D4B8039775C-Propshaft and Rear Final Drive Volkswagen R GMBH

Service
Workshop Manual
Golf 2013 ➤ , Golf 2015 ➤ ,
Golf 2017 ➤ , Golf Variant 2014 ➤ ,
Golf Variant 2017 ➤
Propshaft and rear final drive Volkswagen R GmbH
CJXC CJXB CYF CJX DLR
B CJXD G DJHA DJHB DJJA
Engine ID
A
DNU
E
Edition 02.2020
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
39 - Final drive - rear differential
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2020 Volkswagen AG, Wolfsburg D4B8039775C

Golf 2013 ➤ , Golf 2015 ➤ , Golf 2017 ➤ , Golf Variant 2014 ➤ , Golf V ...
Propshaft and rear final drive Volkswagen R GmbH - Edition 02.2020
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when using testers and measuring instruments during a road test . . . . 1
1.2 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Identification of final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Allocation gearbox - engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Assembly overview - final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Removing and installing final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Removing and installing bonded rubber bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 Overview of fitting locations - oil drain and inspection plugs . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Checking gear oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 High performance oil for all-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Checking fluid level in all-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Draining and replenishing high performance oil for all-wheel drive coupling . . . . . . . . . . . . 24
4.3 Changing high performance oil for all-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . 26
5 Oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1 Overview of fitting locations - seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2 Renewing right oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3 Renewing left seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4 Renewing input shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6 All-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1 Assembly overview - all-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2 Checking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3 Removing and installing all-wheel drive coupling pump V181 . . . . . . . . . . . . . . . . . . . . . . 41
6.4 Removing and installing all-wheel drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.5 Removing and installing control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7 Propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.1 Assembly overview – propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.2 Removing and installing propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.3 Removing and installing front flexible coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.4 Removing and installing rear flexible coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Contents i
ii Contents
00 – Technical data
1 Safety information
(VRL014001; Edition 02.2020)
⇒ “1.1 Safety precautions when using testers and measuring in‐
struments during a road test”, page 1
⇒ “1.2 Safety measures when working on vehicles with a start/
stop system”, page 1
1.1 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring instru‐
ments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test and measuring equip‐
ment on the rear seat.
1.2 Safety measures when working on ve‐

hicles with a start/stop system
When working on vehicles with start/stop system, observe the
following:
Risk of injury due to unexpected motor start
If the vehicle’s start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1. Safety information 1
2 Identification
⇒ “2.1 Identification of final drive”, page 2
2.1 Identification of final drive
Note
♦ The final drive is fitted with an »all-wheel drive coupling«.

♦ The final drive and »all-wheel drive coupling« have separate
oil circuits.
♦ The final drive “0CQ” is equipped with the »generation V all-
wheel drive coupling«. Identification
Allocation of rear final drive

Rear final drive -0CQ-
Note
The marking -arrow- on the »bottom« of the final drive provides

information about which final drive is installed.
Identification example:
-Arrow A- Part number of final drive
-Arrow B- Code of final drive
-Arrow C- Date of production of final drive
MYT 26 03 12
I I I I
I I I I
Identification Day Month Year of manufacture
code -2012-
2 Rep. gr.00 - Technical data

3 Repair instructions
⇒ “3.1 General repair instructions”, page 3
⇒ “3.2 Gaskets and seals”, page 4
⇒ “3.3 Nuts and bolts”, page 4
3.1 General repair instructions

⇒ “3.1.1 General information”, page 3
⇒ “3.1.2 Oil”, page 3
⇒ “3.1.3 Locking devices”, page 3
⇒ “3.1.4 Mountings”, page 4
⇒ “3.1.5 Shims”, page 4
3.1.1 General information

To ensure flawless and successful gearbox repairs, the greatest
care and cleanliness as well as the use of good and proper tools
are essential. Also note the basic rules on safety when performing
repair procedures.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. They apply for this particular workshop
manual.
♦ Before performing repairs on the all-wheel drive coupling, de‐
termine the cause of the fault as accurately as possible using
guided fault finding , vehicle self-diagnosis and
test instruments with ⇒ vehicle diagnostic tester .
3.1.2 Oil
Note
The final drive and all-wheel drive coupling have separate »oil
circuits«.
The final drive is filled with “axle oil”, the all-wheel drive coupling
is filled with “high performance oil for all-wheel drive coupling”.
Oil for the “final drive” and fluid for the “all-wheel drive coupling”
are available as replacement parts ⇒ Electronic parts catalogue
(ETKA) .
Do not mix »additives« in oil.
Oil which has been drained out cannot be added again.
Caution
Use caution when handling oil. Dispose of used oil properly.
3.1.3 Locking devices

♦ Do not overstretch retaining rings.
♦ Always renew retaining rings which have been damaged or
overstretched.
♦ Retaining rings must locate properly in grooves.
3. Repair instructions 3
3.1.4 Mountings
♦ Install needle bearings with lettered side (thicker metal) to‐
wards fitting tool.
♦ Lubricate all gearbox bearings with gear oil before installing.
♦ Tapered roller bearings fitted to one shaft must be renewed as
a set. Use same make of bearings.
♦ Heat inner races to about 100°C before installing.
♦ Do not interchange outer or inner races of bearings of the
same size. The bearings are matched in pairs.
3.1.5 Shims
♦ Measure shims at several points with a micrometer. The var‐
ious thicknesses make it possible to achieve the exact shim
thickness required.
♦ Check for burrs and damage.
♦ Install only flawless shims.
3.2 Gaskets and seals

♦ Renew O-rings, seals and gaskets.
♦ After removing gaskets and seals, always inspect contact sur‐
face of housing or shaft for burrs resulting from removal or for
other signs of damage.
♦ Before installing seals, lightly oil outer diameter and half-fill
space between sealing lips -arrow- with sealing grease -
G 052 128 A1- .
♦ The open side of the oil seals faces toward the side with fluid
filling.
♦ Only use DSG transmission oil. Other lubricants will cause
problems in function.
♦ Check oil level in all-wheel drive coupling after renewing O-
rings, gaskets and seals.
3.3 Nuts and bolts

♦ Loosen and tighten securing bolts and securing nut for covers
and housings diagonally.
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Clean threads of bolts which are to be installed with locking
fluid using a wire brush. Then insert bolts with locking fluid -
AMV 185 101 A1- .
♦ Threaded holes into which self-locking bolts or bolts with lock‐
ing agent have been screwed must be cleaned (e.g. with a
screw tap). Otherwise there is a danger that the bolts will shear
off when refitted.
♦ Always renew self-locking bolts and nuts.

4 Technical data
⇒ “4.1 Allocation gearbox - engine”, page 5
⇒ “4.2 Capacities”, page 5
4.1 Allocation gearbox - engine

Rear final 0CQ
drive
(All-wheel drive coupling generation V)
Gearbox 6-speed dual 6-speed man‐ 7-speed dual
type clutch gearbox ual gearbox clutch gearbox
DQ 250-6A MQ 350-6A DQ 381-7A
Identification PYP RUT RUT
code
Engine 2.0 l 2.0 l 2.0 l
206/215/221 k 213/215/228 213/215/228
W TFSI kW TFSI kW TFSI
Ratio: Z2 : 27 : 17 = 1.588 27 : 17 = 1.588 27 : 17 = 1.588
Z1
Glean following data from ⇒ Electronic Parts Catalogue (ETKA) :

♦ Production dates
♦ Allocation of gearbox
♦ Allocation of engine
♦ Drive shaft flange diameter
4.2 Capacities
Rear final drive 0CQ
(All-wheel drive coupling generation V)
Final drive capaci‐ 0.95 l
ty
Capacity of all- 0.85 l
wheel drive cou‐
pling
Replacement vol‐ 0.65 l
ume in all-wheel
drive coupling
• Change inter‐
vals: ⇒ Mainte‐
nance tables
4. Technical data 5
5 Electrical components
⇒ “5.1 Overview of fitting locations - electrical components”, page
6
5.1 Overview of fitting locations - electrical components
Note
Rear final drive “0CQ” with all-wheel coupling generation V
1 - All-wheel drive coupling

pump - V181-
❑ Can be checked using
⇒ Vehicle diagnostic
tester in “Guided fault
finding” mode.
❑ Removing and installing
⇒ page 41
2 - All-wheel drive control unit
- J492-
❑ All-wheel drive control
unit - J492- receives im‐
portant signals from en‐
gine control unit and
control unit for ABS with
EDL - J104- via data
bus.
⇒ page 48
3 - Diagnostic connection -
U31-
❑ Location: in footwell,
front left
4 - Accelerator position sender
- G79- and accelerator position
sender 2 - G185-
⇒ Rep. gr. 20 ; Accel‐
erator mechanism; re‐
moving and installing
accelerator module

39 – Final drive - rear differential

1 Final drive
⇒ “1.1 Assembly overview - final drive”, page 7
⇒ “1.2 Removing and installing final drive”, page 7
1.1 Assembly overview - final drive
1 - Bolts
❑ Qty. 3
❑ Renew after removal
❑ 60 Nm +180°
2 - Stop plate
❑ attach onto bonded rub‐
ber mounting
⇒ page 20
3 - Washer
❑ Installation position:
driver assistance sys‐
tem (small diameter)
faces towards subframe
4 - Bolts
❑ 60 Nm +180°
5 - Rear subframe
6 - Stop plates
❑ attach onto bonded rub‐
ber mounting
⇒ page 20
7 - Rear final drive
⇒ page 7
bonded rubber bush
⇒ page 17
1.2 Removing and installing final drive

Brief description
The rear axle is lowered at the rear bearings.
The rear anti-roll bar and springs are removed, and the drive
shafts are unbolted from the final drive. The electrical connectors
and breather lines are separated at the final drive.
The rear section of the exhaust system with heat shield is re‐
moved and the propshaft is unbolted from the final drive.
The final drive is to be lowered diagonally with the gearbox jack
facing in direction of travel.
1. Final drive 7
Special tools and workshop

equipment required
♦ Socket insert - T10035- and, if necessary, bits - T10099-

♦ Counter-hold tool - T10172- with adapter - T10172/5-
♦ Assembly tool - 3301- and -3301/2-
♦ Engine and gearbox jack - VAS 6931- or -V.A.G 1383 A-
♦ Spindle - 3346/2- and nut - 3346/3-
Removing
Caution
Risk of damage to the flexible joint

♦ Do not allow the decoupling element to kink by more than
10°.
♦ Do not subject the decoupling element to tensile force.
♦ Do not damage wire mesh on decoupling element.
8 Rep. gr.39 - Final drive - rear differential

– Separate exhaust system at clamp -arrows- and remove rear

section of exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/
silencers; Assembly overview - silencer .
– Insert a pipe or tyre lever -3- into front exhaust pipe -1- and
rest on tunnel cross member -2-.
– Remove rear anti-roll bar ⇒ Running gear, axles, steering;
Rep. gr. 42 ; Anti-roll bar; Removing and installing anti-roll
bar .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
– Unscrew bolts -2- and -3- for pendulum support.
Note
Disregard -item 1-.
– Loosen bolts -arrows- for centre bearing of propshaft, but do

not unscrew them.
1. Final drive 9
– Check whether there is a marking (paint dot) on flexible cou‐

pling and on flange for propshaft on rear final drive -arrows-.
– If there is no marking, mark position of flexible coupling relative
to flange for propshaft on rear final drive.
– For loosening screw joints of propshaft, counterhold at rear

final drive with counterhold tool - T10172- and adapter -
T10172/5- .
– Unscrew bolts -arrows- securing propshaft to rear final drive.
– Press engine/gearbox assembly forwards, and secure it in

place with an appropriate piece of wood -A-.
Note
Disregard -item 1-.

– When pulling off or pushing on propshaft, always ensure that

sleeve -arrow- is not damaged.
Note
If seal is damaged, propshaft must be renewed.
– Pull propshaft -A- off centring pin on rear final drive, and tie it
up to one side on body, e.g. using wire -B-.
– Position engine and gearbox jack - V.A.G 1383 A- under rear
final drive. Place a piece of wood between engine and gearbox
jack and rear final drive.
– Loosen rear axle at rear bearings -arrows-.
1. Final drive 11
– Screw spindle -3346/2- with assembly tool - 3301- and nut

-3346/3- into body up to a depth of 15 mm, as shown in illus‐
tration.
1- Assembly tool - 3301-
2- Nut -3346/3-
3- Spindle -3346/2-
– Screw nut -3346/3- onto spindle -3346/2- as far as dimension
-a- = 40 mm.
Note
Do not lower subframe more than 40 mm.
– Lower engine and gearbox jack - V.A.G 1383 A- until subframe

rests against assembly tool - 3301- .
WARNING
Risk of accident.
♦ Do not lower the engine and gearbox jack - V.A.G 1383
A- during installation work or leave it unattended under the
vehicle.
– Unbolt drive shafts from rear final drive ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Drive shaft; Removing and installing
drive shaft .
– Unscrew rear bolts for final drive with socket insert - T10035-
from rear axle. A bit - T10099/1- can also be used for un‐
screwing the bolts.
– Unscrew bolt -B- from bonded rubber mounting at front.

– Remove washer -C- from top of bonded rubber mounting.

– Raise -arrow 1- rear section of final drive -A- and push to right
as far as possible -arrow 2-.
– Remove left drive shaft -B- from flange and carefully lower.
– Raise -arrow 1- rear section of final drive -A- and push to left
as far as possible -arrow 2-.
– Remove right drive shaft -B- from flange and carefully lower.
– Move final drive back to installation position.
– Secure final drive against falling using strap as shown in illus‐

tration.
Note
Illustrated with final drive removed.
– Tilt final drive using engine and gearbox jack - V.A.G 1383 A-
as shown in illustration and lower slightly.
– Pull connector -B- off all-wheel drive control unit - J492- -A-.
Disregard item -C-.
1. Final drive 13
– Pull breather lines -arrows- off final drive.
Note
-Item A- can be disregarded.
– To remove, lower final drive further, and pull it forwards. En‐

sure that there is sufficient clearance to other components.
Installing
Install in reverse order of removal, observing the following:
– Secure final drive against falling using strap from gearbox

support.
– Bring rear final drive into position shown.
– Ensure that the limit stop washers -B- are placed as shown
from above on rear bearings. When properly positioned, the
rubber nipples -A- prevent the washers from slipping or falling
out during installation.

– Before installing the final drive, first insert 2 new bolts from
above into the rear bearings -arrows-.
If the final drive has been renewed:
– Check fluid level in all-wheel drive coupling ⇒ page 23 .
– Check oil level in final drive ⇒ page 21 .
Specified torques
♦ ⇒ “1.1 Assembly overview - final drive”, page 7
♦ ⇒ “7.1 Assembly overview – propshaft”, page 50
♦ Assembly mountings; Assembly overview - assembly mount‐
ings ⇒ Rep. gr. 10 ; Assembly mountings; Assembly overview
- assembly mountings .
♦ Exhaust pipes/silencers; Assembly overview - silencers ⇒
Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview -
silencers .
♦ Drive shafts; Assembly overview – drive shafts ⇒ Running
gear, axles, steering; Rep. gr. 42 ; Drive shaft; Assembly
overview – drive shaft
♦ Subframe; Assembly overview - subframe ⇒ Running gear,
axles, steering; Rep. gr. 42 ; Subframe; Assembly overview -
subframe
♦ Anti-roll bar; Assembly overview - anti-roll bar ⇒ Running
gear, axles, steering; Rep. gr. 42 ; Anti-roll bar; Assembly
overview - anti-roll bar .
♦ Noise insulation; Assembly overview - noise insulation ⇒
General body repairs, exterior; Rep. gr. 66 ; Noise insulation;
Assembly overview - noise insulation
1. Final drive 15
2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 16
⇒ “2.2 Removing and installing bonded rubber bush”, page 17
2.1 Assembly overview - assembly mount‐

ings
Note
Renew bonded rubber bushes »in pairs« (upper and lower bush‐
es).
1 - “Upper rear” bonded rubber

bush
❑ With stop plate
❑ For allocation refer to ⇒
Electronic parts cata‐
logue (ETKA)
❑ To remove or install, re‐
move stop plate
⇒ page 17
2 - “Lower rear” bonded rubber
bush
❑ Without stop plate
logue (ETKA)
⇒ page 17
3 - “Lower rear” bonded rubber
bush
logue (ETKA)
⇒ page 17
4 - “Lower front” bonded rubber
bush
❑ With stop plate
logue (ETKA)
❑ To remove or install, re‐
move stop plate
❑ Removing and installing ⇒ page 17
❑ Remove to renew bonded rubber bushes ⇒ page 17
6 - “Upper front” bonded rubber bush
❑ For allocation refer to ⇒ Electronic parts catalogue (ETKA)

7 - “Upper rear” bonded rubber bush
❑ With stop plate
❑ To remove or install, remove stop plate
2.2 Removing and installing bonded rubber bush

equipment required
♦ Locking pin - 30 - 505-

♦ Thrust piece - VW 554-
♦ Fitting tool - 3128-
♦ Thrust piece - T40033/1-
♦ Bracket - T10030/5-
♦ Spindle - 3346/2-
♦ Nut - 3346/3-
2. Assembly mountings 17
♦ Internal puller e.g. KUKKO 21-1 - VAS 251 601-
♦ Counter support e.g. KUKKO 22-1 - VAS 251 621-
Removing
– Remove rear final drive ⇒ page 7 .
Pulling out “upper rear” bonded rubber bush
A - Counter support, e.g. KUKKO 22-1 - VAS 251 621-
B - Internal puller e.g. KUKKO 21-1 - VAS 251 601-
– To allow placement of counter support , break out a piece from
collar of bonded rubber bush -arrow-.
– Insert internal puller in gap of upper and lower bonded rubber
mounting, and tension it.
Driving out “lower rear” bonded rubber bush
Note
If the bonded rubber bush is to be renewed separately, it can also

be pulled out with counter support, e.g. KUKKO 22-1 - VAS 251
621- and internal puller, e.g. KUKKO 21-1 - VAS 251 601-
⇒ page 18 .

Pulling in “upper rear” -A- and “lower rear” -B- bonded rubber
bushes
– Place a washer measuring »15 mm internally« and »no less
than 27 mm externally« on spindle - 3346/2- before attaching
spindle.
Note
Instead of thrust piece - T40033/1- the thrust piece - 3416/1- may

also be used.
Pulling out “lower front” bonded rubber bush

– To prevent oil escaping from final drive and all-wheel drive
coupling during the following step, seal both breather pipes.
– Then place final drive on workbench upside down, and pull out
bonded rubber bush.
A - Counter support, e.g. KUKKO 22-1 - VAS 251 621-
B - Internal puller e.g. KUKKO 21-1 - VAS 251 601-
– To allow placement of counter support , break out a piece from
collar of bonded rubber bush -arrow-.
– Insert internal puller in gap of upper and lower bonded rubber
mounting, and tighten it.
Driving out “upper front” bonded rubber bush
Note
If the bonded rubber bush is to be renewed separately, it can also

be pulled out with counter support, e.g. KUKKO 22-1 - VAS 251
621- and internal puller, e.g. KUKKO 21-1 - VAS 251 601-
⇒ page 19 .
Pulling in “lower front” -A- and “upper front” -B- bonded rubber
bushes
– Place a washer measuring »15 mm internally« and »no less
than 27 mm externally« on spindle - 3346/2- before attaching
spindle.
Note
Instead of thrust piece - T40033/1- the thrust piece - 3416/1- may

also be used.
2. Assembly mountings 19
Identifying “rear upper” and “front lower” bonded rubber bushes

The “rear upper” and “front lower” bonded rubber bushes differ in
height.
Dimension “a” mm Bonded rubber bush

22 “Rear upper”
17 “Front lower”
Installation position of bonded rubber bushes “rear upper” and

“front lower” when fitting stop plate -B-
• Final drive in installation position
Installation position of “rear upper” and “front lower” bonded rub‐
ber bushes:
♦ The pins -A- of the “rear upper” bonded rubber mountings
⇒ Item 1 (page 16) face upwards.
♦ The pins -A- of the “front lower” bonded rubber mounting
⇒ Item 4 (page 16) face downwards.
Attachment of stop plate -B-
– Pull pins -A- into holes of stop plate -B- -arrows-.
The stop plate -B- is then permanently joined to the bonded rub‐
ber bush.

3 Gear oil
⇒ “3.1 Overview of fitting locations - oil drain and inspection
plugs”, page 21
⇒ “3.2 Checking gear oil level”, page 21
3.1 Overview of fitting locations - oil drain and inspection plugs
1 - Drain plug for all-wheel

drive coupling
❑ 32 Nm
2 - Oil filler plug for all-wheel
drive coupling
❑ 15 Nm
3 - Oil drain plug for gear oil
❑ 19 Nm
4 - Oil filler plug for gear oil
❑ 19 Nm
3.2 Checking gear oil level

Special tools and workshop equipment required
3. Gear oil 21
♦ Drip tray for workshop hoist - VAS 6208-
♦ Filling device for all-wheel drive coupling - VAS 6291A-
Conditions for testing

• Vehicle is level.
• Gear oil specification for rear final drive ⇒ Electronic Parts
Catalogue .
Note
Check oil level.
– Place drip tray - VAS 6208- under final drive.

– Unscrew oil filler plug -arrow- for gear oil .
The oil level is correct, if the rear final drive is filled up to lower
edge of filler plug drilling.
– Tighten new oil filler plug -arrow-.
Topping up oil:
– Using filling device for all-wheel drive coupling - VAS 6291A- ,
add enough oil so that it runs out between the adapter of the
filling device and the gear housing.
– Remove filling device and adapter; excess fluid may still run
out.
The oil level is correct, if the rear final drive is filled up to lower
edge of filler plug drilling.
– Tighten new oil filler plug -arrow-.
Specified torques
♦ ⇒ “3.1 Overview of fitting locations - oil drain and inspection
plugs”, page 21

4 High performance oil for all-wheel

drive coupling
⇒ “4.1 Checking fluid level in all-wheel drive coupling”,
page 23
⇒ “4.2 Draining and replenishing high performance oil for all-
wheel drive coupling”, page 24
⇒ “4.3 Changing high performance oil for all-wheel drive cou‐
pling”, page 26
4.1 Checking fluid level in all-wheel drive

coupling
High performance oil for all-wheel drive coupling is available as a
replacement part ⇒ Electronic parts catalogue ETKA .
♦ Vehicle diagnostic tester
Conditions for testing

• Oil temperature must be 20 to 40°C.
• The oil temperature can be attained by running engine until
warm.
• In order to perform the oil level check, the final drive must be
in installation position.
– Read oil temperature ⇒ Vehicle diagnostic tester Guided
functions .
• Oil temperature must be 20 to 40°C.
4. High performance oil for all-wheel drive coupling 23

Check fluid level

– Unscrew bolt -A- for checking oil level.
Note
Oil level is correct when all-wheel drive coupling is filled to lower

edge or at least to within about 3 mm of lower edge of filler hole.
– Top up high performance oil for all-wheel drive coupling as

needed ⇒ page 24 .
Specified torques
plugs”, page 21
4.2 Draining and replenishing high perform‐

ance oil for all-wheel drive coupling
♦ Filling device for all-wheel drive coupling - VAS 6291A-
Draining oil
– Place drip tray underneath.

– Unscrew drain plug -arrow- and drain high performance oil for
all-wheel drive coupling completely.
– Screw in new drain plug -arrow-, and tighten it to specified
torque.
Filling with oil
– Use filling device for all-wheel drive coupling - VAS 6291A- to

replenish.
– Unscrew oil filler plug -A- for high-performance oil for all-wheel
drive coupling .
– Separate adapter -A- and angled piece -B-.

– Screw adapter -A- in to stop.
– Engage elbow -B- in adapter -A-.
– Route hose of filling device above drive shaft.
• Do not allow hose to sag. It must exit at rear of vehicle above
left rear wheel.
– Lower vehicle.
– Ensure that valve -arrow- is closed.

– Screw oil reservoir -A- onto filling device for all-wheel drive
coupling - VAS 6291A- .
– Open valve -arrow- and hold oil reservoir as shown in figure.
The all-wheel drive coupling will now be filled.

Note
If all-wheel drive coupling has been properly filled, oil runs out at
adapter -A-.
– Raise vehicle.
– When oil runs out, place oil reservoir under all-wheel drive
coupling (e.g. on workshop trolley).
Excess oil will now flow back into oil reservoir.
– When no more oil flows back, remove filling device for all-
wheel drive coupling - VAS 6291A- .
• The all-wheel drive coupling is now filled up to the bottom edge
of the oil filler hole.
– Screw in new oil filler plug -A-.

– Then check oil level in all-wheel drive coupling ⇒ page 23 .
Specified torques
plugs”, page 21
4.3 Changing high performance oil for all-

wheel drive coupling
♦ High-performance oil for all-wheel drive coupling ⇒ Electronic

parts catalogue
Procedure
– Place drip tray underneath.

– Screw in new drain plug -arrow-, and tighten it to specified
torque.
– Unscrew oil filler plug -A- for high-performance oil for all-wheel
drive coupling , and replenish high-performance oil for all-
wheel drive coupling ⇒ page 24 .
– Then check oil level in all-wheel drive coupling ⇒ page 23 .
Specified torques
plugs”, page 21

5 Oil seals
⇒ “5.1 Overview of fitting locations - seals”, page 28
⇒ “5.2 Renewing right oil seal”, page 29
⇒ “5.3 Renewing left seal”, page 30
⇒ “5.4 Renewing input shaft seal”, page 32
5.1 Overview of fitting locations - seals
1 - Nut
❑ Secure with locking fluid
- D 000 600- ⇒ Elec‐
tronic Parts Catalogue
(ETKA)
❑ 210 Nm
2 - Flange for propshaft
⇒ page 32
3 - Seal for propshaft flange
❑ Renewing ⇒ page 32
4 - Sealing ring, right
❑ For right flange shaft
5 - Retaining ring
❑ Renew after removing
flange shaft.
6 - Right flange shaft
8 - Left seal
❑ For left flange shaft
9 - Left flange shaft

5.2 Renewing right oil seal

equipment required
♦ Multi-purpose tool - VW 771-

♦ Removal tool - VW 681-
♦ Puller - 18/2-
♦ Thrust piece - 3305-
♦ Pin - 3282/34-
♦ Sealing grease - G 052 128 A1-
Removing
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 42 ; Drive shaft; Removing and installing drive shaft .
In the following illustrations, the left side of the final drive is shown
removed. The procedure for the right side is the same.
5. Oil seals 29
– Unscrew spindle from bridge of puller - 18/0- , and screw in pin

- 3282/34- instead.
– Bolt bridge -A- to flange shaft using two bolts M8 x 30
-arrows-.
– Pull out flange shaft.
– Lever out flange shaft oil seal using oil seal extractor - VW
681- .
Installing
– Lightly moisten outer diameter of new seal -1- with oil, and
drive in seal with thrust piece - T10049- until dimension -a- is
reached. Do not cant oil seal in the process.
• Dimension -a- = 4.8 ± 0.1 mm; measured from end face of
housing to seal.
• Do not drive in seal to stop.
• Ensure seal -1- is parallel to end face of housing of 0.25 mm
max.
– Half-fill space between sealing lip and dust lip with sealing
grease - G 052 128 A1- .
Renewing retaining rings
– Clamp flange shaft in vice with protective jaw covers.

– Use new retaining ring -A- to press old retaining ring out of
groove in flange shaft.
– Drive in flange shaft using plastic mallet and, if necessary, a
drift.
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
42 ; Drive shaft; Removing and installing drive shafts .
– Checking gear oil level in rear final drive ⇒ page 21 .
5.3 Renewing left seal


equipment required
♦ Multi-purpose tool - VW 771-

♦ Puller - 18/2-
♦ Thrust piece - 3305-
♦ Pin - 3282/34-
♦ Sealing grease - G 052 128 A1-
Removing
– Remove left drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 42 ; Drive shafts; Removing and installing drive shafts .
In the following illustrations, the final drive is shown removed.
5. Oil seals 31
– Unscrew spindle from bridge of puller - 18/0- , and screw in pin

- 3282/34- instead.
– Bolt bridge -A- to flange shaft using two bolts M8 x 30
-arrows-.
– Pull out flange shaft.
– Lever out flange shaft oil seal using oil seal extractor - VW
681- .
Installing
– Lightly moisten outer diameter of new seal -1- with oil, and
drive in seal with thrust piece - T10049- until dimension -a- is
reached. Do not cant oil seal in the process.
• Dimension -a- = 4.8 ± 0.1 mm; measured from end face of
housing to seal.
• Do not drive in seal to stop.
• Ensure seal -1- is parallel to end face of housing of 0.25 mm
max.
– Half-fill space between sealing lip and dust lip with sealing
grease - G 052 128 A1- .
Renewing retaining rings
– Clamp flange shaft in vice with protective jaw covers.

– Use new retaining ring -A- to press old retaining ring out of
groove in flange shaft.
– Drive in flange shaft using plastic mallet and, if necessary, a
drift.
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
42 ; Drive shaft; Removing and installing drive shafts .
– Checking gear oil level in rear final drive ⇒ page 21 .
5.4 Renewing input shaft seal


equipment required
♦ Tube - VW 416 B-
♦ Counter-hold tool - 3415-
♦ Thrust piece - T10019-
♦ Tensioning strap - T10038-
♦ Used oil collector and extractor - V.A.G 1782-
5. Oil seals 33
♦ Three arm puller, e.g. KUKKO 12-1 - VAS 251 201-
♦ Locking fluid - D 000 600-

♦ Bolt M10 x 25
♦ Hexagon socket bolt M8 x 15
Removing
– Secure vehicle to support arms of lifting platform on both sides
using tensioning straps - T10038- .
1- Tensioning strap - T10038-
WARNING
If the vehicle is not strapped down, it may slip off the lifting
platform.

sulation .
Caution

10°.


– Insert a pipe or tyre lever -3- into front exhaust pipe -1- and
rest on tunnel cross member -2-.

not unscrew them.


T10172/5- .
5. Oil seals 35
– Press engine/gearbox assembly forwards, and secure it in

place with an appropriate piece of wood -A-.
Note
Disregard -item 1-.

Note
If seal is damaged, propshaft must be renewed.
– Pull propshaft -A- off centring pin on rear final drive, and tie it
up to one side on body, e.g. using wire -B-.

– Remove propshaft flange hexagon nut.

A - Hexagon bolts M10 x 25
B - Hexagon socket bolt M8 x 15 (screwed from back side into
counterhold - 3415- ).
– Pull off propshaft flange. If this proves to be difficult, use three-

arm puller, e.g. KUKKO 12-1 - VAS 251 201- .
– Pull out seal using oil seal extractor lever - VW 681- .

Installing
– Lightly oil new oil seal around outer circumference and be‐
tween sealing lips with high-performance oil for all-wheel drive
coupling before installing.
– Drive in new oil seal to stop using thrust piece - T10019- . Do

not cant oil seal in the process.
5. Oil seals 37
– Drive on propshaft flange -A- using tube - VW 416 B- .
– Insert new hexagon nut with locking fluid - D 000 600- , and
tighten it.
A - Hexagon bolts M10 x 20
B - Hexagon socket bolt M8 x 15 (screwed from back side into
counterhold - 3415- ).
– Check fluid level of all-wheel drive coupling ⇒ page 23 .
Specified torques

6 All-wheel drive coupling

⇒ “6.1 Assembly overview - all-wheel drive coupling”, page 39
⇒ “6.2 Checking function”, page 41
⇒ “6.3 Removing and installing all-wheel drive coupling pump
V181 ”, page 41
⇒ “6.4 Removing and installing all-wheel drive coupling”,
page 43
⇒ “6.5 Removing and installing control unit”, page 48
6.1 Assembly overview - all-wheel drive

coupling
⇒ “6.1.1 Assembly overview - all-wheel drive coupling, generation
V”, page 39
6.1.1 Assembly overview - all-wheel drive

coupling, generation V
Note
All-wheel drive coupling is removed and installed with final drive

in situ.
6. All-wheel drive coupling 39

1 - O-ring
❑ Moisten with high-per‐
formance oil for all-
wheel drive coupling ,
and insert
2 - All-wheel drive control unit
- J492-
⇒ page 48
3 - Bolts
❑ Qty. 2
❑ 9.5 Nm
4 - Seal for propshaft flange
5 - Propshaft flange
⇒ page 32
6 - Nut
❑ Secure with locking fluid
- D 000 600-
❑ 210 Nm
7 - Bolts
❑ Qty. 4
❑ 50 Nm
8 - Housing for all-wheel drive
coupling
all-wheel drive coupling
⇒ page 43
9 - O-ring
❑ Qty. 2
❑ Diameter 43.5 mm
❑ For all-wheel drive coupling pump - V181-
❑ Moisten with high-performance oil for all-wheel drive coupling , and insert
10 - All-wheel drive coupling pump - V181-
11 - Bolts
❑ Qty. 2
❑ 9.5 Nm

6.2 Checking function
Note
All-wheel drive coupling is checked during a road test using Ve‐

hicle diagnosis and service information system - VAS 5052- .
WARNING
To avoid accidents, observe the safety instructions for meas‐

uring and road tests ⇒ page 1 .
– Checking function ⇒ Vehicle diagnostic tester Guided func-

tions .
– Start final control diagnosis and proceed by following the in‐

structions on the display of vehicle diagnostic tester.
6.3 Removing and installing all-wheel drive

coupling pump - V181-
⇒ “6.3.1 Removing and installing all-wheel drive coupling pump
V181 , generation V”, page 41
6.3.1 Removing and installing all-wheel drive

coupling pump - V181- , generation V
Removing
– Switch off ignition.
– Position used oil collection and extraction unit - V.A.G 1782-
under rear final drive.

– Screw in drain plug -A- with new seal, and tighten it.
– Pull connector -arrow- off all-wheel drive control unit - J492- .
– Unclip wiring harness -3- for all-wheel drive coupling pump -

V181- from housing and move it clear to one side.
Note
Disregard bolt -arrow-.

– Unscrew bolts -1- of all-wheel drive coupling pump - V181-
-2-.
– Pull all-wheel drive coupling - V181- -2- out of housing of all-
wheel drive coupling.
Installing
– If the removed all-wheel drive coupling pump - V181- is to be

re-installed, renew O-rings -1- and -2-.
– Thinly coat O-rings -1- and -2- with high-performance oil for
all-wheel drive coupling .

– Push all-wheel drive coupling pump - V181- -2- into housing

for all-wheel drive coupling as far as stop. When doing so, en‐
sure that the wiring harness is properly routed -3-.
Note
Disregard bolt -arrow-.
– Tighten bolts -1-.
– Fit electrical connector -arrow- for all-wheel drive coupling

pump - V181- on all-wheel drive control unit - J492- .
– Fill with high-performance oil for all-wheel drive coupling , and
check oil level in all-wheel drive coupling ⇒ page 23 .
Specified torques
plugs”, page 21
♦ ⇒ “6.1 Assembly overview - all-wheel drive coupling”,
page 39
6.4 Removing and installing all-wheel drive

coupling
⇒ “6.4.1 Removing and installing all-wheel drive coupling,
generation V”, page 43
6.4.1 Removing and installing all-wheel drive coupling, generation V


equipment required

♦ Guide pins - T10093-
Removing
Caution

10°.

– Remove nuts for clamp -arrows- and push clamp backwards.

– Tie up front exhaust pipe on underbody.
– Remove rear part of exhaust system ⇒ Rep. gr. 26 ; Exhaust
system/silencer; Assembly overview - silencers .

not unscrew them.
– Check whether there is a factory marking (paint dot) on the

flexible coupling and on the flange for the propshaft on the rear
final drive -arrows-.

T10172/5- .

– Pull propshaft off centring pin on rear final drive, pressing

propshaft slightly towards front. To do so, unscrew bolts on
centre propshaft bearing if necessary.
Caution
Risk of damage to seal -arrow- in propshaft flange.

♦ Pull propshaft horizontally off centring pin.
– Then tie up rear section of propshaft -A- to one side on body

e.g. using wire -B-.
– Separate electrical connector -B- on all-wheel drive control

unit - J492- -A-.
Note
Do not pull off electrical connector -C-.


– Screw in drain plug -arrow- with new seal, and tighten it.
– Unscrew securing bolts -arrows- and pull out all-wheel drive

coupling from rear final drive.
Installing
– Remove old O-ring -arrow- from all-wheel drive coupling.
– Insert new O-ring -arrow- and moisten lightly with high-per‐
formance oil for all-wheel drive coupling .
– Insert all-wheel drive coupling -1- in rear final drive. In order to

obtain exact guidance, screw in guide pins - T10093- .
– Turn propshaft flange -2- and insert all-wheel drive coupling
as far as it will go.

– Tighten bolts -arrows-.
– Push electrical connector -B- onto all-wheel drive control unit

- J492- -A-.
Electrical connector -C- must also be pushed on.
– Attach propshaft to rear final drive ⇒ page 51 .
– Install exhaust system and align it free of tension ⇒ Rep. gr.
26 ; Exhaust pipes/silencers; Assembly overview - silencer .
– Fill with high-performance oil for all-wheel drive coupling , and
check oil level in all-wheel drive coupling ⇒ page 23 .
Specified torques
plugs”, page 21
♦ ⇒ “6.1 Assembly overview - all-wheel drive coupling”,
page 39
6.5 Removing and installing control unit

⇒ “6.5.1 Removing and installing all-wheel drive control unit J492 ,
generation V”, page 48
6.5.1 Removing and installing all-wheel drive

control unit - J492- , generation V
Removing
– Disconnect connectors -B- and -C- from all-wheel drive control
unit - J492- -A-.

– Unscrew bolts -arrows- for securing all-wheel drive control unit

- J492- to all-wheel drive coupling.
– Remove all-wheel drive control unit - J492- -A-.
Installing
Specified torques
Component Specified torque
Bolt securing all-wheel drive control 9.5 Nm
unit - J492- to all-wheel drive cou‐
pling

7 Propshaft
⇒ “7.1 Assembly overview – propshaft”, page 50
⇒ “7.2 Removing and installing propshaft”, page 51
⇒ “7.3 Removing and installing front flexible coupling”,
page 55
⇒ “7.4 Removing and installing rear flexible coupling”,
page 57
7.1 Assembly overview – propshaft
Note
No repairs can be made to the propshaft.
1 - Gearbox with bevel box

2 - Bolt
logue (ETKA)
❑ For flexible coupling to
propshaft
❑ 50 Nm and turn 90° fur‐
ther
3 - Front flexible coupling
logue (ETKA)
4 - Bolt
logue (ETKA)
❑ For flexible coupling to
bevel box
❑ 60 Nm
5 - Propshaft
❑ Cannot be separated at
joint -arrow-
logue (ETKA)
⇒ page 51
6 - Bolt
logue (ETKA)
❑ 25 Nm
7 - Centre bearing
❑ Align free of tension

8 - Bolt
❑ For flexible coupling to propshaft
❑ 50 Nm and turn 90° further
9 - Bolt
❑ For flexible coupling to final drive
❑ 60 Nm
10 - Flexible coupling with vibration damper
7.2 Removing and installing propshaft

♦ Counter-hold tool - T10172A-
♦ Engine and gearbox jack - VAS 6931- or -V.A.G 1383 A-
7. Propshaft 51
Note
♦ If possible, use a twin pillar lifting platform when working on

the propshaft.
♦ Before removing, mark positions of all parts relative to each
other. Reinstall in the same position otherwise imbalance will
be excessive, the mountings could be damaged causing rum‐
bling noises.
♦ Keep propshaft straight; store and transport fully extended on‐
ly.
♦ Do not let propshaft »hang« during removal; always support
it.
♦ Always pull propshaft from or push it onto drive flange hori‐
zontally .
Removing
sulation .
– Remove exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes, si‐
lencers; Assembly overview - silencer .
– If necessary, remove emission control system ⇒ 4-cyl. direct
injection engine (2.0 l, 4V, turbocharger, chain drive,
generation III) Volkswagen R GmbH; Rep. gr. 26 ; Emission
control .
– Unscrew bolts -2, 3- for pendulum support.
Note
Disregard -item 1-.
– Press engine and gearbox forwards and secure in position

with a suitable piece of wood -A-.
– Remove drive shaft heat shield from bevel box ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .

– Unscrew bolts -A- and -B- from bevel box and remove heat
shield -1-.
– Remove heat shield for centre tunnel beneath centre prop‐
shaft bearing ⇒ General body repairs, exterior; Rep. gr. 66 ;
Underbody cladding; Assembly overview - underbody clad‐
ding .
– Remove rear tunnel cross member ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Assembly over‐
view - underbody cladding .


T10172/5- .
Note
♦ Now, the propshaft is held in position solely by the centring

pins on bevel box and final drive as well as by the centre prop‐
shaft bearing in the middle.
♦ A second mechanic is required for further removal of the prop‐
shaft.
7. Propshaft 53
– While a second mechanic is holding the propshaft in installa‐

tion position, remove centre propshaft bearing -arrows- and
remove propshaft towards rear with the joint as straight as
possible.

WARNING
To avoid damaging the protective boot in the centre bearing,

remove, store and install the propshaft with the joint as straight
as possible.
Installing
Note
♦ Install all parts which were marked in relation to each other in

their original positions.
♦ Renew bolts that are tightened with turning further angle.
– Fit propshaft to rear final drive so that the markings -arrows-

align.

– Start bolts -arrows- for centre bearing, but do not yet tighten
them.
– Tighten bolts securing flexible coupling of propshaft to bevel
box and rear final drive.
– Align centre bearing in its elongated holes so that neither
propshaft nor centre bearing is under tension.
– Tighten bolts -arrows-.
Specified torques
♦ Subframe; Assembly overview - subframe ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Assembly overview -
subframe
♦ Exhaust pipes/silencers; Assembly overview - silencers ⇒
Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview -
silencers .
♦ Tunnel cross-piece ⇒ Underbody cladding; Assembly over‐
view - underbody cladding ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody cladding; Assembly overview - un‐
derbody cladding .
♦ Heat shield ⇒ Mouldings/trims/extensions; Assembly over‐
view - heat shield ⇒ General body repairs, exterior; Rep. gr.
66 ; Mouldings/trims/extensions; Assembly overview - heat
shield .
♦ Noise insulation; Assembly overview - noise insulation ⇒
General body repairs, exterior; Rep. gr. 66 ; Noise insulation;
Assembly overview - noise insulation
Component Specified torque
Bolt -A- securing heat shield to bevel 20 Nm
box
Bolt -B- securing heat shield to bevel 40 Nm
box
7.3 Removing and installing front flexible

coupling
♦ Engine and gearbox jack - V.A.G 1383 A-
7. Propshaft 55
♦ Counter-hold tool - T10172-
Brief description
The front flexible coupling can only be removed and installed with
propshaft removed.
Removing
Note
♦ A twin pillar lifting platform should be used when working on

the propshaft.
bling noises.
ly.
– Remove propshaft ⇒ page 51 .

– Place propshaft down with the joint as straight as possible.
In the following illustrations the flexible coupling is shown in in‐
stalled condition.
Unbolt front flexible coupling from propshaft -arrows-.

– Counterhold with counterhold tool - T10172- when loosening

or tightening bolts.
Installing
Note
♦ Do not damage seals in propshaft flanges -arrow- during re‐

moval and installation.
♦ Renew propshaft if damaged.
♦ Do not cant propshaft, push horizontally onto centring pin.
♦ All parts of propshaft which have been marked relative to each
other must be reinstalled in the same positions.
– Attach flexible coupling to propshaft using new bolts.

Installation position of flexible coupling with heat shield
♦ The open side of the guard plate faces away from propshaft
tube.
♦ Install flexible coupling so that the guard plate lies against the
propshaft flange.
– Install propshaft ⇒ page 51 .
Specified torques
7.4 Removing and installing rear flexible

coupling
♦ Engine and gearbox jack - V.A.G 1383 A-
7. Propshaft 57
Removing
Note
♦ A twin pillar lifting platform should be used when working on

the propshaft.
bling noises.
ly.
The procedure described below is only applicable for reinstalla‐

tion of previously removed parts.
– Before removal, check if there are coloured marks on flexible
coupling, on flange of final drive and on propshaft flange
-arrows-. If not, mark installation position of flexible coupling
-arrows-.
Continued for all:
sulation .
– Support front section of exhaust system using engine and
gearbox jack - V.A.G 1383 A- .

Note
Do not bend the flexible joint of the exhaust system more than 10°
– risk of damage.
– Unscrew bolts -1- and -2- of pendulum support.

– Press »engine and gearbox« slightly forwards and secure in

position with an appropriate piece of wood -A-.
– Remove heat shield for centre tunnel beneath centre prop‐
shaft bearing ⇒ General body repairs, exterior; Rep. gr. 66 ;
Underbody cladding; Assembly overview - underbody clad‐
ding .
– Unbolt flexible coupling with vibration damper from rear final

drive -arrows-.
– Have a second mechanic depress and hold brake pedal while
loosening and tightening threaded connection of propshaft
and final drive.
– Unscrew centre propshaft bearing bolts -arrows-.

– Pull propshaft off final drive and rest on tunnel cross member,
first laying a cloth on the tunnel cross member to protect the
shaft.

7. Propshaft 59
– After propshaft has been pulled off, secure centre propshaft

bearing on body using two bolts -arrows-. This prevents the
flexible coupling from being unnecessarily exposed to strain.
Unbolt rear flexible coupling with vibration damper from propshaft.
Installing
Note
♦ Do not damage seals in propshaft flanges -arrow- during re‐

moval and installation.
♦ Renew propshaft if damaged.
♦ Do not cant rear propshaft tube; push horizontally onto cen‐
tring pin.
♦ All parts of propshaft which have been marked relative to each
other must be reinstalled in the same positions.
– Attach flexible coupling to propshaft using new bolts. Specified

torques: ⇒ page 50
Installation position, flexible coupling with vibration damper:

♦ Collar on outer circumference -arrows- faces away from prop‐
shaft tube.
♦ 3 projecting sleeves each on propshaft flange and flange of
final drive engage in flexible coupling mounting holes.
The procedure described below is only applicable for reinstalla‐
tion of previously removed flexible coupling.
– Attach propshaft to propshaft flange of rear final drive so that

marks -arrows- align.


Note
Installing intermediate bearing free of tension
– Align intermediate bearing in its elongated holes so that nei‐

ther propshaft nor intermediate bearing is under tension.
– Do not tighten intermediate bearings until propshaft has been
fitted.
– Tighten propshaft and intermediate bearing bolts.
– Bolt on pendulum support using »new« bolts. Specified tor‐

ques ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe;
Assembly overview - subframe .
– Install heat shield for centre tunnel beneath centre propshaft
bearing ⇒ General body repairs, exterior; Rep. gr. 66 ; Un‐
derbody cladding; Assembly overview - underbody cladding .
– Install rear section of exhaust system ⇒ Rep. gr. 26 ; Exhaust
pipes/silencers; Assembly overview - silencer .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Assembly overview – noise insula‐
tion .
Specified torques
7. Propshaft 61

D4B8039775C-Propshaft and Rear Final Drive Volkswagen R GMBH

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D4B8039775C-Propshaft and Rear Final Drive Volkswagen R GMBH

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Service

Service Department. Technical Information

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Copyright © 2020 Volkswagen AG, Wolfsburg D4B8039775C

39 - Final drive - rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Safety measures when working on ve‐

2.1 Identification of final drive

♦ The final drive is fitted with an »all-wheel drive coupling«.

Allocation of rear final drive

The marking -arrow- on the »bottom« of the final drive provides

2 Rep. gr.00 - Technical data

3.1 General repair instructions

3.1.1 General information

Use caution when handling oil. Dispose of used oil properly.

3.1.3 Locking devices

3.2 Gaskets and seals

3.3 Nuts and bolts

4 Rep. gr.00 - Technical data

4.1 Allocation gearbox - engine

Glean following data from ⇒ Electronic Parts Catalogue (ETKA) :

5.1 Overview of fitting locations - electrical components

Rear final drive “0CQ” with all-wheel coupling generation V

1 - All-wheel drive coupling

6 Rep. gr.00 - Technical data

39 – Final drive - rear differential

1.1 Assembly overview - final drive

1.2 Removing and installing final drive

Special tools and workshop

♦ Socket insert - T10035- and, if necessary, bits - T10099-

Risk of damage to the flexible joint

8 Rep. gr.39 - Final drive - rear differential

– Separate exhaust system at clamp -arrows- and remove rear

– Unscrew bolts -2- and -3- for pendulum support.

Disregard -item 1-.

– Loosen bolts -arrows- for centre bearing of propshaft, but do

– Check whether there is a marking (paint dot) on flexible cou‐

– For loosening screw joints of propshaft, counterhold at rear

– Unscrew bolts -arrows- securing propshaft to rear final drive.

– Press engine/gearbox assembly forwards, and secure it in

Disregard -item 1-.

10 Rep. gr.39 - Final drive - rear differential

– When pulling off or pushing on propshaft, always ensure that

If seal is damaged, propshaft must be renewed.

– Loosen rear axle at rear bearings -arrows-.

– Screw spindle -3346/2- with assembly tool - 3301- and nut

Do not lower subframe more than 40 mm.

– Lower engine and gearbox jack - V.A.G 1383 A- until subframe

– Unscrew bolt -B- from bonded rubber mounting at front.

12 Rep. gr.39 - Final drive - rear differential

– Secure final drive against falling using strap as shown in illus‐

Illustrated with final drive removed.

– Pull breather lines -arrows- off final drive.

-Item A- can be disregarded.

– To remove, lower final drive further, and pull it forwards. En‐

– Secure final drive against falling using strap from gearbox

14 Rep. gr.39 - Final drive - rear differential

2.1 Assembly overview - assembly mount‐

1 - “Upper rear” bonded rubber

16 Rep. gr.39 - Final drive - rear differential

2.2 Removing and installing bonded rubber bush

Special tools and workshop

♦ Locking pin - 30 - 505-

♦ Internal puller e.g. KUKKO 21-1 - VAS 251 601-