensioning strap T10038 on the driveshaft intermediate bearing.

Fig 4: Supporting Front Exhaust Pipe Using Tensioning Strap T10038 On Intermediate Bearing

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-- Remove the exhaust pipe bracket bolt -arrow- and bracket from the subframe.

Fig 5: Identifying Exhaust Pipe Bracket Bolt

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-- Disconnect the exhaust system at the clamping sleeve -arrows- and remove the rear exhaust system. Refer to [For transmission(s) 0A6, 09M] Description and Operation .

Fig 6: Disconnecting Exhaust System At Double Clamp

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-- Remove the noise insulation below the engine/transmission. Refer to Description and Operation

-- Remove the pendulum support bolts -1 and 2-.

Fig 7: Identifying Pendulum Support Bolts

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In order not to damage the left rear level control system sensor:

-- Disconnect the harness connector, remove the sensor -1- and lay it on the control arm -A-.

Fig 8: Identifying Control System Sensor & Control Arm

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-- Loosen but do not remove the driveshaft intermediate bearing bolts -arrows-.

Fig 9: Locating Center Bracket Screws

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-- Press the engine and transmission forward by hand and secure in this position with a suitable piece of wood -A-.

Fig 10: Identifying Wooden Block

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So that noises due to imbalance do not occur later:

-- See if there are marks (colored dots) on the driveshaft flexible disc and rear final drive input flange -arrows-. If not, mark the position of the driveshaft flexible disc and rear final drive input flange with respect to one another -arrows-.

Fig 11: Aligning Markings On Driveshaft At Flange Of Haldex Clutch

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-- Remove the driveshaft flexible disc to input flange bolts -arrows-.

Fig 12: Identifying Rear Driveshaft Tube At Rear Final Drive With Joint Washer And Vibration Damper

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-- Remove the driveshaft from the final drive, and guide it upward in the center until it is under the fuel tank -2-. In this position, support it on the tunnel brace -1- using a suitable piece of wood.

Fig 13: Guiding Driveshaft Upward And Support It In Position With Suitable Piece Of Wood On Tunnel Support

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CAUTION:

When doing this, be careful not to push in the fuel tank -2-.

When removing and installing the drive axles, the final drive must be moveable in the rear area.

-- To do this, loosen the bolt -arrow- on the front mounting bracket no more than 5 turns.

Fig 14: Identifying Screw From Front Final Drive Bracket

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-- Disconnect the left drive axle from the final drive.

-- Lift the final drive -A- in the rear -arrow 1- and push it as far as possible to the right -arrow 2-.

Fig 15: Lifting Final Drive In Rear And Pushing It As Far Right As Possible

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-- Remove the left drive axle -B- from the flange and carefully lower it.

-- Put the final drive back into its installed position.

-- Disconnect the right drive axle from the final drive.

-- Lift the final drive -A- in the rear -arrow 1- and push it as far as possible to the left -arrow 2-.

Fig 16: Lifting Final Drive In Rear And Pushing It As Far As Possible To The Left

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-- Remove the right drive axle -B- from the flange and carefully lower it.

-- Put the final drive back into its installed position.

-- Support the final drive using the engine-/gearbox jack V.A.G 1383 A and secure it using the universal support with the strap to keep it from falling.

-- Remove the bolt -arrow- at the front mounting bracket.

Fig 17: Identifying Screw From Front Final Drive Bracket

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You must replace this bolt later.

-- Remove the washer -C- on top of the mounting bracket.

Fig 18: Identifying Wood Block Place On Universal Support And Supporting Final Drive With Engine And Transmission Jack V.A.G 1383 A

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-- Position the final drive in the vehicle on an angle as shown in the illustration while lowering it at the same time.

Fig 19: Positioning Final Drive In Vehicle On An Angle

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-- Disconnect the harness connector -A- from the all wheel drive control module.

Fig 20: Identifying Ventilation Lines At Final Drive And All-Wheel Drive Control Module J492 Connector

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-- Remove the vent lines -arrows- from the final drive.

-- To remove, lower the final drive more and pull it forward, while ensuring that there is sufficient clearance with respect to other components.

Installing

-- Secure the final drive with the universal support strap to prevent it from falling.

-- Move the final drive to the illustrated position.

Fig 21: Positioning Final Drive In Vehicle On An Angle

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-- Lift the final drive, and move the rear bushings -arrows- above the subframe while ensuring sufficient clearance with respect to the other components.

Fig 22: Identifying Final Drive Rear Bushings

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-- Connect the connector -A- to the all wheel drive control module.

Fig 23: Identifying Ventilation Lines At Final Drive And All-Wheel Drive Control Module J492 Connector

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-- Slide the vent lines -arrows- onto the final drive vent tubes.

-- Lift the final drive using the engine-/gearbox jack into the installed position.

-- Place the washer -C- on the front mounting bracket.

Fig 24: Identifying Wood Block Place On Universal Support And Supporting Final Drive With Engine And Transmission Jack V.A.G 1383 A

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When installing the drive axles, the final drive must be moveable in the rear area.

-- Install the front bolt by hand, do not tighten it more than 5 turns.

Fig 25: Identifying Screw From Front Final Drive Bracket

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-- Remove the engine-/gearrbox jack from under the vehicle.

-- Lift the final drive -A- in the rear -arrow 1- and push it as far as possible to the left -arrow 2-.

Fig 26: Lifting Final Drive In Rear And Pushing It As Far As Possible To The Left

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-- Carefully guide the right drive axle -B- upward into the flange.

-- Put the final drive back into its installed position.

-- Connect the right drive axle on the final drive.

-- Lift the final drive -A- in the rear -arrow 1- and push it as far as possible to the right -arrow 2-.

Fig 27: Lifting Final Drive In Rear And Pushing It As Far Right As Possible

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-- Carefully guide the left drive axle -B- upward into the flange.

-- Put the final drive back into its installed position.

-- Connect the left drive axle on the final drive.

-- Tighten the driveshaft flexible disc to the input flange. Tightening specifications, refer to DRIVESHAFT OVERVIEW .

-- Tighten the final drive from below -arrow-. Tightening specification, refer to Specifications .

Fig 28: Identifying Screw From Front Final Drive Bracket

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-- Tighten drive axles. Tightening specifications, refer to Specifications .

-- Secure the pendulum support with new bolts. For the correct tightening specifications, refer to Specifications .

Fig 29: Identifying Pendulum Support Bolts

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-- Install the noise insulation. Refer to Description and Operation .

-- Align the center bearing free of tension and tighten the bolts -arrows-. Tightening specifications, refer to DRIVESHAFT OVERVIEW .

Fig 30: Locating Center Bracket Screws

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-- Install the left rear level control system sensor. Refer to Removal and Installation .

Adjust the headlamps. Refer to the vehicle diagnostic tester.

-- Install the exhaust system. Refer to [For transmission(s) 0A6, 09M] Description and Operation .

-- Install the stabilizer bar. Refer to Removal and Installation .

-- Insert two new bolts -arrow- through the holes in the luggage compartment floor and tighten them. Tightening specification, refer to Specifications .

Fig 31: Identifying Luggage Compartment Floor Holes

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-- Seal the holes. To do this, use the caps N 908 572 01.

If the final drive is replaced:

-- Check the oil level in the Haldex clutch. Refer to HALDEX CLUTCH OIL LEVEL, CHECKING OR FILLING .

-- Check the oil level in the final drive. Refer to REAR FINAL DRIVE OIL LEVEL, CHECKING OR FILLING .