PH 42 Eng

Rear axle (front and all wheel drive), servicing .
1 2
Volkswagen Phaeton
42 - 2
Rear axle (front and all wheel drive), servicing

Note :
If components with bonded rubber bushings were

replaced or bolts/nuts on these components were
loosened, corresponding wheel suspension must be
lifted into curb weight position 40-2, Wheel
bearing, lifting to curb weight position .
Always replace self-locking nuts.
Always replaced corroded nuts and bolts.
I - Subframe, assembly overview 42-

3, I - Subframe, assembly overview
II - Link, tie rod, air spring strut,

assembly overview 42-4, II - Link, tie
Rear axle (front and all wheel drive), servicing . 2 2
rod, air spring strut, assembly

overview
III - Wheel bearing, assembly overview

42-5, III - Wheel bearing, assembly
overview
IV - Driveshaft, assembly overview

42-6, IV - Drive axle, assembly
overview
I - Subframe, assembly overview . 1 8
42 - 3
I - Subframe, assembly overview
On vehicles with front wheel drive, only

subframe and mounting components are
installed.
Final drive
Removing and installing
Repair Manual, Automatic

Transmission, Repair Group 39, Rear
final drive, removing and installing
Hex bolt
Washer
Hex nut
40 Nm
Self-locking
Always replace
Hex bolt
130 Nm plus an additional 90

( 1 / 4 turn)
Always replace
Washer
Washer
Subframe
Steel version
This version is replaced in 2004

with the aluminum version
Application Electronic Parts

Catalog "ETKA"
Subframe
Aluminum version

Catalog "ETKA"
Hex socket head bolt
55 Nm
Washer
Hex nut
40 Nm
Self-locking
Always replace
Cross member
Hex bolt
Final drive support
For vehicles with V6 and W12

drivetrain

Catalog "ETKA"
Final drive support
For vehicles with V8 and V10

drivetrain

Catalog "ETKA"
Hex bolt
( 1 / 4 turn)
Always replace
Multi-point socket head bolt
20 Nm
Brace
Between rear final drive and

final drive support
For vehicles with V8 and V10

drivetrain

Catalog "ETKA"
Subframe, removing and installing

Special tools, testers and auxiliary items

required
Engine/transmission jack V.A.G

1383 A
Tightening strap T10038
Torque wrench V.A.G 1332
Removing
- Brake pedal loading device V.A.G 1869/2 .
- Remove rear wheels.
- Remove rear cover on rear bumper

Repair Manual, Body Exterior, Repair Group 63, Bumper

cover, removing and installing
- Disconnect all electrical wires from body to rear axle.
Note:
Secure vehicle to hoist to continue procedure.
- Remove plugs (2 per vehicle side).
- Secure vehicle to hoist lifting arm with Tensioning Strap

T10038 .
- Remove rear section of exhaust system
Repair Manual, Engine Mechanical, Fuel Injection

Ignition, Repair Group 26, Exhaust system parts, removing
and installing
- Disconnect brake lines.
- Remove brake cable from rear axle
Repair Manual, Brake System, Repair Group 46, Rear

brake cable, removing and installing
.
- Remove heat shield - 1 - from spare wheel well - arrows -

.
- Remove drive shaft from rear final drive and tie up to body
Repair Manual, Automatic Transmission, Repair Group

39, Drive shaft, removing and installing
- Place engine/transmission jack V.A.G 1383 A with

Support 1359/2 below final drive.
- Remove nut - 1 - , remove bolt - 2 - and press air spring

strut - 3 - to center of vehicle.
- Remove subframe from body.
- Slowly lower rear axle.
Installing
Installation is in reverse order of removal, note the

following:
- Tighten subframe with bolts originally installed. Replace

these with new bolts after vehicle alignment.
- Tighten bolts originally installed to specified torque

without additional tightening.
- Tighten drive shaft to rear final drive
Repair Manual, Automatic Transmission, Repair Group

39, Drive shaft, removing and installing
- Attach brake caliper to brake carrier

brakes, servicing; Disc brakes
- Adjust parking brake

brakes, servicing; Disc brakes; Parking brake, adjusting
- Bleed brake system
Repair Manual, Brake System, Repair Group 47, Brake

system, bleeding
- Install wheels and tighten 44-2, Wheel mounting .
- Perform vehicle alignment 44-3, Wheel alignment .
Tightening torque
Bumper to body
Repair Manual, Body Exterior, Repair Group 63, Bumper cover,

removing and installing
Exhaust system to
body
Repair Manual, Engine Mechanical, Fuel Injection Ignition, Repair
Group 26, Exhaust system components, removing and installing
Drive shaft to body
and final drive
Repair Manual, Automatic Transmission, Repair Group 39, Drive

shaft, removing and installing
Air spring damper to 80 Nm plus an additional 1 / 4 turn (90 )
lower link
1)
2)
Subframe to body 130 Nm plus an additional 1 / 4 turn (90

1)
1) Always use new nuts and bolts

2) Tighten bolts and nuts in curb weight position
II - Link, tie rod, air spring strut, assembly overview . 1 31
42 - 4
II - Link, tie rod, air spring strut, assembly overview

Note :
If components with bonded rubber bushings were

replaced or bolts/nuts on these components were
loosened, corresponding wheel suspension must be
lifted into curb weight position 40-2, Wheel
bearing, lifting to curb weight position .
Welding and straightening work on supporting or

wheel carrying components of the suspension is not
permitted.
Always replace self-locking nuts.
Always replaced corroded bolts and nuts.

Wheel bearing housing

42-5, Wheel bearing housing,
Wheel bearing unit, removing

and installing 42-5, Wheel
bearing unit, removing and
installing
Eccentric washer
Hex nut
95 Nm
Self-locking
Always replace
Coupling rod
For tie rod to lower link

42-4, Tie rod to lower link
connecting links, removing
and installing
Washer
Hex nut
95 Nm
Self-locking
Always replace
Hex nut
80 Nm plus an additional 1 / 4
turn (90 )
Self-locking
Always replace
Hex nut
turn (90 )
Self-locking
Always replace
Hex head bolt
Lift the wheel bearing housing

before fastening
Always replace
Lower link

42-4, Lower link, removing
and installing
Bracket
Hex nut
turn (90 )
Self-locking
Always replace
Lift wheel bearing housing

before fastening
Hex nut
Self-locking
Always replace
Hex head bolt
turn (90
Always replace

before fastening
Hex head bolt

turn (90
Always replace

before fastening
Bracket
Hex bolt
10 Nm
Hex bolt

before fastening
replace after every removal
Hex bolt
Always replace
Hex nut
Self-locking
Always replace
Connecting link for vehicle level

sensor
Do not pull connecting link

from ball joint!
Hex bolt
10 Nm
Coupling rod
For stabilizer bar to lower link

42-4, Stabilizer bar to lower
link connecting links,
25 Nm
Stabilizer bar clamp
Stabilizer bar

42-4, Stabilizer bar, removing
and installing
Hex bolt
turn (90 )
Always replace
Cable channel
Hex bolt
turn (90 )
Always replace
Upper link

42-4, Upper link, removing
and installing
Hex nut
Self-locking
Always replace
Eccentric bolt
For toe adjustment
Bolt
Bolt
Tie rod

42-4, Tie rod, removing and
installing
Eccentric washer
Hex nut
95 Nm
Self-locking
Always replace

before fastening
Air spring strut
The air spring damper

protective boot must not
sustain any indentations!

42-4, Air spring strut,
Hex bolt
turn (90
Always replace
Hex nut
Self-locking
Always replace
Eccentric bolt
For camber adjustment
Air spring strut, removing and installing
Special tools, testers and auxiliary items required

Removing
During assembly work, make sure that no indentations

form on boot of air spring strut!
- Remove level control system sensor bolt - 2 - from lower

link.

- Remove wheel housing liner

Repair Manual, Body Exterior, Repair Group 66, Wheel

housing liner, removing and installing; Rear wheel housing
liner
Left rear
- Remove air line (yellow) from reservoir. Seal off both air
connections after air is released.
- Remove reservoir - A - by removing air line - 1 - and hex

nuts - arrows - .
- Disconnect damper adjustment switching valve electrical

connector.
Right rear
- Remove hex screw - 1 - and move tank - B - as far down

as possible.
- Disconnect damper adjustment switching valve electrical

connector.
- Remove air line from air spring strut and seal off both
connectors.
Continued for all vehicles
The wheel bearing housing must be pulled down slightly so

that the strut can be removed.
If air spring strut is to be replaced, first read the following

42-4, Air spring strut, filling .
Installing
Installation is in reverse order of removal, note the

following:
During assembly work, make sure that no indentations

form on boot of air spring shock absorber!
- Insert air spring strut and tighten.
- Attach air spring strut to link.
- Raise wheel bearing housing to tighten.
- Check basic setting of level control system Vehicle

Diagnosis, Testing and Information System VAS 5051 .
Tightening torque
Connecting link from vehicle 10 Nm
level sensor to lower link
Air spring strut to lower link 80 Nm plus an additional 1 / 4 turn (90 )
1)
2)
Wheelhouse liner to body
Repair Manual, Body Exterior, Repair Group 66,

Wheelhouse liner, removing and installing; Rear wheelhouse
liner
Air line to air spring strut 5 Nm
Reservoir to body 9 Nm
Air spring strut to body 30 Nm

Air spring strut, filling

Adapter T10157
Air suspension strut charger VAS 6231 , not

illustrated
Steel gas cylinder filled with Argon or Corgon, not

depicted
Note:
Air spring struts are supplied as replacement parts

with a minimum pressure. By sitting in storage for
extended periods this minimum pressure can
diminish (just like a tire). Before the air spring strut is
removed from its packaging, this minimum pressure
must be controlled and restored by "refilling" . Without
this necessary refilling, folds can form in the under-
filled air spring boot. These folds cause damage
which can lead to premature failure.
- Remove cover from packaging.
- Remove union bolt - arrow - from residual pressure

retaining valve. Illustration shows front air spring strut.
- Close steel gas bottle pressure valve.

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Volkswagen, Skoda, Seat, Audi
- Become familiar with relevant rules for prevention of

accidents for pressurized containers and technical gases.
- Connect air spring filler unit VAS 6231 and adapter

T10157 as shown in illustration.
Air spring strut in packaging

Steel gas bottle for argon, corgon with gauges
Air spring filler unit VAS 6231
Adapter T10157
- Set flow rate limiter gauge to 2.0 L/min - arrow - .
- Fill gas into air spring strut using several individual

pressure bursts.
The display only shows a correct gas pressure if the

"oscillatory pressure" of the residual pressure retaining
valve is overcome. The "oscillatory pressure" is at approx.
3.5 bar. When the display reaches 3.5 to 4.5 bar, air spring
damper is sufficiently filled with gas.
- Make sure gas pressure does not exceed 4.5 bar when
filling.
- Disconnect air spring filler unit VAS 6231 from adapter

T10157 . This dissipates the gas above an internal
pressure of 3.5 bar.
Minimum pressure is reproduced, air spring strut can be

removed from packaging.
- After installation, first drive the vehicle at high ride height

and then at normal ride height. Repeat this sequence once
more.
By moving the ride height settings twice, the majority of the

gas is exchanged with filtered air from the air supply motor.
- Install air spring strut 42-4, Installing .
Stabilizer bar, removing and installing

Removing
- Remove wheels.
- Remove heat shield - 1 - from spare wheel well - arrows -

.
- Remove stabilizer bar - 1 - from left and right connecting

links - arrow - .
- Remove tie rod 42-4, Removing .


- Remove bolts - arrows - evenly on both sides.
- Turn stabilizer bar so that clamps - 1 - can be guided out

of notches on subframe.
- Remove clamps - 1 - from stabilizer bar brackets.
- Turn stabilizer bar so that connecting link mounts face

downward.
- Guide stabilizer bar out toward left.
Installing
- Guide in stabilizer bar from left over exhaust system.
- Place clamps on stabilizer bar bracket. Make sure longer

clamp tab faces opposite to direction of travel.
- Turn stabilizer bar in subframe so that clamps - 1 - project

into subframe notches.
- Install bolts - arrows - hand-tight evenly on both sides

and tighten to specified torque.
- Move air spring strut - 3 - outward on link bracket and

upward.
- Insert bolt - 2 - and tighten nut - 1 - to specified torque.
- Install tie rod 42-4, Installing .
- Tighten stabilizer bar - 1 - at left and right connecting links

- arrow - .
- Attach heat shield - 1 - to spare wheel well - arrows - .
- Install wheels and tighten 44-2, Wheel mounting .
Tightening torque
Air spring strut to upper link 80 Nm plus an additional 1 / 4 turn (90 )
1)
2)
Connecting link to stabilizer bar 65 Nm plus an additional 1 / 4 turn (90 )

1)
2)
Stabilizer bar to body 25 Nm

Upper link, removing and installing
Removing
- Remove wheel.
- Remove brake caliper with brake carrier and brake disc

caliper, removing and installing
- Remove bolts - 1 - and remove cover plate - 2 - from

wheel bearing housing.

- Remove cable channel - 1 - from upper link - 2 - .

- Mark position of eccentric washer - 3 - to wheel bearing

housing, e.g. using a felt tip pen.
- Remove nut - 4 - and remove bolt - 5 - from wheel bearing

housing.
- Remove nut from bolt - 1 - for securing upper link - 2 - to

subframe.
- Remove bolt - 1 - until it comes in contact with fuel tank -

4 - - arrow - .
- Lightly press bolt - 1 - in direction of - arrow - downward

toward subframe while moving it slightly toward upper link.
- Remove bolt - 1 - .
- Move upper link toward wheel bearing housing until it

comes out of subframe.
- Remove upper link behind lower link.
Installing
- Insert upper link in subframe.

- Insert bolt - 1 - at a slight angle in upper link and then

push in direction of - arrow - toward fuel tank - 4 - .
- Insert bolt - 1 - straight into upper link and secure with a

new nut.
- Install bolt - 5 - together with an eccentric washer - 3 - and

nut - 4 - .
- Install cable channel - 1 - to upper link - 2 - .
- Install eccentric washer - 3 - to marking applied to wheel

bearing housing and tighten nut - 4 - to specified torque.

upward.
- Install bolt - 2 - and tighten nut - 1 - to specified torque.
- Tighten upper link and subframe bolted connection to

specified torque.
- Place cover plate - 2 - on wheel bearing housing and

secure with screws - 1 - .
- Install brake disc and brake caliper with brake carrier

- Install wheel and tighten 44-2, Wheel mounting .
Tightening torque
Upper link to subframe 80 Nm plus an additional 1 / 4 turn (90 )
1)
2)
Upper link to wheel bearing housing 95 Nm

1)
2)
Air spring strut to upper link 80 Nm plus an additional 1 / 4 turn (90 )

1)
2)
Cover plate to wheel bearing housing 10 Nm

Tie rod, removing and installing
Removing
- Remove wheel.
- Mark location of eccentric washer to subframe, e.g. with a

felt-tip pen.
- Remove nut - 2 - , remove eccentric washer and eccentric

bolt.
- Pivot tie rod - 3 - down.

- Remove nut - 1 - from tie rod.
- Lightly press brake caliper upward and at the same time,

remove tie rod from connecting link/wheel bearing housing
mount.
Installing
- Lightly press brake caliper upward and place tie rod in

connecting link/wheel bearing housing mount.
- Pivot tie rod - 3 - upward in subframe.
- Insert eccentric bolt and eccentric washer.
- Turn eccentric bolt to marking applied to subframe and

tighten nut - 2 - to specified torque.
- Install nut - 1 - to tie rod and tighten to specified torque,

counter holding at tie rod hex head, if necessary.
Tightening torque
Tie rod to subframe 95 Nm
1)
2)
Tie rod to wheel bearing housing 95 Nm

1)
2)
1) Use new nut

Stabilizer bar to lower link connecting links, removing

and installing

Removing
- Remove wheel.
- Remove bolt - 1 - .
- Disconnect connecting link/lower link bolted connection -

2-.
- To remove bolt from connecting link, push wheel bearing

housing downward.
- Remove connecting link - 3 - .
Installing
- Attach connecting link - 3 - to lower link.
- Insert a new bolt - 2 - for this and at the same time, attach
brake line bracket - 4 - .
- Hand-tighten new nut.
- Screw connecting link to stabilizer bar with a new bolt - 1 -

.
- Tighten connecting link/stabilizer bar bolt - 1 - to specified

torque.
- Tighten connecting link/lower link nut to specified torque.
Tightening torque
Coupling rod to stabilizer 65 Nm plus an additional 1 / 4 turn (90 )
1)
2)
Connecting link to lower link 50 Nm plus an additional 1 / 4 turn (90 )

2)
3)
1) Use new bolt

3) Use new bolt and nut
2) Tighten bolts in curb weight position
Tie rod to lower link connecting links, removing and

installing
Removing
- Remove wheel.
- Remove tie rod 42-4, Removing .
- Remove nut - 1 - .
- Remove bolt - 2 - from lower link/connecting link.
- Remove connecting link - 3 - from lower link.
Installing
- Insert connecting link - 3 - in lower link.
- Insert bolt - 2 - and hand-tighten nut - 3 - .
- Install tie rod 42-4, Installing .
- Tighten bolt - 2 - to specified torque.
Tightening torque
Connecting link to lower link 80 Nm plus an additional 1 / 4 turn (90 )
1)
2)

Lower link, removing and installing
Removing
- Remove wheel.

1-.

housing downward.
- Remove bolt from - 2 - level control system sensor.

- Remove brake line bracket bolt - 4 - .


- Remove bolted connection nuts - 1 to 4 - from lower link -

6-.
- Remove screw - 5 - .
- First remove bolt - 3 - and then bolt - 4 - .
- Remove lower link from notches on subframe and swing

downward.
- Remove bolt - 1 - and disengage lower link - 2 - from

connecting link - 3 - .
Installing
- Engage lower link - 2 - in wheel bearing housing and

control link - 3 - .
- Insert bolt - 1 - and secure with a new nut.
- Pivot lower link - 2 - upward and press into notches in

subframe.
- First insert bolt - 3 - and then bolt - 4 - .
Note:
To insert bolt, holes in bracket must be aligned with

subframe.
- Move tie rod downward and place bolt - 5 - in lower link

and connecting link.
Note:
To insert bolt, trapezoidal link holes must be aligned

with connecting link.

upward.
- Install brake line bracket bolt - 4 - .

- Tighten bolted connection nuts - 1 to 4 - .

secure with bolts - 1 - .

- Connect connecting link/lower link bolted connection - 1 -

and tighten to specified torque.
- Install bolt in - 2 - level control system sensor.

Tightening torque
Lower link to subframe 80 Nm plus an additional 1 / 4 turn (90
1)
2)
)
Lower link to wheel bearing housing 80 Nm plus an additional 1 / 4 turn (90

1)
2)
)
Level control system sensor connecting link to lower 10 Nm

link
Air spring strut to lower link 80 Nm plus an additional 1 / 4 turn (90
1)
2)
)
Stabilizer bar connecting link to lower link 80 Nm plus an additional 1 / 4 turn (90
1)
2)
)
Tie rod connecting link to lower link 50 Nm plus an additional 1 / 4 turn (90
1)
2)
)

III - Wheel bearing, assembly overview . 1 16
42 - 5
III - Wheel bearing, assembly overview
Wheel bearing housing

42-5, Wheel bearing housing,
Servicing 42-5, Wheel

bearing housing bonded
rubber bushings, replacing
Wheel bearing
Replacing 42-5, Wheel

bearing, replacing
Slide washer
Always replaced together with

wheel bearing Item - 2 - or

wheel hub Item - 4 -
Replacing 42-5, Slide

washer, prying out
Wheel hub
Replacing 42-5, Wheel

bearing, replacing
Wheel bearing unit
Consists of wheel bearing

Item - 2 - , slide washer
Item - 3 - and wheel hub
Item - 4 -

42-5, Wheel bearing unit,
Shield plate
Bolt, 10 Nm
Hex socket head collar bolt
200 Nm plus an additional

180 ( 1 / 2 turn)
Always replace

before fastening
Bolt, 23 Nm
Cover
Drive axle

42-6, Drive axle, removing
and installing
Servicing 42-6, Drive axle,

servicing

Catalog "ETKA"
Bolt, 70 Nm
First pre-tighten to 10 Nm
then tighten diagonally to
specified torque
Backing plate
Stub axle
Bonded rubber bushing
Bearing with large contact

surface
Replace with bonded rubber

bushing Item - 16 -
Installing 42-5, Wheel

Bonded rubber bushing
Bearing with small contact

surface
Replace with bonded rubber

bushing Item - 15 -
Installing 42-5, Wheel

Cap bolts
Follow tightening sequence:

turn
Rotate bolt back 360
( 1 / 4 turn)
Always replace
Wheel bearing housing, removing and installing

Removing
- Remove hex socket head collar bolt from drive axle 42-
6, Drive axle, removing and installing .
- Remove bolt - 1 - from speed sensor - 2 - .
- Pull speed sensor out from wheel bearing housing.




- Remove tie rod - 2 - 42-4, Removing .
- Mark location of bolted connection eccentric bolt - 1 - to

wheel bearing housing - 4 - , e.g. with a felt-tip pen.
- Remove bolt - 1 - from upper link.

- Remove bolt - 3 - from lower link.
- Remove wheel bearing housing - 4 - from drive axle and

out of suspension.
- If wheel bearing unit should be removed, then clamp

wheel bearing housing in vise with protective covers.
- To remove wheel bearing unit, remove bolts - arrows - .
Installing
- Place wheel bearing housing - 4 - on drive axle.
- Insert wheel bearing housing - 4 - on upper link and in

lower link.
- Install new bolts - 1 - and - 3 - and secure with new nuts
- Install tie rod - 2 - 42-4, Installing .
- Turn bolted connection eccentric washer - 1 - to mark

placed on wheel bearing housing and tighten nut to
specified torque.
Note:
Do not turn eccentric bolt more than 90 left or right

(that is smallest to largest possible adjustment).
- Tighten bolt - 3 - to specified torque.

secure with bolts - 1 - .

upward.

.
- Insert speed sensor - 2 - in wheel bearing housing and

tighten bolt - 1 - .
- Tighten drive axle hex socket head collar bolt Topic 42-
6.
Tightening torque
Lower link to wheel bearing housing 80 Nm plus an additional 90 ( 1 / 4 turn)
1)
2)
Upper link to wheel bearing housing 95 Nm

1)
2)
Air spring strut to lower link 80 Nm plus an additional 90 ( 1 / 4 turn)

1)
2)

Wheel bearing unit, removing and installing
Removing
- Remove axle pins or drive axle 42-6, Drive axle,

removing and installing .


- Remove bolts - 1 - .
- Remove wheel bearing unit from wheel bearing housing.
Installing
- Insert wheel bearing unit in wheel bearing housing and

tighten bolts - 1 - .

- Install axle pins or drive shaft Topic 42-6 .
Tightening torque
Wheel bearing unit to wheel bearing housing Follow tightening sequence:
1) 1st, 80 Nm plus an additional 135
2nd, turn bolt back 360

3rd, 80 Nm plus an additional 90 ( 1 / 4 turn)
1) Use new botls
Wheel bearing, replacing

required
Thrust plate VW 401
Thrust plate VW 402
Punch VW 407
Punch VW 412
Thrust pad VW 511

Press tube 30-100
KUKKO separating tool 17/2 Abbildung 3
Assembly tool T40089/2
Pressing out hub

- Press out wheel hub.
- Insert separating tool in bearing inner race ring groove -

arrow - and pretension threaded spindle.
Note:
Use a commercially-available separating tool , for

example Kukko 17/2 .
This deforms slide washer and it must be replaced.
- Press bearing inner race of wheel hub.

Pressing off bearing inner ring
Slide washer, prying out
- Carefully pry out old slide washer - 1 - with a screwdriver.
Wheel hub, pressing in
- Position new slide washer on wheel hub.

- Install special tools as shown in illustration.
Press piece VW 473

Assembly tool T40089/2
Slide washer
Wheel hub
Thrust plate VW 401
Note:
Slide washer must be pressed on up to wheel bearing

hub radius.
- Press wheel hub into wheel bearing to stop.
Wheel bearing housing bonded rubber bushings,

replacing

Assembly tool 3292
Press piece 3292/3
Observe installation position:
Bonded rubber bushing - 1 - with larger contact surface

faces toward wheel bearing housing side - arrow - .
Bonded rubber bushing - 2 - with smaller contact surface

faces away from wheel bearing housing.
- Insert new bearing into wheel bearing housing with thrust

pieces 3292/3 and threaded spindle 3292 .
Note:
Do not use lubricant!
Carefully insert bearing so that it does not tilt.
- Screw thrust pieces together to stop.
Outer sleeve collar on both bearings must contact

IV - Drive axle, assembly overview . 1 24
42 - 6
IV - Drive axle, assembly overview
Hex socket head collar bolt
200 Nm plus an additional

180 ( 1 / 2 turn)
Vehicle must be standing on

the ground when
loosening/tightening
Always replace
Outer constant velocity joint
Replace only as a unit
Checking 42-6, Outer

constant velocity (CV) joint,
checking
Driving off 42-6, Outer

constant velocity joint,
servicing
Installing: Drive onto shaft

using plastic hammer until
compressed circlip seats.
Circlip must lie in joint

chamfer when guiding in,
guide with pliers if necessary.
Clamp
Always replace
Tensioning 42-6, Clamp

large clamping sleeve to outer
joint
Outer constant velocity

protective joint boot
Check for tears and chafing,

replace if necessary
Circlip
Always replace
Insert in shaft groove
Axle shaft
Clamp
Always replace

small clamping sleeve to inner
joint
Protective boot for inner

constant velocity joint
Check for tears and chafing,

replace if necessary
Axle shaft must be cleaned

before new protective joint
boot is installed
Lightly lubricate axle shaft

profile before installing

protective joint boot
Clamp
Always replace

large clamping sleeve to outer
joint
Cover
Carefully drive off using drift
Before installing on constant

velocity joint, coat sealing
surface with D-3
Adhesive surface must be

free of oil and grease
Pre-tighten to 10 Nm in
diagonal sequence
Tighten to 70 Nm
Always replace
Backing plate
Inner constant velocity joint
Replace only as a unit
Checking 42-6, Inner

constant velocity (CV) joint,
checking
Pressing off 42-6, Inner CV

joint, servicing
Pressing on Topic 42-6
Circlip
Always replace
Gasket
Replacing. Pull off protective

foil and stick into joint.
Cover
Pry out with screwdriver

42-6, Inner CV joint, servicing
Always replace
Replace seal before attaching

to CV joint Item - 15 -
Pressing on Topic 42-6
Drive axle, removing and installing
engine/transmission jack V.A.G 1383 A
Removing
- Only loosen hex socket head bolt - arrow - 90 ,

otherwise wheel bearing is damaged.
Warning!
When loosening collar bolt, vehicle must stand on

wheels -risk of accident-.
- Remove wheel.
- Install all 4 wheel bolts hand-tight.
- Activate parking brake.
- Remove collar bolt.
If collar bolt is loose or removed, wheel bearings must

not be loaded.
If bearings are loaded by the vehicles own weight the

wheel bearing will be damaged. The wheel bearings
will be stressed and the life expectancy reduced.
If a vehicle that has a drive axle removed is to be moved,

an outer CV joint must be installed in place of the drive axle
and be tightened to 200 Nm. Otherwise, wheel bearing will
be damaged.
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru

Volkswagen, Skoda, Seat, Audi
- Remove bolts - 2 - and cover.
- Remove bolts - 1 - .
- Loosen parking brake.

1-.

housing downward.
- Remove bolt from - 2 - level control system sensor.


- Remove brake line bracket bolt - 4 - .
- Loosen bolted connection nuts - 1 and 2 - from lower link

-6-.
- Remove bolted connection bolts - 3 and 4 - .
- Remove lower link from notches on subframe and swing

downward.
- Loosen double clamp and retainers on exhaust system

center muffler and lower this as much as possible

and installing
- Push wheel bearing housing towards outside in order to

remove drive axle from flange on transmission rear axle.
- Move drive axle inward until it can be removed from wheel

hub.
- Remove drive axle from vehicle behind lowered lower link.

Installing
- Insert drive axle in vehicle behind lowered link.
- Insert drive axle in wheel hub to stop.
- Push wheel bearing housing towards outside in order to

insert drive axle in flange on transmission rear axle.
- Pivot lower link upward into notches on subframe and

secure with new bolts and nuts - 1 and 2 - .
- Attach brackets on exhaust system center muffler to

vehicle underbody and fasten double clamp to designated
position

and installing
- Align drive axle holes and flange shaft/transmission to

each other.
- Install bolts - 1 - and tighten to specified torque.
- Insert cover and combi-bolts - 2 - and tighten to specified

torque.

upward.
- Install brake line bracket bolt - 4 - .
- Tighten bolted connection nuts - 1 to 4 - to specified

torque.
- Connect connecting link/lower link bolted connection - 1 -

tighten to specified torque without additional tightening.
- Install bolt - 2 - in level control system sensor.
- Activate parking brake.
- Tighten drive axle collar bolt to 200 Nm.
- Tighten collar bolt to specified additional torque angle of

180 .
Warning!
When tightening collar bolt to additional torque angle,

vehicle must be standing on wheels -risk of accident-.
Drive axle, servicing

required
Thrust plate VW 401

Thrust plate VW 402
Punch V 409
Punch VW 412
Support sleeve VW 522
Clamp 40-204 A
Assembly tool T10065 can also be

used instead of clamp 40-204 A .

required
Bracket 2036/1
Sleeve 3144
CV joint boot clamp tool V.A.G

1275
CV joint boot clamp tool V.A.G

1682
Assembly tool T10065
Sealant D 454 300 A2
Circlip pliers (commercially-

available)
Inner CV joint, servicing
Inner CV joint, removing
- Secure drive axle with protective covers in vise.
- Pry off cap, e.g. with a screwdriver.

- Remove sealing ring - arrow - .
- Drive protective joint boot cap under with a brass or

copper drift.
Note:
Clamping sleeves must not be loosened.
- Remove circlip.
- Press inner CV joint off of drive axle with special tool

shown in illustration.
- Open small clamping sleeve on drive axle and remove

protective joint boot from drive axle.
Inner CV joint, installing

- Apply sealant - hatched surface - to clean surface on

inner side of protective joint boot cover. Sealant bead:
unbroken, diameter 2 to 3 mm, skirting area around inner
holes - arrow - .
- Use sealant D 454 300 A2 for this.
- Slide protective joint boot with small clamping sleeve on

drive axle.
Shaft, protective joint boot and cap contact surfaces must

be free of grease.
- Press on joint until stop.
Chamfer on inner diameter of ball hub (splines) must face

contact shoulder of drive axle.
Use special tool shown in illustration.
You can also use assembly tool T10065 instead of clamp

40-204 A .
Clamp 40-204 A or assembly tool T10065 and clamping

surfaces on drive axle must be free of grease.
Circlip must be replaced.

- Install circlip.
- Check circlip for correct seating.
- Before installing cover, apply 60 grams of drive axle

grease in CV joint through ball paths.
Make sure you do not damage sealant bead.
- Align cover with bolts - arrows - to bolt holes.
It must be aligned exactly because it cannot be aligned

after driving on.
- Drive cover on with a plastic hammer.
- Wipe away any sealant leaking out.
- Apply 60 grams of joint grease to CV joint through ball

paths.
- Lubricate contact surfaces for sealing ring.

- Remove adhesive foil from seal and adhere to CV joint.
- Align new cover - A - to bolt holes.
It must be aligned exactly because it cannot be aligned

after pressing on.
- Press cover - A - on with special tool shown in illustration.
Flat steel in an appropriate size can be used instead of

bracket 2036/1 .
- Position protective joint boot in outer groove - arrow 2 - .
Inner groove - arrow 1 - must remain visible "identifying

groove" (for correct installation of protective joint boot).
Clamp large clamping sleeve to outer joint
- Use CV joint boot clamp tool V.A.G 1682 as shown in

illustration. Make sure that the jaws of the tension clamp
seat in the corners - arrows B - of hose clip.
- Tighten hose tie by turning spindle using a torque wrench

(do not bend tensioning clamp).
Note:
A stainless steel clamp must be used due to the

hardness of the CV boot material (compared to
rubber). This clamp can only be tensioned using the
CV joint boot clamp tool V.A.G 1682 .
Torque specification: 25 Nm
Use torque wrench - C - with a range of 5 to 50 Nm

(e.g. V.A.G 1331 ).
Be sure thread of spindle - A - of clamp tool moves

freely. Grease with grease MOS 2 if necessary.
If does not move freely, e.g. due to dirt in thread,

required clamp tension will not be achieved at
specified torque.
Clamp small clamping sleeve to inner joint
Inner constant velocity (CV) joint, checking
In order to replace grease in case of strong soiling, joint

must be disassembled and if journal surfaces and balls
must be checked for wear and damage.
Disassembling
Note:
Ball hub and joint are paired and should be identified

before removal. Do not interchange cage allocation.
- Pivot ball hub and ball cage.
- Press out ball joint housing in direction of - arrow - .
- Press balls out of cage.

- Flip out ball hub from ball cage via running path of ball -
arrows - .
- Check joint housing, ball hub, ball cage and balls for
indentations (pitting) and signs of seizure.
Note:
Excessive circumferential backlash in joint makes

itself noticed via tip-in shock. In such cases the joint
must be replaced. Flattening and running marks of
balls are no reason to replace joint.
Assembling
- Insert ball hub into ball cage via two chamfers. The hub
can be installed in any position. Press balls into cage.
- Insert hub with cage and balls at right angle to joint.

When inserting make sure that the wide space - a -

on joint housing is aligned with the narrow space - b -
on hub after swiveling in.
Chamfer on inner diameter of wheel hub (splines)

must face toward drive axle.
- Install ball hub, whereby the hub must be swiveled out of

cage - arrows - far enough to allow balls to fit into ball
tracks.
- Press cage firmly - arrow - until hub swings fully in

position.
Constant velocity joint, checking for function
Constant velocity joint is properly assembled, if ball hub

can be slid back and forth by hand over whole
compensation length.
- Press grease into joint body.
Outer constant velocity joint, servicing
Outer CV joint, removing
- Secure axle shaft with protective covers in vise clamp.
- Open both clamping sleeves and remove protective joint

boot from outer joint.
- Strike a copper or brass drift - A - on CV joint inner race

with a hammer.
- Remove joint and protective joint boot.
Outer CV joint, installing
- Slide joint protective boot onto drive axle.

Joints and protective joint boots must be free of grease.
1 - Circlip (snap ring), must be replaced.
- Position protective joint boot between - arrows - .
- Apply 40 grams of joint grease to inside of joint.
- Screw old drive shaft bolt into joint as shown in

illustration.
- Drive joint onto shaft with plastic hammer until circlip

engages.
- Apply 50 grams of joint grease in boot side of joint.
Install clamping sleeve on outer joint and clamp
- Install clamping sleeve on outer joint.

- Bleed protective joint boot.
- Tension clamp using pliers V.A.G 1275 .
Outer constant velocity (CV) joint, checking
In order to replace grease in case of strong soiling, joint

must be disassembled or if journal surface of balls must be
checked for wear and damage.
Disassembling
- Before disassembling mark ball hub position in relation to

ball cage and housing using an electric scriber or oil stone.
- Swivel ball hub and ball cage.
- Remove balls one after another.
- Turn cage, until two rectangular windows - arrow -

contact joint body.
- Lift out cage together with hub.

- Swing hub segment with smaller pins into rectangular

window on cage.
- Tilt hub out of cage.
Checking
6 balls for each joint belong to a tolerance group. Check

stub axle, hub, cage and balls for small indentations
(pitting) and signs of seizure. Excessive circumferential
backlash in joint makes itself noticed via tip-in shock, in
such cases joint should be replaced. Flattening and running
marks of balls are no reason to replace joint.
Assembling
- Install cage with hub in the joint housing.
Note:
Cage must be installed laterally correct.
- Press in opposing balls in sequence, during this, previous

position of ball hub to ball cage and to joint body must be
re-established.
- Press grease into joint body.

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Rear axle (front and all wheel drive), servicing .

Rear axle (front and all wheel drive), servicing

If components with bonded rubber bushings were

Always replace self-locking nuts.

Always replaced corroded nuts and bolts.

I - Subframe, assembly overview 42-

II - Link, tie rod, air spring strut,

rod, air spring strut, assembly

III - Wheel bearing, assembly overview

IV - Driveshaft, assembly overview

I - Subframe, assembly overview

On vehicles with front wheel drive, only

Removing and installing

Repair Manual, Automatic

130 Nm plus an additional 90

This version is replaced in 2004

Application Electronic Parts

Application Electronic Parts

Hex socket head bolt

Final drive support

For vehicles with V6 and W12

Application Electronic Parts

Final drive support

For vehicles with V8 and V10

Application Electronic Parts

Multi-point socket head bolt

Between rear final drive and

For vehicles with V8 and V10

Application Electronic Parts

Subframe, removing and installing

Special tools, testers and auxiliary items

Engine/transmission jack V.A.G

Tightening strap T10038

Torque wrench V.A.G 1332

- Brake pedal loading device V.A.G 1869/2 .

- Remove rear wheels.

- Remove rear cover on rear bumper

Repair Manual, Body Exterior, Repair Group 63, Bumper

- Disconnect all electrical wires from body to rear axle.

Secure vehicle to hoist to continue procedure.

- Remove plugs (2 per vehicle side).

- Secure vehicle to hoist lifting arm with Tensioning Strap

- Remove rear section of exhaust system

Repair Manual, Engine Mechanical, Fuel Injection

- Disconnect brake lines.

- Remove brake cable from rear axle

Repair Manual, Brake System, Repair Group 46, Rear

- Remove heat shield - 1 - from spare wheel well - arrows -

Repair Manual, Automatic Transmission, Repair Group

- Place engine/transmission jack V.A.G 1383 A with

- Remove nut - 1 - , remove bolt - 2 - and press air spring

- Remove subframe from body.

- Slowly lower rear axle.

Installation is in reverse order of removal, note the

- Tighten subframe with bolts originally installed. Replace

- Tighten bolts originally installed to specified torque

without additional tightening.

- Tighten drive shaft to rear final drive