REAR FINAL DRIVE

• HEADINGS
  • 00 General, Technical data
    • Rear final drive identification
    • Code letters, transmission ratios, capacities
      • Allocation of mechanical units: 5-speed Manual Transmission 01A AWD
      • Allocation of mechanical units: 6-speed Manual Transmission 01E, AWD
      • Allocation of mechanical units: 6-speed Manual Transmission 02X, AWD
      • Allocation of mechanical units: 6-speed Manual Transmission 0A3, AWD
      • Allocation of mechanical units: Automatic Transmission 01V FWD and AWD
      • Allocation of mechanical units: Automatic Gearbox 09L, AWD
    • Transmission layout
      • Transmission layout
    • Repair instructions
      • Repair instructions
  • 39 Final drive, Differential
    • Drive shaft, servicing
      • Drive shaft, servicing
      • Drive shaft, removing and installing
        • Removing
        • Installing
      • Drive shaft flange, measuring and marking radial run-out
    • Gear oil level in rear final drive, checking
      • Gear oil level in rear final drive, checking
    • Flange shaft oil seals, replacing
      • Flange shaft oil seals, replacing
    • Drive shaft flange seal, replacing
      • Drive shaft flange seal, replacing
        • Removing
        • Calculate dimension "a" and dimension "b"
        • Installing
    • Rear final drive, removing and installing
      • Rear final drive, removing and installing
      • Rear final drive, attaching to assembly bracket
        • Secure complete rear final drive on a repair stand with bracket VW 540
    • Rear final drive, disassembling and assembling
      • Assembly overview
    • Differential, removing and installing
      • Differential, removing and installing
        • Secure final drive on repair stand
        • Removing and installing flange shaft
        • Press in cover until stop
        • Installation position vent sleeve
        • Removal
        • Installing
    • Differential, disassembling and assembling
      • Differential, disassembling and assembling
        • Driving small taper roller bearing outer race out of cover
        • Pressing in taper roller bearing outer race small until stop into housing
        • Pulling off inner race for small taper roller bearing
        • Pressing on small taper roller bearing inner race
        • Pulling off inner race for large taper roller bearing
        • Pressing on large taper roller bearing inner race
        • Driving out outer race for large taper roller bearing out of cover
        • Pressing in outer race for large taper roller bearing into cover
        • Driving ring gear off housing
        • Installing ring gear
        • Installing small bevel gears
        • Adjusting differential bevel gears
    • Drive pinion, removing and installing and disassembling and assembling
      • Drive pinion, removing and installing and disassembling and assembling
        • Removing nut for drive pinion
        • Pulling flange for drive shaft off drive pinion
        • Pulling out seal for flange for drive shaft
        • Pressing drive pinion out of inner race for small taper roller bearing
        • Pulling out small taper roller bearing outer race
        • Driving out outer race for large taper roller bearing
        • Pressing inner race for large taper roller bearing off drive pinion
        • Pressing inner race for large taper roller bearing onto drive pinion
        • Pulling in outer race for large taper roller bearing
        • Pressing in small taper roller bearing outer race
        • Pressing on small taper roller bearing inner race
        • Inserting O-ring
        • Tapping in seal for flange for drive shaft
        • Installing flange
        • Tighten nut for drive pinion and adjusting friction torque
        • Measuring frictional torque
        • Removing nut for drive pinion
    • Drive pinion and ring gear, adjusting
      • Drive pinion and ring gear, adjusting
      • Gear sets, adjusting and marking
      • Position of shims
      • Adjustment overview
      • Final drive, readjustment sequence
      • Drive pinion, adjusting
      • Ring gear, adjusting
        • Determining total shim thickness "Stotal" for shims "S1" + "S2"
        • Determine "Stotal" (S1 + S2)
        • Determining thickness of shim "S1*"
        • Measuring frictional torque (check)
        • Adjusting backlash
        • Determining average backlash
        • Determining thickness of shim "S2"
        • The following shims are available for "S2"
        • Determining thickness of shim "S1"
        • The following shims are available for "S1"
        • Check measurement
• FIGURES
  • Fig. 1: Locations Of Final Drive Identification
  • Fig. 2: Final Drive 01R
  • Fig. 3: Locating Code Letters And Date Of Manufacture Of Final Drive
  • Fig. 4: Transmission, Overview
  • Fig. 5: Transmission, Overview
  • Fig. 6: Identifying Space Between Oil Seal Sealing Lips
  • Fig. 7: Identifying Spring Pins Installation Position
  • Fig. 8: Exploded View Of Drive Shaft
  • Fig. 9: Alignment Fixture-4W Dr. Shaft 3139
  • Fig. 10: Identifying Pry Lever 80-200
  • Fig. 11: Identifying Engine/Transmission Jack V.A.G. 1383 A
  • Fig. 12: Using Press Lever - RMV Outside Mirror 80-200 To Pry Off Rear Attachments Of Heat Shield For Drive Shaft & Removing Securing Bolts For Center Bearing
  • Fig. 13: Identifying Driveshaft Shield
  • Fig. 14: Driveshaft, Removing And Installing
  • Fig. 15: Engaging Alignment Fixture-4W dr. Shaft 3139
  • Fig. 16: Removing/Installing Securing Bolts For Center Bearing
  • Fig. 17: Loosening Front And Rear Driveshaft Bolts
  • Fig. 18: Driveshaft, Removing And Installing
  • Fig. 19: Removing/Installing Securing Bolts For Center Bearing
  • Fig. 20: Loosening Front And Rear Driveshaft Bolts
  • Fig. 21: Removing/Installing Securing Bolts For Center Bearing
  • Fig. 22: Installing Heat Shield, Screwing In Securing Bolts For Left/Right Center Bearing & Heat Shield On Right/Left At Center Bearing Using Bolts
  • Fig. 23: Installing Rear Securing Clips For Heat Shield
  • Fig. 24: Identifying Dial Gauge Holder VW 387
  • Fig. 25: Install Measuring Tools (Vehicles With Threaded Hole In Facing Side Of Rear Final Drive)
  • Fig. 26: Identifying Drip Tray V.A.G 1306
  • Fig. 27: Identifying Sealing Plug For Gear Oil Inspection Plug
  • Fig. 28: Fitting Drift 2062
  • Fig. 29: Identifying Drip Tray V.A.G 1306
  • Fig. 30: Removing/Installing Heat Shields From Final Drive
  • Fig. 31: Removing/Installing Flange Shaft Bolt
  • Fig. 32: Removing Flange Shaft Oil Seals
  • Fig. 33: Driving In New Flange Seal
  • Fig. 34: Removing/Installing Heat Shields From Final Drive
  • Fig. 35: Identifying Special Tools - Drive Shaft Flange Seal, Replacing
  • Fig. 36: Drive Pinion 3143
  • Fig. 37: Markings On Driveshaft Flange (Dots)
  • Fig. 38: Removing/Installing Securing Bolts At Transmission Support
  • Fig. 39: Determining Dimension "A" And Dimension "B"
  • Fig. 40: Screw On Retainer 3028 And Unscrew Securing Nut For Drive Pinion
  • Fig. 41: Pull Off Flange Using Puller VW 391
  • Fig. 42: Pulling Out Sealing Ring
  • Fig. 43: Inserting O-Ring
  • Fig. 44: Driving In Seal For Driveshaft Flange
  • Fig. 45: Driving Drive Shaft Flange Onto Drive Pinion
  • Fig. 46: Checking Dimension "A" And Dimension "B"
  • Fig. 47: Locking Drive Pinion Hexagon Nut
  • Fig. 48: Removing/Installing Securing Bolts At Transmission Support
  • Fig. 49: Identifying Engine/Transmission Jack V.A.G. 1383 A
  • Fig. 50: Markings On Driveshaft Flange (Dots)
  • Fig. 51: Tying Drive Shaft To Exhaust System Bracket Using Wire
  • Fig. 52: Place Engine/Transmission Jack V.A.G 1383 A With Universal Transmission Support V.A.G 1359/2 Under Final Drive And Secure Final Drive
  • Fig. 53: Removing/Installing Securing Bolts At Transmission Support
  • Fig. 54: Removing Nuts From Left/Right Of Cross Piece
  • Fig. 55: Removing/Installing Securing Bolts From Crossmember
  • Fig. 56: Driveshaft, Removing And Installing
  • Fig. 57: Pushing Rear Final Drive At Left-Hand Drive Axle Upward & Constant Velocity Joint Of Drive Axle Outward Until Limit Stop And Lower Toward Flange Shaft
  • Fig. 58: Removing/Installing Securing Bolts At Transmission Support
  • Fig. 59: Removing Nuts From Left/Right Of Cross Piece
  • Fig. 60: Holding Fixture VW 540
  • Fig. 61: Clamp Rear Final Drive In Assembly Fixture
  • Fig. 62: Rear Final Drive, Overview
  • Fig. 63: Rear Differential, Overview
  • Fig. 64: Clamping Rear Final Drive In Assembly Fixture
  • Fig. 65: Removing/Installing Drive Flange
  • Fig. 66: Pressing In Cover Up To Stop
  • Fig. 67: Installed Location Of Breather Sleeve
  • Fig. 68: Identifying Drip Tray V.A.G 1306
  • Fig. 69: Removing/Installing Drive Flange
  • Fig. 70: Removing/Installing Drive Flange
  • Fig. 71: Identifying Special Tools - Differential, Disassembling And Assembling (1 Of 2)
  • Fig. 72: Identifying Special Tools - Differential, Disassembling And Assembling (2 Of 2)
  • Fig. 73: Tapered Roller Bearing Puller V.A.G 1582
  • Fig. 74: Tapered Roller Bearing Puller V.A.G 1582
  • Fig. 75: Rear Differential, Overview
  • Fig. 76: Driving Small Tapered Bearing/Outer Race Out Of Housing
  • Fig. 77: Pressing Small Tapered Bearing/Outer Race Into Housing To Stop
  • Fig. 78: Pulling Off Small Inner Race/Tapered Bearing
  • Fig. 79: Pressing On Small Tapered Bearing Inner Race
  • Fig. 80: Pulling Off Large Inner Race/Tapered Bearing
  • Fig. 81: Pressing On Inner Race Of Large Taper Roller Bearing
  • Fig. 82: Driving Off Outer Race/Tapered Bearing From Cover
  • Fig. 83: Pressing Outer Race/Tapered Bearing Into Cover
  • Fig. 84: Driving Out Ring Gear From Housing
  • Fig. 85: Installing Ring Gear
  • Fig. 86: Installing Small Differential Bevel Gears
  • Fig. 87: Differential Planetary Gears, Adjusting
  • Fig. 88: Installing Differential Bevel Gear Shim
  • Fig. 89: Identifying Special Tools - Drive Pinion, Removing And Installing And Disassembling And Assembling (1 Of 4)
  • Fig. 90: Identifying Special Tools - Drive Pinion, Removing And Installing And Disassembling And Assembling (2 Of 4)
  • Fig. 91: Identifying Special Tools - Drive Pinion, Removing And Installing And Disassembling And Assembling (3 Of 4)
  • Fig. 92: Identifying Special Tools - Drive Pinion, Removing And Installing And Disassembling And Assembling (4 Of 4)
  • Fig. 93: Exploded View Of Drive Pinion Assembly
  • Fig. 94: Removing/Installing Nut For Pinion
  • Fig. 95: Pull Off Flange Using Puller VW 391
  • Fig. 96: Pulling Out Sealing Ring
  • Fig. 97: Pressing Off Drive Pinion From Inner Race/Tapered Bearing
  • Fig. 98: Pulling Off Small Outer Race/Tapered Bearing
  • Fig. 99: Driving Out Large Outer Race/Tapered Bearing
  • Fig. 100: Pressing Off Inner Race Of Large Taper Roller Bearing
  • Fig. 101: Pressing On Inner Race Of Large Taper Roller Bearing
  • Fig. 102: Pulling In Large Outer Race/Tapered Bearing
  • Fig. 103: Pressing In Small Outer Race/Tapered Bearing
  • Fig. 104: Installing Small Taper Roller Bearing Inner Race
  • Fig. 105: Inserting O-Ring
  • Fig. 106: Driving In Seal For Driveshaft Flange
  • Fig. 107: Driving Drive Shaft Flange Onto Drive Pinion
  • Fig. 108: Removing/Installing Nut For Pinion
  • Fig. 109: Measuring Friction Torque
  • Fig. 110: Locking Drive Pinion Hexagon Nut
  • Fig. 111: Identifying Gear Set Markings And Adjustment Dimensions
  • Fig. 112: Identifying Gear Set Markings And Adjustment Dimensions
  • Fig. 113: Identifying Differential Adjustment Shim Positions
  • Fig. 114: Universal Measuring Device VW 385
  • Fig. 115: Holding Fixture VW 540
  • Fig. 116: Installing Small Taper Roller Bearing Inner Race
  • Fig. 117: Measuring Friction Torque
  • Fig. 118: Setting Adjusting Rings Of Measuring Bar VW 385/1
  • Fig. 119: Assemble Measuring Bar According
  • Fig. 120: Placing Magnetic Plate Onto Drive Pinion Face
  • Fig. 121: Insert Measuring Mandrel In The Housing
  • Fig. 122: Insert Universal Mandrel And Perform Check Measurement
  • Fig. 123: Insert Measuring Mandrel In The Housing
  • Fig. 124: Identifying Special Tools - Ring Gear, Adjusting
  • Fig. 125: Installing Special Tools VW 521/4 And 521/8 Onto Housing Side In Differential Housing
  • Fig. 126: Installing Measuring Tools
  • Fig. 127: Read Play On Dial Gauge
  • Fig. 128: Measuring Differential Frictional Torque
  • Fig. 129: Installing Measuring Tools
  • Fig. 130: Installing Measuring Tools
• TABLES

REAR DIFFERENTIAL

Rear Final Drive

00 General, Technical data

Rear final drive identification

The 01R rear final drive in the Audi A4 2001 > is assigned to the following transmissions:

• 5-Speed Manual Transmission 01A, AWD
• 6-speed Manual Transmission 01E, AWD
• 6-speed Manual Transmission 02X, AWD
• 6-speed Manual Transmission 0A3, AWD

• Automatic Transmission 01V, AWD
• Automatic Transmission 09L, AWD

Allocation. Refer to Allocation of mechanical units: 5-speed Manual Transmission 01A AWD, Technical data

Fig. 1: Locations Of Final Drive Identification
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Location on final drive

Code letters and date of manufacture (arrow 1)

Final drive 01R (arrow 2)

Fig. 2: Final Drive 01R
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Final drive 01R (arrow 2)

Fig. 3: Locating Code Letters And Date Of Manufacture Of Final Drive
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Code letters and manufacturing data for the final drive

Example:	EUB	26	04	00
	I	I	I	I
	I	I	I	I
	Code letters	Day	Month	Year (2000) of manufacture

Additional data is production-related

Code letters, transmission ratios, capacities

Allocation of mechanical units: 5-speed Manual Transmission 01A AWD

Rear final drive		01R
Code letters		ETT	ETS
Production	from	02.01	09.00
	to	-	-
Allocation	Model	Audi A4 2002 >	Audi A4 2002 >
	Engine	1.8 l -110 kW 1.8 l -120 kW	1.8 l -125 kW 2.0 l -132 kW 3.0 l -162 kW
Ratio	Final drive Z2:Z1 = i	35 : 9 = 3.889	35 : 9 = 3.889
Capacity		1.5 ltr.
Specification		Gear oil G 052 145 A1 (container size, 0.5 liter) Gear oil G 052 145 S2 (container size, 1.0 liter)
Axle shaft flange diameter		70.7 mm	75.5 mm

Allocation of mechanical units: 6-speed Manual Transmission 01E, AWD

Rear final drive		01R
Code letters		ETQ	FUB
Production	from	09.00	11.02
	to	-	-
Allocation	Model	Audi A4 2002 >	Audi A4 2002 >
	Engine	3.0 l - 162 kW	1.8 l - 140 kW 3.0 l - 162 kW
Ratio	Final drive Z2:Z1 = i	37 : 9 = 4.111	35 : 8 = 4.375
Capacity		1.5 ltr.
Specification		Gear oil G 052 145 A1 (container size, 0.5 liter) Gear oil G 052 145 S2 (container size, 1.0 liter)
Axle shaft flange diameter		75.5 mm	75.5 mm

Allocation of mechanical units: 6-speed Manual Transmission 02X, AWD

Rear final drive		01R
Code		ETQ	ETR	ETS
Production	from	09.00	06.03	09.00
	to	-	-	-
Allocation	Model	Audi A4 2002 >	Audi A4 2002 >	Audi A4 2002 >
	Engine	1.8 l - 125 kW	1.8 l - 120 kW	3.0 l - 162 kW
Ratio	Final drive Z2 : Z1 = i	37 : 9 = 4.111	37 : 9 = 4.111	35 : 9 = 3.889
Capacity		1.5 ltr.
Specification		Gear oil G 052 145 A1 (container size, 0.5 liter) Gear oil G 052 145 S2 (container size, 1.0 liter)
Axle shaft flange diameter		75.5 mm	70.7 mm	75.5 mm

Allocation of mechanical units: 6-speed Manual Transmission 0A3, AWD

Rear final drive		01R
Code		EXZ
Production	from	11.02
	to	-
Allocation	Model	Audi A4 2002 >
	Engine	4.2 l - 253 kW
Ratio	Final drive Z2 : Z1 = i	35 : 9 = 3.889
Capacity		1.5 ltr.
Specification		Axle oil G 052 145 A1 (container size, 0.5 liter) Axle oil G 052 145 S2 (container size, 1.0 liter)
Axle shaft flange diameter		75.5 mm

Allocation of mechanical units: Automatic Transmission 01V FWD and AWD

Rear final drive		01R
Code letters		ETQ	ETS
Production	from	09.00	09.00
	to	-	-
Allocation	Model	Audi A4 2002 >	Audi A4 2002 >
	Engine	1.8 l - 125 kW 2.0 l - 132 kW 3.0 l - 162 kW	3.0 l - 162 kW
Ratio	Final drive Z2:Z1 = i	37 : 9 = 4.111	35 : 9 = 3.889
Capacity		1.5 ltr.
Specification		Gear oil G 052 145 A1 (container size, 0.5 liter) Gear oil G 052 145 S2 (container size, 1.0 liter)
Axle shaft flange diameter		75.5 mm	75.5 mm

Allocation of mechanical units: Automatic Gearbox 09L, AWD

Rear final drive		01R
Code		GDF
Production	from	07.03
	to	-
Allocation	Model	Audi A4 2002 >
	Engine	4.2 L - 253 kW
Ratio	Final drive Z2 : Z1 = i	31 : 10 = 3.100
Capacity		1.5 ltr.
Specification		Axle oil G 052 145 A1 (container size, 0.5 liter) Axle oil G 052 145 S2 (container size, 1.0 liter)
Axle shaft flange diameter		75.5 mm

Transmission layout

Transmission layout

Fig. 4: Transmission, Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Illustrated with the 6-speed manual transmission 01E all wheel drive

Designation

1 - Engine

2 - Clutch

3 - Manual transmission

4 - Input shaft

5 - Front differential

6 - Front drive pinion (output shaft)

7 - Hollow shaft

8 - Torsen differential

9 - Drive shaft

10 - Rear drive pinion

11 - Rear differential

Arrows in direction of travel

Fig. 5: Transmission, Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Ratio

I	-	1st gear
II	-	2nd gear
III	-	3rd gear
IV	-	4th gear
V	-	5th gear
VI	-	6th gear
R	-	Reverse gear
A1	-	Front final drive
A2	-	Rear final drive
T	-	Speedometer drive

Arrows in direction of travel

Repair instructions

Repair instructions

The maximum possible care and cleanliness and proper tools are essential to ensure satisfactory and successful transmission repairs. The usual basic safety precautions also naturally apply when carrying out vehicle repairs.

A number of generally applicable instructions for individual repair operations, which are otherwise mentioned at various points in the article, are summarized here. They apply to this article.

Transmission

• When replacing rear final drive the oil level in rear final drive must be checked and, if necessary, corrected. Refer to Gear oil level in rear final drive, checking.
• Capacities and specifications. Refer to Allocation of mechanical units: 5-speed Manual Transmission 01A AWD.
• When assembling mounting brackets as well as waxed components clean contact surfaces. The contact surfaces must be free of wax and grease.

Gaskets, sealing rings

• Replace O-rings.
• Radial shaft oil seals.

Before installing:

Fig. 6: Identifying Space Between Oil Seal Sealing Lips
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lightly oil outer circumference and pack space between sealing lips -arrow- half-full with sealing grease G 052 128 A1.

After installation:

Check gear oil in rear final drive; if necessary top off to lower edge of oil filler hole, specification. Refer to Allocation of mechanical units: 5-speed Manual Transmission 01A AWD.

Locking elements

• Replace circlips.
• Do not over-stretch circlips.
• Circlips must be properly seated in the base of the groove.

Fig. 7: Identifying Spring Pins Installation Position
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Replace spring pins.

Installation position: Slot longitudinal to line of force.

Nuts, bolts

• Nuts and bolts which secure covers and housings should be loosened and tightened diagonally.
• Parts which are particularly sensitive must not be tilted; loosen or tighten diagonally in stages.
• Tightening torques stated apply to non-oiled nuts and bolts.
• Replace self-locking bolts and nuts.

• Make sure with all screw connections that contact surfaces as well as bolts and nuts are only waxed after assembly, if necessary.

Bearings

• Attach needle bearing with the written side (greater plate thickness) to the installing tool.
• Install new taper roller bearings in delivery condition and do not oil.
• Always replace taper roller bearings on one shaft together and use new bearings from a single manufacturer.
• Heat inner races to approx. 100°C before installing.

• Do not interchange outer or inner races of bearings of the same size. The bearings are paired.

Adjustment shims

• Check thickness of shims by measuring at several points with a micrometer. Different tolerances make it possible to obtain exact shim thickness required.
• Check for burrs and damage.
• Install only adjustment shims which are in perfect condition.

39 Final drive, Differential

Drive shaft, servicing

Drive shaft, servicing

NOTE:

General repair instructions. Refer to Repair instructions. Drive shaft may be bent without force up to stop of the central constant velocity joint. Further bending may cause damage to the joint or to the boots. Only store and transport drive shaft extended. No repair work can be carried out on the drive shaft with the exception of removing, installing and adjusting. If the drive shaft is only detached at the transmission or from rear final drive then the drive shaft is to be tied-up at the constant velocity joint. The drive shaft may also be bent without force up to the stop of the central constant velocity joint, if necessary. Prior to removal mark the position of all parts in relation to each other. Reinstall in the same positions otherwise the imbalance will be excessive; the bearings could be damaged and humming noises may occur. After removing the drive shaft from the rear final drive, a thick washer that may be located between the shim and the hexagon socket head bolt must not be reinstalled. If complaints are received (noises, vibrations), it is essential to check the radial run-out to drive flange at the rear final drive. A correct adjustment may repair the problem. Refer to Drive shaft flange, measuring and marking radial run-out.

Fig. 8: Exploded View Of Drive Shaft
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Rear final drive

2 - Drive shaft

• Removing and installing. Refer to Drive shaft, removing and installing.

3 - Gasket

• Replace
• Detach protective foil and stick self-adhesive side of the gasket onto flange shaft
• Degrease flange shaft

4 - Shim

5 - Hex socket-head bolt - 55 Nm

• Self-locking
• Replace
• The tapped holes for the bolts in the flange shaft must always be cleaned (e.g. with a thread tap)

6 - Combi bolt - 23 Nm

7 - Transmission

Drive shaft, removing and installing

Special tools, testers and auxiliary equipment required

Fig. 9: Alignment Fixture-4W Dr. Shaft 3139
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Assembly tool 3139

Fig. 10: Identifying Pry Lever 80-200
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pressing lever 80-200
• Bolt M8 x 30 (2x)

Special tools, testers and auxiliary items required

Fig. 11: Identifying Engine/Transmission Jack V.A.G. 1383 A
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Engine/transmission jack V.A.G 1383 A with universal transmission mounting V.A.G 1359/2

Removing

• See notes. Refer to Drive shaft, servicing
• Remove rear section of exhaust system as from clamp(s):

Refer to

• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
• 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

; Removing and installing exhaust-system components

Fig. 12: Using Press Lever - RMV Outside Mirror 80-200 To Pry Off Rear Attachments Of Heat Shield For Drive Shaft & Removing Securing Bolts For Center Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Use press lever - RMV outside mirror 80-200 to pry off rear attachments -A- of heat shield for drive shaft.
• Remove securing bolts -B- for center bearing.

NOTE:

When removing the securing bolts support the drive shaft by hand. Do not bend drive shaft. Refer to Drive shaft, servicing.

• Remove heat shield. Continue supporting drive shaft.
• Screw in securing bolts for center bearing again hand-tight.

Fig. 13: Identifying Driveshaft Shield
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove heat shield for drive shaft off transmission -arrows-.

Fig. 14: Driveshaft, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Check for a factory marking (colored dot) on drive shaft and on drive shaft flange on final drive at the rear. If no colored dot is present, mark the position of the drive shaft flange -arrow A- relative to the rear final drive -arrow B- with a colored dot.

Fig. 15: Engaging Alignment Fixture-4W dr. Shaft 3139
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Engage alignment fixture-4W dr. shaft 3139 and tighten plastic nuts.

NOTE:

Never install assembly appliance onto balance plates.

Fig. 16: Removing/Installing Securing Bolts For Center Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove securing bolts -arrows- for the center bearing.

Fig. 17: Loosening Front And Rear Driveshaft Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Screw in bolt -3- M10 x 100 into rear final drive.
• To loosen bolts -1- of the rear and front drive shaft, counterhold with an assembly lever -2-.
• Remove securing bolts at the front constant velocity joint, detach the drive shaft and support it using engine/transmission jack V.A.G 1383 A.
• Remove securing bolts at rear constant velocity joint and detach drive shaft.

NOTE:

Only transport and store drive shaft when extended.

Installing

Installation is carried out in reverse order. Note the following:

NOTE:

Fig. 18: Driveshaft, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. To avoid imbalance, the flanges of the drive shaft -arrow A- and of the rear final drive -arrow B- must be installed so that the factory color markings or the markings made subsequently are in line. If a new drive shaft is installed and if the factory color marking on the flange of the rear final drive is no longer visible, the radial run-out on the drive shaft flange must be measured. Refer to Drive shaft flange, measuring and marking radial run-out and the color marking on the drive shaft placed in line with the new marking on the flange. Replace gaskets on flange shafts (detach protective foil and stick gasket onto flange shaft). Remove the old and dry high-temperature grease from the constant velocity joints and the flanges for the drive shaft. Replace with the exact same quantity of new high-temperature grease G 000 633. Note the installation position of the drive shaft: The central constant velocity joint is located behind the center bearing facing toward the rear final drive. After removing the drive shaft from the rear final drive, a thick washer that may be located between the shim and the bolt head must not be reinstalled. It is essential that the locking fluid remaining in the threads in the flange shafts on the transmission and rear final drive is cleaned out after removing the drive shaft. Otherwise there is a danger that the new bolts will seize when they are screwed in and then shear if they have to removed later. The threaded holes can be cleaned with a thread tap. Replace drive shaft bolts (self-locking).

• Install drive shaft and attach bolts for constant velocity joint.

Fig. 19: Removing/Installing Securing Bolts For Center Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Screw in securing bolts -arrows- for center bearing hand-tight.

Fig. 20: Loosening Front And Rear Driveshaft Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Screw in bolt -3- M10 x 100 into rear final drive.
• To tighten bolts -1- of the rear and front drive shaft, counterhold with an assembly lever -2-.

Fig. 21: Removing/Installing Securing Bolts For Center Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove assembly device 3139
• Remove securing bolts -arrows- for the center bearing. The drive shaft must be supported manually by a second mechanic.

NOTE:

When removing the securing bolts support the drive shaft by hand. Refer to Drive shaft, servicing.

Fig. 22: Installing Heat Shield, Screwing In Securing Bolts For Left/Right Center Bearing & Heat Shield On Right/Left At Center Bearing Using Bolts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install heat shield -2-. Continue supporting drive shaft.
• Screw in securing bolts -4- for left and right center bearing several turns.
• Secure heat shield -2- on right and left at the center bearing -3- using bolts -1- (M8x30).

NOTE:

When tightening the combination bolt -4- make sure that the center plug -arrow A- is located at the securing bore -arrow B-.

Fig. 23: Installing Rear Securing Clips For Heat Shield
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Tighten securing bolts -2- for the center bearing.
• Install rear securing clips for the heat shield.
• Remove bolts -1-
• Install exhaust system and align stress-free:

Refer to

• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
• 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

; Removing and installing exhaust-system components

Tightening torques

Component	Nm
Intermediate bearing on body	23
Drive shaft to transmission	55
Drive shaft to rear final drive	55
Heat shield for drive shaft to transmission	25

Drive shaft flange, measuring and marking radial run-out

Special tools, testers and auxiliary equipment required

Fig. 24: Identifying Dial Gauge Holder VW 387
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Universal dial indicator bracket VW 387
• Dial indicator
• Bolt M10 x 85

NOTE:

The radial run-out must always be measured when the drive shaft flange on the rear final drive has been removed. Affix a new colored dot and remove the old color marking. If a new drive shaft is installed and if the marking on the flange shaft of the rear final drive is no longer visible, the position of maximum radial run-out must be determined and marked by a colored dot. The colored dot on the drive shaft is positioned opposite the above colored dot. Refer to Installing. The radial run-out can be measured when rear final drive is installed but the drive shaft must be disconnected at rear final drive. See notes. Refer to Drive shaft, servicing

Fig. 25: Install Measuring Tools (Vehicles With Threaded Hole In Facing Side Of Rear Final Drive)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Secure universal dial indicator holder VW 387 with dial indicator at rear final drive.
• Position dial indicator on ground diameter in drive shaft flange -arrow- and set to "0" with 1 mm preload.
• Rotate differential by turning the two rear wheels (left and right-hand flange shafts) simultaneously in one direction until the drive shaft flange has undergone one complete revolution.
• Mark the position of greatest radial run-out on flange exterior by a colored dot (equates to greatest distance from rotational axis).

• Remove old marking from drive shaft flange.
• Install drive shaft. Refer to Drive shaft, removing and installing.

Gear oil level in rear final drive, checking

Gear oil level in rear final drive, checking

Special tools, testers and auxiliary equipment required

Fig. 26: Identifying Drip Tray V.A.G 1306
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drip tray V.A.G 1306

• Place drip tray V.A.G 1306 underneath.

Fig. 27: Identifying Sealing Plug For Gear Oil Inspection Plug
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove screw plug -1- to gear oil control.

The oil level is correct when rear final drive is filled to lower edge of filler hole.

• Top off with gear oil, if necessary:

Specification. Refer to Allocation of mechanical units: 5-speed Manual Transmission 01A AWD.

• Install screw plug.

Tightening torque

Component	Nm
Screw plug	35

Flange shaft oil seals, replacing

Flange shaft oil seals, replacing

Special tools, testers and auxiliary equipment required

Fig. 28: Fitting Drift 2062
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Driver 2062

Fig. 29: Identifying Drip Tray V.A.G 1306
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drip tray V.A.G 1306

• Observe general repair instructions. Refer to Repair instructions

• Rear final drive installed

NOTE:

The illustration shows the left-hand side of the rear final drive. The procedure for removing and installing the joint flange and sealing ring on the right-hand side is identical.

Removing

Fig. 30: Removing/Installing Heat Shields From Final Drive
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove heat shields from final drive -arrows-.
• Disconnect drive axle.

Refer to 42 - REAR SUSPENSION ; Removing and installing drive axle

• Place drip tray underneath to collect oil.

Fig. 31: Removing/Installing Flange Shaft Bolt
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove securing bolt for flange shaft, then screw two bolts into the flange and counterhold the flange shaft using the assembly lever.
• Pull out flange shaft.

Fig. 32: Removing Flange Shaft Oil Seals
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Pry out flange shaft oil seals using a suitable lever.

Installing

Installation is carried out in reverse order. Note the following:

• Pack space between sealing and dust lips half-full with sealing grease G 052 128 A1.
• Lightly oil outer circumference of seal.

Fig. 33: Driving In New Flange Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drive new seal in onto stop, for this purpose do not cant seal.
• Insert flange shaft.
• Fasten flange shaft with cone head bolt.
• Top off gear oil in rear final drive and check oil level. Refer to Gear oil level in rear final drive, checking.

• Attach drive axles.

Refer to 42 - REAR SUSPENSION ; Removing and installing drive axle

Fig. 34: Removing/Installing Heat Shields From Final Drive
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Attach heat shields to final drive -arrows-.

Tightening torques

Component	Nm
Drive flange on rear final drive	25
Heat shields on rear final drive	23

Drive shaft flange seal, replacing

Drive shaft flange seal, replacing

Fig. 35: Identifying Special Tools - Drive Shaft Flange Seal, Replacing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

The following special tools and testing devices are required:

• V.A.G 1383A Engine/transmission jack with universal mounting V.A.G 1359/2
• 3028 - Retainer
• VW 391 -Puller
• VW 771 - Slide hammer-complete set

• VW 771/37 Additional part for VW 771
• 3026 - Mandrel

Fig. 36: Drive Pinion 3143
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drive pinion 3143
• Rear final drive installed

• Observe general repair instructions. Refer to Repair instructions

Removing

• Remove rear section of exhaust system as from clamp(s):

Refer to

• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
• 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

; Removing and installing exhaust-system components

Fig. 37: Markings On Driveshaft Flange (Dots)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Check whether there is a factory marking (paint dot) on drive shaft. If you do not find one, mark the position of the constant velocity joint -arrow A- relative to the rear final drive -arrow B-with a colored dot
• Disconnect drive shaft from rear final drive and tie it up to exhaust system brackets. Refer to Drive shaft, removing and installing.
• Place engine/transmission jack V.A.G 1383 A with universal transmission mounting 1359/2 under final drive and secure final drive.

Fig. 38: Removing/Installing Securing Bolts At Transmission Support
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove securing bolts -arrows- of left final drive support.
• Carefully lower final drive until flange is freely accessible.
• Color-mark the position of the securing nut for the drive pinion.

Calculate dimension "a" and dimension "b"

Fig. 39: Determining Dimension "A" And Dimension "B"
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Distance of flange to drive pinion =

Dimension a

• Distance of flange to securing nut for the drive pinion =

Dimension b

• Note calculated dimensions
• Count turns when unscrewing the securing nut and make a note of them.

NOTE:

Illustrations show the final drive removed for the following procedure.

Fig. 40: Screw On Retainer 3028 And Unscrew Securing Nut For Drive Pinion
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install support tool 3028 and remove drive pinion nut.
• Place drip tray underneath to collect oil.

Fig. 41: Pull Off Flange Using Puller VW 391
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Detach flange with removal tool VW 391.

A - Screw in two hex bolts M8 x 30 into flange.

Fig. 42: Pulling Out Sealing Ring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove sealing ring.

Installing

Installation is carried out in reverse order. Note the following:

Fig. 43: Inserting O-Ring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Replace O-ring between drive pinion bearing and flange.
• Lightly oil O-ring before installing.
• Pack space between sealing and dust lips half-full with sealing grease G 052 128 A1.
• Lightly oil outer circumference of seal.

Fig. 44: Driving In Seal For Driveshaft Flange
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drive in seal for drive shaft flange onto stop with drift 3026.

Fig. 45: Driving Drive Shaft Flange Onto Drive Pinion
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drive shaft flange onto drive pinion until securing nut can be mounted.

NOTE:

Use the old hex nut to reattach the flange to the drive pinion. Otherwise the original installed position will not be relocated.

• Clean drive pinion nut and threads on drive pinion of oil and grease residues. Thinly coat threads with locking fluid D 000 600.

NOTE:

The number of turns when reattaching must be the same as during unscrewing.

Fig. 46: Checking Dimension "A" And Dimension "B"
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Perform control measurement - check dimension "a" and dimension "b". Refer to Calculate dimension "a" and dimension "b" onward.

NOTE:

O-ring -1- must be installed when measuring. The hex nut must be returned to exactly the marked position. Maximum permissible deviation from original measurements: ± 0.3 mm.

Fig. 47: Locking Drive Pinion Hexagon Nut
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Lock hex nut.
• Move final drive back to installation position.

Fig. 48: Removing/Installing Securing Bolts At Transmission Support
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Screw final drive to front mounting bracket -arrows-.
• Top off gear oil in rear final drive and check oil level. Refer to Gear oil level in rear final drive, checking.
• If there was a factory marking at the drive shaft determine now the radial run-out at the flange/drive shaft. Refer to Drive shaft flange, measuring and marking radial run-out. Attach drive shaft in such a way that the color coding at the drive shaft are aligned with new marking at flange.
• If the position of the drive shaft relative to the flange/drive shaft were marked before removal the drive shaft must be reattached at same position. Refer to Drive shaft, removing and installing.

Observe installation instructions. Refer to Drive shaft, servicing

• Replace seal on drive shaft flange and tighten drive shaft to torque. Refer to Drive shaft, removing and installing.
• Stress-free alignment of exhaust system:

Refer to

• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
• 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

; Removing and installing exhaust-system components

Tightening torques

Component	Nm
Front transmission support on final drive	40
Drive shaft on rear final drive	55

Rear final drive, removing and installing

Rear final drive, removing and installing

Special tools, testers and auxiliary equipment required

Fig. 49: Identifying Engine/Transmission Jack V.A.G. 1383 A
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Engine/transmission jack V.A.G 1383 A with universal transmission mounting V.A.G 1359/2

Removing

• Remove rear section of exhaust system as from clamp(s):

Refer to

• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
• 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

; Removing and installing exhaust-system components

Fig. 50: Markings On Driveshaft Flange (Dots)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Check whether there is a factory marking (paint dot) on drive shaft. If you do not find one, mark position of the drive shaft flange -arrow A- relative to rear final drive -arrow B- with a colored dot.
• Remove drive shaft from rear final drive. Refer to Drive shaft, removing and installing

Fig. 51: Tying Drive Shaft To Exhaust System Bracket Using Wire
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Tie drive shaft to exhaust system bracket using a wire.
• Remove heat shields for drive axles at final drive.
• Remove drive axles from left and right from the flanges of the rear final drive.

Refer to 42 - REAR SUSPENSION ; Removing and installing drive axle

Fig. 52: Place Engine/Transmission Jack V.A.G 1383 A With Universal Transmission Support V.A.G 1359/2 Under Final Drive And Secure Final Drive
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Place engine/transmission jack V.A.G 1383 A with universal transmission mounting 1359/2 under rear final drive and secure rear final drive.

Fig. 53: Removing/Installing Securing Bolts At Transmission Support
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove securing bolts of mounting bracket of rear final drive -arrows-.

Fig. 54: Removing Nuts From Left/Right Of Cross Piece
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove nuts -arrows- from left and right of cross piece.
• Pull bolts out of subframe as far as possible.

NOTE:

The bolts remain in the subframe.

• Slightly lower rear section of final drive.
• Move drive axles clear toward top.
• Lower rear section of final drive.

Fig. 55: Removing/Installing Securing Bolts From Crossmember
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• If rear final drive is replaced then remove rear cross piece -arrows-.

Installing

Installation is carried out in reverse order. Note the following:

NOTE:

Always replace self-locking nuts. It is essential that the residues of locking fluid are cleaned out from the threaded holes in flange shaft on the rear final drive after removing the drive shaft. Otherwise there is a danger that the new bolts will seize and then shear when removing them again. The threaded holes can be cleaned with a thread tap. Replace drive shaft bolts (self-locking). Replace gaskets on flange shaft (detach protective foil and stick gasket onto flange shaft). Fig. 56: Driveshaft, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. To prevent imbalance, the flanges must be installed so that the paint markings align -arrows A and B-. Install drive shaft. Refer to Installing.

• When lifting rear final drive, position drive axle onto flange shaft.
• Lift final drive past the right-hand drive axle until installation position.

NOTE:

All components must move freely.

Fig. 57: Pushing Rear Final Drive At Left-Hand Drive Axle Upward & Constant Velocity Joint Of Drive Axle Outward Until Limit Stop And Lower Toward Flange Shaft
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Push rear final drive at left-hand drive axle upward -arrows A-.
• While doing so push constant velocity joint of the drive axle outward until limit stop -arrow B- and lower toward flange shaft -arrow C-.

Fig. 58: Removing/Installing Securing Bolts At Transmission Support
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove securing bolts of mounting bracket of rear final drive -arrows-.
• Push bolts in subframe into cross piece until limit stop.

Fig. 59: Removing Nuts From Left/Right Of Cross Piece
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Secure nuts on left and right at cross piece -arrows-.

Observe installation instructions. Refer to Drive shaft, servicing

• Replace seal on drive shaft flange and tighten drive shaft to torque. Refer to Drive shaft, removing and installing.
• Attach drive axles.

Refer to 42 - REAR SUSPENSION ; Removing and installing drive axle

• Top off gear oil in rear final drive and check oil level. Refer to Gear oil level in rear final drive, checking.
• Install exhaust system and align stress-free:

Refer to

• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
• 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
• 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

; Removing and installing exhaust-system components

Tightening torques

Component	Nm
Rear final drive to cross member -arrows-	55
Rear final drive to cross member -arrows-	55

Component	Nm
Rear final drive to mounting bracket -arrows-	40
Drive shaft to rear final drive	55
Heat shields to rear final drive	23

Rear final drive, attaching to assembly bracket

Special tools, testers and auxiliary equipment required

Fig. 60: Holding Fixture VW 540
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Holding fixture VW 540

Secure complete rear final drive on a repair stand with bracket VW 540

Fig. 61: Clamp Rear Final Drive In Assembly Fixture
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Rear final drive, disassembling and assembling

Assembly overview

Fig. 62: Rear Final Drive, Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Final drive housing

2 - Spacer sleeve

• Replace

3 - Flange for drive shaft

• Removing and installing. Refer to Drive pinion, removing and installing and disassembling and assembling

4 - Pinion shaft

• Is mated with ring gear, replace together as a set
• Removing and installing. Refer to Drive pinion, removing and installing and disassembling and assembling

5 - Final drive cover

6 - Differential

• Removing and installing. Refer to Differential, removing and installing
• Disassembling and assembling. Refer to Differential, disassembling and assembling

7 - Ring gear

• Paired with pinion shaft (final drive set)
• Removing and installing. Refer to Differential, disassembling and assembling.

Differential, removing and installing

Differential, removing and installing

NOTE:

Fig. 63: Rear Differential, Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

• General repair instructions. Refer to Repair instructions.
• Adjustments are required when replacing components marked 1). Refer to Adjustment overview.

Secure final drive on a repair stand. Refer to Rear final drive, attaching to assembly bracket.

1 - Vent sleeve

• With rubber valve
• Installation position. See Fig. 67.

2 - Final drive housing 1)

• Removing and installing drive pinion. Refer to Drive pinion, removing and installing and disassembling and assembling.

3 - Outer race for large taper roller bearing 1)

• Removing and installing. Refer to Differential, disassembling and assembling.

4 - Shim "S1"

• Note thickness
• Adjustment overview. Refer to Adjustment overview.

5 - Cover for final drive 1)

• With O-ring
• Replace O-ring
• Insert O-ring with oil

6 - TORX-screw - 25 Nm

7 - Seal, right

• Replacing. Refer to Flange shaft oil seals, replacing.

8 - Hex socket-head bolt - 25 Nm

9 - Flange shaft, right

• Removing and installing. See Fig. 65

10 - Oil filler plug - 35 Nm

• Checking gear oil level in rear final drive. Refer to Gear oil level in rear final drive, checking

11 - Differential with ring gear 1)

• Disassembling and assembling. Refer to Differential, disassembling and assembling

12 - Oil drain plug, 35 Nm

13 - Socket

• Holds solenoid in position
• Drive in onto stop

14 - Solenoid

15 - Outer race for small taper roller bearing 1)

• Removing and installing. Refer to Differential, disassembling and assembling.

16 - Shim "S2"

• Note thickness
• Adjustment overview. Refer to Adjustment overview

17 - Seal, left

• Replacing. Refer to Flange shaft oil seals, replacing.

18 - Flange shaft, left

• Removing and installing. See Fig. 65

19 - Hex socket-head bolt - 25 Nm

20 - Cap

• Installing. See Fig. 66

Secure final drive on repair stand

Fig. 64: Clamping Rear Final Drive In Assembly Fixture
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing and installing flange shaft

Fig. 65: Removing/Installing Drive Flange
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Press in cover until stop

Fig. 66: Pressing In Cover Up To Stop
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installation position vent sleeve

Fig. 67: Installed Location Of Breather Sleeve
Courtesy of VOLKSWAGEN UNITED STATES, INC.

The vent sleeve must protrude from the housing by 13 mm (dimension -a-) after being pressed in.

The slot in rubber valve is located longitudinally in direction of travel.

Removal

• Rear final drive removed

Special tools, testers and auxiliary equipment required

Fig. 68: Identifying Drip Tray V.A.G 1306
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drip tray V.A.G 1306

• Clamp complete rear final drive into assembly bracket VW 540. Refer to Rear final drive, attaching to assembly bracket.
• Place drip tray underneath to collect oil.
• Drain gear oil.

Fig. 69: Removing/Installing Drive Flange
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove left and right-hand flange shafts.

• To loosen the securing bolt, screw two bolts into flange shaft and counter-hold with a lever.
• Mark flange shafts (left and right) and pull out.
• Remove securing bolts from cover for final drive.
• Take cover for final drive off axle housing and remove differential.

Installing

Installation is in reverse order.

• Insert differential.
• Replace O-ring for cover for final drive and oil when installing.
• Install cover for final drive onto axle housing and using diagonal sequence tighten to 25 Nm.
• Fill space between sealing lip and dust lip with a thin layer of sealing grease G052 128 A1.

Fig. 70: Removing/Installing Drive Flange
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Insert flange shafts and tighten to 25 Nm.
• Top off gear oil in rear final drive and check oil level. Refer to Gear oil level in rear final drive, checking.

Differential, disassembling and assembling

Differential, disassembling and assembling

Fig. 71: Identifying Special Tools - Differential, Disassembling And Assembling (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

The following special tools and testing devices are required:

• Thrust plate VW 401
• Thrust plate VW 402
• Punch VW 407
• Thrust disc VW 412

• Needle bearing drift VW 295
• Punch VW 408 A

Fig. 72: Identifying Special Tools - Differential, Disassembling And Assembling (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Thrust pad VW 442
• Sleeve 40-21
• Thrust piece 40-105
• Thrust plate 2050

• Drift 3138
• Two-arm puller Kukko 44/2

Fig. 73: Tapered Roller Bearing Puller V.A.G 1582
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Taper roller bearing extractor V.A.G 1582

Fig. 74: Tapered Roller Bearing Puller V.A.G 1582
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• V.A.G 1582/6

NOTE:

Fig. 75: Rear Differential, Overview Courtesy of VOLKSWAGEN UNITED STATES, INC. General repair instructions. Refer to Repair instructions. Secure final drive on a repair stand. Refer to Secure complete rear final drive on a repair stand with bracket VW 540. Replace both taper roller bearings together. When replacing the parts marked with 1) adjustment work is required. Refer to Adjustment overview.

1 - Cover for final drive 1)

2 - O-ring

• Replace
• Insert with oil

3 - Final drive housing 1)

4 - Shim "S1"

• Note thickness
• Adjustment overview. Refer to Adjustment overview.

5 - Outer race for small taper roller bearing 1)

• Tapping out. See Fig. 76
• Pressing in. See Fig. 77

6 - Inner race for small taper roller bearing 1)

• Pulling off. See Fig. 78
• Pressing on. See Fig. 79

7 - Bolt - 60 Nm plus an additional45°1/4 turn

• Replace
• Allocation

• Lightly tighten bolts then tighten diagonally to specified torque.

8 - Differential housing 1)

9 - Ring gear 1)

• Paired with pinion shaft (final drive set)
• Allocation based on transmission code letters

• Drive off housing with a drift. See Fig. 84
• Install to differential housing. See Fig. 85

10 - Spring pin

• For securing shaft for bevel gears
• Drive in flush

11 - Inner race for large taper roller bearing 1)

• Pulling off. See Fig. 80
• Pressing on. See Fig. 81

12 - Outer race for large taper roller bearing 1)

• Tapping out. See Fig. 82
• Pressing in. See Fig. 83

13 - Shim "S2"

• Note thickness
• Adjustment overview. Refer to Adjustment overview.

14 - Threaded piece

15 - Large bevel gear

• Installing. See Fig. 86
• Adjusting. See Fig. 87

16 - Small bevel gear

• Installing. See Fig. 86

17 - Shaft for planet wheels

• Drive out with drift

18 - Adjustment shim

• Redefine thickness. See Fig. 87

19 - Thrust washer

• Check for cracks

Driving small taper roller bearing outer race out of cover

Fig. 76: Driving Small Tapered Bearing/Outer Race Out Of Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• After removing check shims for damage.

Pressing in taper roller bearing outer race small until stop into housing

Fig. 77: Pressing Small Tapered Bearing/Outer Race Into Housing To Stop
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pulling off inner race for small taper roller bearing

Fig. 78: Pulling Off Small Inner Race/Tapered Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Two arm puller, e.g. Kukko 44/2

Pressing on small taper roller bearing inner race

Fig. 79: Pressing On Small Tapered Bearing Inner Race
Courtesy of VOLKSWAGEN UNITED STATES, INC.

WARNING:

WARNING! Wear protective gloves!

• Heat inner race to approx. 100°C, position and push to final position.

Pulling off inner race for large taper roller bearing

Fig. 80: Pulling Off Large Inner Race/Tapered Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install thrust plate 40-105 onto differential housing before installing puller.

Pressing on large taper roller bearing inner race

Fig. 81: Pressing On Inner Race Of Large Taper Roller Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

WARNING:

WARNING! Wear protective gloves!

• Heat inner race to approx. 100°C, position and push to final position.

Driving out outer race for large taper roller bearing out of cover

Fig. 82: Driving Off Outer Race/Tapered Bearing From Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• After removing check shims for damage.

Pressing in outer race for large taper roller bearing into cover

Fig. 83: Pressing Outer Race/Tapered Bearing Into Cover
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Driving ring gear off housing

Fig. 84: Driving Out Ring Gear From Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing ring gear

Fig. 85: Installing Ring Gear
Courtesy of VOLKSWAGEN UNITED STATES, INC.

WARNING:

WARNING! Wear protective gloves!

• Locate ring gear guide with centering pins -A- (self-produced) when mounting.
• Heat ring gear to approx. 100°C and position.

Installing small bevel gears

Fig. 86: Installing Small Differential Bevel Gears
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• If large bevel gears have been replaced, measure and select new shims. See Fig. 87.
• Insert large bevel gears with recalibrated shims.
• Insert small bevel gears spaced 180° apart, and then rotate into place -arrow-.
• Insert washers and align.

• Insert threaded pieces.
• Drive small bevel gear shaft into final position and secure.

Adjusting differential bevel gears

Fig. 87: Differential Planetary Gears, Adjusting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Insert large bevel gears with thinnest shims (0.5 mm).
• Insert small bevel gears at a 180° offset with thrust washers.

NOTE:

Do not now interchange bevel gears and thrust washers.

• Drive in shaft for bevel gears.
• Press small bevel gears outward.
• Press large bevel gears in direction of -arrow- and check play.
• Ascertain the thickest - just fitting - shim for large bevel gears on each side.

• Select required shims from table. Part numbers

The following shims are available:

Shim thickness (mm)
0.50	0.70	0.90
0.60	0.80	1.00

NOTE:

Fig. 88: Installing Differential Bevel Gear Shim Courtesy of VOLKSWAGEN UNITED STATES, INC.

The adjustment is also correct if no further play is perceptible, although it is still possible to rotate the differential bevel gears -arrow-.

Drive pinion, removing and installing and disassembling and assembling

Drive pinion, removing and installing and disassembling and assembling

Fig. 89: Identifying Special Tools - Drive Pinion, Removing And Installing And Disassembling And Assembling (1 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and workshop equipment required

• VW 391 Puller
• VW 401 Thrust plate
• VW 402 Thrust plate
• VW 407 Punch

• VW 408 A Punch
• VW 412 Thrust disc

Fig. 90: Identifying Special Tools - Drive Pinion, Removing And Installing And Disassembling And Assembling (2 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and workshop equipment required

• VW 457 Supporting channels
• VW 460 Removal device
• VW 470/1 Assembly ring
• VW 519 Sleeve

• VW 540 Holding fixture
• 30-205 Thrust pad

Fig. 91: Identifying Special Tools - Drive Pinion, Removing And Installing And Disassembling And Assembling (3 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and workshop equipment required

• 2003/3 Inserter ring
• 3005 Thrust pad
• 3028 Retainer
• 3062 Thrust pad

• 3138 Drift
• 3143 Seal driver-Frt wheel bearing

Fig. 92: Identifying Special Tools - Drive Pinion, Removing And Installing And Disassembling And Assembling (4 Of 4)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools and workshop equipment required

• VW 771 Slide hammer-complete set
• 3026 Mandrel
• 3253 Wheel bearing assembly set
• V.A.G 1383 A Engine/transmission jack

NOTE:

Fig. 93: Exploded View Of Drive Pinion Assembly Courtesy of VOLKSWAGEN UNITED STATES, INC. Replace both taper roller bearings together. Install new taper roller bearings in delivery condition and do not oil additionally. When replacing the parts marked with 1) adjustment work is required. Refer to Adjustment overview.

1 - Nut

• Unscrewing. See Fig. 94
• Screwing in. See Fig. 108
• Measuring friction torque. See Fig. 109
• Securing. See Fig. 110

2 - Flange for drive shaft

• Pulling off. See Fig. 95
• Installing. See Fig. 107

3 - Sealing ring

• Pulling out. See Fig. 96
• Tapping in. See Fig. 106

4 - O-ring

• Replace
• Insert with gear oil. See Fig. 105

5 - Inner race for small taper roller bearing 1)

• Pressing out drive pinion. See Fig. 97
• Pressing on. See Fig. 104

6 - Outer race for small taper roller bearing 1)

• Pulling out. See Fig. 98
• Pressing in. See Fig. 103

7 - Spacer sleeve 1)

• Replace

8 - Final drive housing 1)

9 - Shim "S3"

• Note thickness
• Adjustment overview. Refer to Adjustment overview.

10 - Outer race for large taper roller bearing 1)

• Tapping out. See Fig. 99
• Inserting. See Fig. 102

11 - Inner race for large taper roller bearing 1)

• Pressing off. See Fig. 100
• Pressing on. See Fig. 101

12 - Drive pinion 1)

• Is mated with ring gear, replace together as a set

Removing nut for drive pinion

Fig. 94: Removing/Installing Nut For Pinion
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Secure final drive on a repair stand. Refer to Secure complete rear final drive on a repair stand with bracket VW 540.
• Screw in two hexagon nuts M8 x 30 -A-.

B - Socket, long A/F 36

• When nut is loosened the final drive must be supported (e.g. with universal transmission mounting 1359/2 in conjunction with engine/transmission jack V.A.G 1383 A).

Pulling flange for drive shaft off drive pinion

Fig. 95: Pull Off Flange Using Puller VW 391
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Screw two hex nuts M8 x 30 -A- into the flange.

Pulling out seal for flange for drive shaft

Fig. 96: Pulling Out Sealing Ring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pressing drive pinion out of inner race for small taper roller bearing

Fig. 97: Pressing Off Drive Pinion From Inner Race/Tapered Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pulling out small taper roller bearing outer race

Fig. 98: Pulling Off Small Outer Race/Tapered Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

B - Support, e.g. Kukko 22/2

B - Internal puller 46 to 2.28 in, e.g. Kukko 21/7

Driving out outer race for large taper roller bearing

Fig. 99: Driving Out Large Outer Race/Tapered Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• After removing check shims for damage.

Pressing inner race for large taper roller bearing off drive pinion

Fig. 100: Pressing Off Inner Race Of Large Taper Roller Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Separating device 22 to 4.53 in, e.g. Kukko 17/2

Pressing inner race for large taper roller bearing onto drive pinion

Fig. 101: Pressing On Inner Race Of Large Taper Roller Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Heat inner race to approx. 100°C, position and push to final position.

WARNING:

WARNING! Wear protective gloves!

Pulling in outer race for large taper roller bearing

Fig. 102: Pulling In Large Outer Race/Tapered Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Lightly lubricate bearing seat in housing.
• Insert predetermined shim "S3" for drive pinion. Refer to Adjustment overview.

The inscription "top" on pressure plate 3253/4 faces nut of insertion device

Pressing in small taper roller bearing outer race

Fig. 103: Pressing In Small Outer Race/Tapered Bearing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Lightly lubricate the bearing seat in the housing.
• The outer race must be attached with needle bearing drift VW 295 and thrust pad 30-205.

Pressing on small taper roller bearing inner race

Fig. 104: Installing Small Taper Roller Bearing Inner Race
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Insert new drive pinion with a new spacer sleeve.

WARNING:

WARNING! Wear protective gloves!

• Heat inner race for small taper roller bearing to approx. 100°C and install onto drive pinion.
• Press up drive pinion and insert bearing with sleeve 40-21 onto stop.

Inserting O-ring

Fig. 105: Inserting O-Ring
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Insert O-ring with gear oil.

Tapping in seal for flange for drive shaft

Fig. 106: Driving In Seal For Driveshaft Flange
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Lightly oil outer circumference of seal.
• Drive in seal onto stop with Mandrel 3026.
• Pack space between sealing and dust lips half-full with sealing grease G 052 128 A1.

Installing flange

Fig. 107: Driving Drive Shaft Flange Onto Drive Pinion
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drive shaft flange onto drive pinion until securing nut can be mounted.

Tighten nut for drive pinion and adjusting friction torque

Fig. 108: Removing/Installing Nut For Pinion
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Screw in two hex nuts M8 x 30 -A-.

B - Socket, long A/F 36

• When the nut is tightened the final drive must be supported (e.g. with universal transmission mounting 1359/2 in conjunction with engine/transmission jack V.A.G 1383 A).

NOTE:

Only increase tightening torque slowly and read-off frictional torque frequently. If the specified frictional torque is exceeded, the spacer sleeve must be replaced and the adjustment repeated. It is not possible to re-use a spacer sleeve that has been excessively compressed.

Measuring frictional torque

Fig. 109: Measuring Friction Torque
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Do not lubricate new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer.

With torque gauge, 0 to 600 Ncm, standard commercially available

B - Socket, A/F 36

NOTE:

Use 3/4" to 1/2" reducer as necessary.

The following frictional torques should be set:

New bearings	Used bearings 1)
200 to 250 Ncm	30 to 60 Ncm

1) With at least 50 km service

Removing nut for drive pinion

Fig. 110: Locking Drive Pinion Hexagon Nut
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• When the nut has been locked the radial run-out on the drive shaft flange should be measured. Refer to Drive shaft flange, measuring and marking radial run-out.

Drive pinion and ring gear, adjusting

Drive pinion and ring gear, adjusting

NOTE:

Careful adjustment of the drive pinion and ring gear is important for the service life and smooth running of the final drive. For this reason, the drive pinion and ring gear are matched together during manufacture, and checked to ensure a good mesh pattern and quiet running in both directions of rotation. The position of quietest running is found by moving the drive pinion in an axial direction and at the same time lifting the ring gear out of the zero-play mesh position by the amount necessary to maintain the backlash within the specified tolerance. The object of the adjustment is to reproduce the setting for quietest possible running, as obtained on the test machine in production. The deviation "r", which is related to the master gauge "Ro" is measured for the final drive sets supplied as replacement parts and marked on the outer circumference of the ring gear. The final drive set (drive pinion and ring gear) must only be replaced together as a matched pair. Observe the general repair instructions for taper roller bearings and shims. Maximum care and cleanliness are essential for achieving good results when performing repairs and taking measurements.

Gear sets, adjusting and marking

Fig. 111: Identifying Gear Set Markings And Adjustment Dimensions
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Marking "0937" indicates Oerlikon final drive set with transmission ratio 37 : 9.

NOTE:

Klingelnberg final drives "K937" or Gleasen final drives "G937" can be installed.

2 - Gear set pairing number (312).

3 - Deviation (tolerance) "r" is based on the test machine master gauge used in production. The deviation "r" is always given in 1/100 mm. Example: "25" means r = 0.25 mm

Ro - Length of adjustment master "Ro" of tester used.

Ro - Ring gear = 57.50 mm

Fig. 112: Identifying Gear Set Markings And Adjustment Dimensions
Courtesy of VOLKSWAGEN UNITED STATES, INC.

R - Actual dimension between ring gear and face of pinion shaft at point with quietest running for this gear set. R = Ro + r

Vo - Hypoid offset

Position of shims

Fig. 113: Identifying Differential Adjustment Shim Positions
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Adjustment overview when Replacing individual components of transmission. Refer to Adjustment overview.

S1 - Adjustment shim for ring gear in cover for final drive

S2 - Shim for ring gear in final drive housing

S3 - Shim for drive pinion in final drive housing

Adjustment overview

NOTE:

If performing assembly work on the final drive it is only necessary to adjust the drive pinion or final drive set if components have been replaced which have a direct effect on the adjustments of the final drive. To eliminate unnecessary adjustments observe following table:

	To adjust:
Parts replaced: ↓	Ring gear "S1"+"S2" 1) Refer to Ring gear, adjusting	Pinion shaft "S3" 1) Using deviation "r" Refer to Drive pinion, adjusting	Backlash Testing Refer to Adjusting backlash
Final drive housing	X	X	X
Differential housing	X		X
Taper roller bearings for pinion shaft		X	X
Taper roller bearing for differential	X		X
Final drive set 2)	X	X	X
Final drive cover	X		X

1) Shims; installation position. Refer to Position of shims.

2) Drive pinion and ring gear; only replace together.

Final drive, readjustment sequence

The following procedure is recommended to save time when the drive pinion and ring gear have to be adjusted:

1.)	Determine total shim thickness "Stotal" for "S1" + "S2" for the specified preload for taper roller bearings for differential.
2.)	Determine total shim thickness "S3" to reproduce the installation position for the drive pinion determined on the test machine in production.
3.)	Distribute total shim thickness "Stotal" for "S1" + "S2" so that the specified backlash exists between ring gear and drive pinion.

NOTE:

Overview of components and shims. Refer to Position of shims.

Drive pinion, adjusting

Special tools and workshop equipment required

Fig. 114: Universal Measuring Device VW 385
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• VW 385 Universal measuring tool

Fig. 115: Holding Fixture VW 540
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• VW 540 Engine and transmission support

NOTE:

Before adjusting the drive pinion adjust the ring gear (ascertain total shim thickness "S" for shims "S1" + "S2"). Refer to Ring gear, adjusting. Re-adjustment of the drive pinion is only necessary if the final drive set, taper roller bearing for drive pinion or housing for final drive is replaced. Adjustments. Refer to Adjustment overview. Do not oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer.

Determining shim "S3" thickness

(Setting preload of taper roller bearing for drive pinion)

• Clamp final drive into assembly bracket. Refer to Rear final drive, attaching to assembly bracket.
• Insert both outer races for the taper roller bearing without shims into the housing. Refer to Fig. 102 and Fig. 103

Fig. 116: Installing Small Taper Roller Bearing Inner Race
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Insert drive pinion without spacer sleeve.
• Heat inner race for taper roller bearing to approx. 100°C and install onto drive pinion.

WARNING:

WARNING! Wear protective gloves!

NOTE:

Only install spacer sleeve for final frictional torque measurement (after determining shim "S3"). Install new taper roller bearings in delivery condition and do not oil.

• Mount flanges for drive shaft and tighten hex nut for the flange. Refer to Fig. 107

Fig. 117: Measuring Friction Torque
Courtesy of VOLKSWAGEN UNITED STATES, INC.

A - Torque gauge, commercially available, 0 to 600 Ncm

B - Socket, A/F 36

• Tighten drive pinion nut until the following frictional torque is obtained.

New bearings	Used bearings 1)
200 to 250 Ncm	30 to 60 Ncm

1) With at least 50 km service

Fig. 118: Setting Adjusting Rings Of Measuring Bar VW 385/1
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Set adjustment ring of universal mandrel VW 385/1.

• Distance a = 60 mm

• Set sliding adjustment ring.

• Distance b = 55 mm

Fig. 119: Assemble Measuring Bar According
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Assemble universal mandrel as illustrated.

• Dial indicator extension VW 385/15 = 9 mm long

• Set universal master gauge VW 385/30.

• Ro = 57.50 mm

• Set dial indicator (3 mm measuring range) to "0" with 2 mm preload.
• Turn drive pinion 8 turns in both directions so that the taper roller bearings settle.

Fig. 120: Placing Magnetic Plate Onto Drive Pinion Face
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Place end measuring plate VW 385/33 onto drive pinion head.

Fig. 121: Insert Measuring Mandrel In The Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove master gauge and insert measuring mandrel in the housing.

• The centering disc for VW 385/3 faces toward cover for final drive

• Install cover for final drive and tighten 4 bolts.
• Using adjustable ring, move 2nd centering disc out as far as possible so that the mandrel can still just be turned by hand.

Determining measurement "e"

Fig. 122: Insert Universal Mandrel And Perform Check Measurement
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Turn mandrel until the dial indicator point touches the end measuring plate on pinion shaft head, then measure maximum deflection (return point). The measured value is dimension "e" (in red range).

• Measurement in following example: "e" = 1.60 mm

NOTE:

Dimension "e" is required to determine thickness of shim "S3".

• Then, (after removing universal mandrel) check again that the dial indicator, with master gauge VW 385/30 installed, indicates "0" with 2 mm preload, otherwise repeat the measurement.

Determining shim thickness "S3"

Formula:
"S3"	=	"e" - "r"
e	=	Determined value
r	=	Deviation (marked on ring gear in 1 /100 mm)

Example:
	Determined value "e"	1.60 mm
-	Deviation "r"	0.42 mm
=	Thickness of shim "S3"	1.18 mm

• Determine shim(s) as accurately as possible from table. Part numbers

The following shims are available for "S3"

Shim thickness (mm) 1)
0.95	1.20	1.45
1.00	1.25	1.50
1.05	1.30	1.55
1.10	1.35
1.15	1.40

1) Using the shim tolerance variations it is possible to find the exact shim thickness required, insert two shims if necessary.

• Remove universal mandrel.
• Remove drive pinion and outer race for large taper roller bearing and reinstall with calibrated shims "S3" and spacer sleeves. Refer to Fig. 94.
• Insert inner race for small taper roller bearing and tighten drive pinion nut until specified frictional torque is achieved. Refer to Fig. 108.

NOTE:

Do not oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer. Only increase tightening torque slowly and read-off frictional torque frequently. If the specified frictional torque is exceeded, the spacer sleeve must be replaced and the adjustment repeated. It is not possible to re-use a spacer sleeve that has been excessively compressed.

• Set to following frictional torques:

New bearings	Used bearings 1)
200 to 250 Ncm	30 to 60 Ncm

1) With at least 50 km service

Performing check measurement

Checking dimension "r"

• Turn drive pinion 8 turns in both directions so that the taper roller bearings settle.

Fig. 123: Insert Measuring Mandrel In The Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Insert universal mandrel and check measurement.

• If the shims have been correctly selected, the dial indicator, reading counter clockwise (in red range), will show deviation "r" within a tolerance of ± 0.05 mm

• Peen drive pinion nut with a punch.
• The radial run-out at flange for drive shaft must always be measured and marked. Refer to Drive shaft flange, measuring and marking radial run-out.

Ring gear, adjusting

Fig. 124: Identifying Special Tools - Ring Gear, Adjusting
Courtesy of VOLKSWAGEN UNITED STATES, INC.

(Adjusting differential)

Special tools and workshop equipment required

• VW 385/17 Magnetic plate 50 mm dia.
• VW 387 Dial gauge holder
• VW 388 Measuring lever
• VW 521 Adjustment tool for ring gear

• V.A.G 1331 Torque wrench

It is necessary to readjust the ring gear when:

Final drive housing, cover for final drive, taper roller bearing for differential, differential housing or drive pinion are replaced.

Adjustment overview. Refer to Adjustment overview

NOTE:

Differential taper roller bearings are low friction bearings. Therefore the frictional torque only has a limited use as a check. Correct adjustment is only possible by determining the total shim thickness "Stotal". Do not oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer.

Determining total shim thickness "Stotal" for shims "S1" + "S2"

(Setting preload of taper roller bearing for differential)

• Drive pinion is removed!

NOTE:

If only the taper roller bearings for the differential are being replaced, the ring gear can be removed from the differential housing. The pinion shaft does not need to be removed.

• Pry out seals for flange shaft using a suitable lever.
• Remove outer races of differential taper roller bearings and remove shims. Refer to Differential, disassembling and assembling
• Drive outer race/taper roller bearing for left differential (housing side) with shim "S2*" of thickness 1.00 mm into housing. Refer to Differential, disassembling and assembling.

NOTE:

For measurement purposes a shim "S2" with a thickness of 0.04 in is initially inserted. It is referred to as "S2*" in the following. After determining the backlash "S2*" will be replaced by the correct "S2".

• Drive outer race/taper roller bearing for right differential (cover side) without shim in onto stop. Refer to Differential, disassembling and assembling.
• Insert differential into housing. The ring gear is positioned on the right side (cover side).
• Install cover and tighten bolts to 25 Nm.

Fig. 125: Installing Special Tools VW 521/4 And 521/8 Onto Housing Side In Differential Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install special tools VW 521/4 and 521/8 onto housing side in differential housing.
• Turn cover side of differential housing upward.
• Turn differential 8 turns in both directions so that the taper roller bearings settle.
• Place measuring plate VW 385/17 onto differential.

Fig. 126: Installing Measuring Tools
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install measuring tools.

A - Dial indicator extension approx. 30 mm long

B - Hex bolt M8 x 45

• Position dial indicator extension in middle of measuring plate VW 385/17.
• Set dial indicator (3 mm measuring range) to "0" with 2 mm preload.

Fig. 127: Read Play On Dial Gauge
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Lift differential without turning; read off play on dial indicator and write it down.

• Measurement in following example: 0.50 mm

• If you want to repeat the measurement differential 8 turns in both directions so that the taper roller bearings settle.

Determine "Stotal" (S1 + S2)

Formula:
"Stotal"	=	"S2*" + measurement + bearing preload

Example:
	Inserted shim(s) "S2*"	1.00 mm
+	Measurement	0.50 mm
+	Bearing preload (constant)	0.30 mm
=	Total shim thickness "Stotal" for shims "S1" + "S2"	1.80 mm

Determining thickness of shim "S1*"

NOTE:

The preliminary adjustment shim "S1*" will be replaced with the final shim "S1" after determining the backlash. The total shim thickness "Stotal" remains the same.

Formula:
"S1*"	=	"Stotal" - "S2*"

Example:
	Total shim thickness "Stotal" for shims "S1" + "S2"	1.80 mm
-	Inserted shim(s) "S2*"	1.00 mm
=	Thickness of shim "S1*"	0.80 mm

• Define shim(s) as precisely as possible based on the table. Refer to The following shims are available for "S1".

Measuring frictional torque (check)

• Pinion shaft removed
• Differential installed with shims "S1*" and "S2*"

Fig. 128: Measuring Differential Frictional Torque
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install torque gauge 0 to 600 Ncm -A- onto differential.
• Read off friction torque.

Frictional torque specified values:

New bearings	Used bearings 1)
150 to 300 Ncm	30 to 60 Ncm

1) With at least 50 km service

NOTE:

Differential taper roller bearings are low friction bearings. Therefore the frictional torque only has a limited use as a check. Correct adjustment is only possible by determining the total shim thickness "Stotal". Do not oil new taper roller bearings for frictional torque measurement. The bearings have already been treated with special oil by the manufacturer. If the final drive set is being re-adjusted, the adjustment of the pinion shaft should be performed now, and the adjustment should be checked. Refer to Drive pinion, adjusting.

Adjusting backlash

• Drive pinion with shim "S3" installed
• Differential with shims "S1*" + "S2*" installed

• Insert differential into final housing mount cover and tighten all bolts to 25 Nm.
• Turn differential 5 turns in both directions so that the taper roller bearings settle.

Fig. 129: Installing Measuring Tools
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Install measuring tools.
• Use dial indicator extension VW 382/10 (6 mm flat).
• Set measuring lever VW 388 to dimension "a" = 60 mm.
• Measure play between teeth flanks (backlash) as follows:

• Turn ring gear until it makes contact with a tooth flank (end of backlash travel).
• Preload dial indicator to 1 mm and set to zero.
• Turn ring gear back until lying against an opposite tooth flank (backlash).
• Read off backlash and note value.

• Turn ring gear through 90° and repeat measurements a further 3 times.

Determining average backlash

Example:
	1st Measurement	0.28 mm
+	2nd Measurement	0.30 mm
+	3rd Measurement	0.30 mm
+	4th Measurement	0.28 mm
=	Sum of measured values	1.16 mm

• Result: The average backlash is 1.16 divided by 4 = 0.29 mm

NOTE:

If the individual measurements differ by more than 0.06 mm from each other, the installation of the ring gear or the final drive set itself is not correct. Check installation; replace final drive set, if necessary.

Determining thickness of shim "S2"

Formula:
"S2"	=	"S2*" - backlash + lift

Example:
	Inserted shim "S2*"	1.00 mm
-	Average backlash	0.29 mm
+	Lift (constant)	0.15 mm
=	Thickness of shim "S2"	0.86 mm

• Determine shim(s) as accurately as possible from table. Part numbers

The following shims are available for "S2"

Shim thickness (mm) 1)
0.15	0.50	1.50
0.20	0.80
0.25	1.00

1) Using the shim tolerance variations it is possible to find the exact shim thickness required, insert two shims if necessary.

Determining thickness of shim "S1"

Formula:
"S1"	=	"Stotal" - "S2"

Example:
	Total shim thickness "Stotal" for "S1" + "S2"	1.80 mm
-	Thickness of shim "S2"	0.86 mm
=	Thickness of shim "S1"	0.94 mm

• Determine shim(s) as accurately as possible from table. Part numbers

The following shims are available for "S1"

Shim thickness (mm) 1)
0.15	0.50	0.90
0.20	0.60	1.00
0.30	0.70	1.20
0.40	0.80

1) Using the shim tolerance variations it is possible to find the exact shim thickness required, insert two shims if necessary.

Check measurement

Fig. 130: Installing Measuring Tools
Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Drive pinion with shim "S3" installed
• Differential with shims "S1" (cover side) + "S2" (housing side) installed

• Turn differential 5 turns in both directions so that the taper roller bearings settle.
• Measure backlash four times on circumference.

• Specification: 0.12 to 0.22 mm

NOTE:

If the backlash is beyond the tolerance, the adjustments must be repeated. Refer to Determining thickness of shim "S2". The total shim thickness "Stotal" must not be changed. The individual measurements must not differ by more than 0.06 mm from each other.

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