Rear drive axle, removing and installing

Page 1 of 15

42-93

Rear drive axle, removing and

installing
1 - Rear final drive
2 - Gasket
Always replace
Remove protective backing and stick onto
joint
3 - Drive axle
Servicing

page 42-99

CAUTION!
Do not attempt to move a vehicle from which
the drive axle has been removed. Otherwise
wheel bearing damage will result. If the vehicle
must be moved, install an outer CV joint in
place of the drive axle.
4 - Spacer plate
5 - Bolts
40 Nm (30 ft lb)
6 - Subframe

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11/20/2002

Rear drive axle, removing and installing

Page 2 of 15

42-94

7 - Collar bolt
Always replace
Switching from or mixing old and new bolts
is permissible
M14 bolt: 115 Nm (85 ft lb) + 1/2-turn
(180 )
WARNING!
The vehicle must be standing on its wheels
when loosening or tightening. Otherwise the
risk of an accident exists.
8 - Self-locking nut
Always replace
70 Nm (52 ft lb) + 1/4-turn (90 )
9 - Washer
Always replace
10 - Bolt
Always replace

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11/20/2002

Rear drive axle, removing and installing

Page 3 of 15

42-95

Removing and installing drive axle (left-hand

side)
Vehicle must be standing on its wheels
above vehicle lift
- Remove wheel trim.
On light alloy wheels use puller in vehicle tool kit
to remove trim cap
- Loosen collar bolt.
WARNING!
The vehicle must be standing on its wheels
when loosening or tightening the collar bolt
for the drive axle. Otherwise the risk of an
accident exists.
- Loosen wheel bolts.
- Raise vehicle on lift.
- Remove wheel.
- Pull ABS wheel speed sensor slightly out of
wheel bearing housing.

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11/20/2002

Rear drive axle, removing and installing

Page 4 of 15

- Remove collar bolt.

- Remove bolts from inner CV joint to rear final
drive.

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11/20/2002

Rear drive axle, removing and installing

Page 5 of 15

42-96

- Remove nut and bolt for connecting link to wheel bearing housing
(arrow -2-) page 42-43 .
Tightening torque: 50 Nm (37 ft lb)

- Remove bolted connection from upper control arm to wheel bearing

housing (arrow -1-) page 42-94 .
- Remove exhaust system, rear silencer and center silencer:
Repair Manual, Engine Mechanical, Repair Group 26
- Lower drive axle on inside at rear final drive and remove from wheel
bearing housing.
Installation is the reverse of removal.
CAUTION!
Bonded rubber bushings can only be turned to a limited extent. The
bolted connection must only be tightened when the vehicle is
standing on the ground. Otherwise the bonded rubber bushings will
be subjected to a torsional stress resulting in shortened service life

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11/20/2002

Rear drive axle, removing and installing

Page 6 of 15

42-97

Removing and installing drive axle (righthand side)

Vehicle must be standing on its wheels
above vehicle lift
- Remove wheel trim.
On light alloy wheels use puller in vehicle tool kit
to remove trim cap
- Loosen collar bolt.
WARNING!
The vehicle must be standing on its wheels
when loosening or tightening the collar bolt
for the drive axle. Otherwise the risk of an
accident exists.
- Loosen wheel bolts.
- Raise vehicle on lift.
- Remove wheel.
- Pull ABS wheel speed sensor slightly out of
wheel bearing housing.

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11/20/2002

Rear drive axle, removing and installing

Page 7 of 15

- Remove collar bolt.

- Remove bolts from inner CV joint to rear final
drive.

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11/20/2002

Rear drive axle, removing and installing

Page 8 of 15

42-98

- Remove nut and bolt for connecting link to wheel bearing housing
(arrow -2-) page 42-43 .
Tightening torque: 50 Nm (37 ft lb)

- Remove bolted connection of upper control arm to wheel bearing

housing (arrow -1-) page 42-94 .
- Lower drive axle on inside at rear final drive and remove from wheel
bearing housing.
Installation is the reverse of removal.
CAUTION!
Bonded rubber bushings can only be turned to a limited extent. The
bolted connection must only be tightened when the vehicle is
standing on the ground. Otherwise the bonded rubber bushings will
be subjected to a torsional stress resulting in shortened service life

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11/20/2002

Rear drive axle, removing and installing

Page 9 of 15

42-99

Rear drive axle, servicing

Note:
Constant Velocity (CV) joints are packed with
grease G-6.
Outer
joint dia.

Total grease
required

Proportions:
Joint

89 mm
(3.5 in.)

Boot

90 g (3.2 oz.)

40 g (1.4 50 g (1.8
oz)
oz)

80 g (2.8 oz.)

30 g (1.1 50 g (1.8
oz)
oz)

Inner
100 mm
(3.9 in.)
Note:
Re-grease the joint, if necessary, when replacing
the CV joint boot.
1 - Circlip
Always replace
Use VW161a circlip pliers to remove and
install Fig. 5

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11/20/2002

Rear drive axle, removing and installing

Page 10 of 15

42-100

2 - Gasket
Always replace; remove protective backing
and stick onto joint
3 - Inner CV joint
O.D.: 100 mm (3.9 in.)
Replace only as complete joint
Removing

Fig. 3

Pressing on
Greasing

Fig. 4
Note, page 42-99

4 - Dished washer
Installation position

Fig. 7

5 - Inner CV joint boot with cap

Examine for splits and signs of chafing
Use drift to remove
Coat sealing surface of CV joint with D-3
before attaching to CV joint
6 - Axle shaft
Identical length on left and right-sides
7 - Outer CV joint boot
Examine for splits and signs of chafing
Ventilate before tightening clamp

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Fig. 2

11/20/2002

Rear drive axle, removing and installing

Page 11 of 15

42-101

8 - Clamp
Always replace
Tightening

Fig. 1

9 - Dished washer
Larger diameter (concave side) contacts
thrust ring
Installation position

Fig. 6

10 - Spacer ring
Installation position

Fig. 6

11 - Circlip
Always replace
Insert into annular groove of shaft when
installing; not visible when joint installed
12 - Outer CV joint
O.D.: 89 mm (3.5 in.)
Replace only complete joint
Removing

Fig. 8

Installing: drive joint onto shaft using

plastic-headed hammer until circlip
engages in groove
Greasing

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Note, page 42-99

11/20/2002

Rear drive axle, removing and installing

Page 12 of 15

42-102

Fig. 1

Tightening clamp

Fig. 2

Venting CV joint boot

Attaching the CV joint boot onto the outer body of the joint frequently
requires compressing or squeezing the boot. This produces a vacuum in
the joint boot, which may cause a crease to the inside when driving
(arrow).
For this reason, after installing the joint boot, vent it briefly by letting some
air in at the small diameter to balance the pressure and restore the correct
boot shape.

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Rear drive axle, removing and installing

Page 13 of 15

42-103

Fig. 3

Removing inner CV joint

Notes:
Use arbor to drive off boot first.
Support ball hub.

Fig. 4

Pressing on inner CV joint

Note:
Chamfer on the inner diameter of the ball hub (splines) must be facing
toward the shoulder of the drive axle.
- Press joint on up to stop.
- Install circlip.

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11/20/2002

Rear drive axle, removing and installing

Page 14 of 15

42-104

Fig. 5

Removing and installing circlip

Fig. 6

Installation position of dished washer and spacer ring

1 - Dished washer
2 - Spacer ring (plastic)

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Rear drive axle, removing and installing

Page 15 of 15

42-105

Fig. 7

Installing dished washer in correct position

Fig. 8

Pressing off outer CV joint

- Clamp drive axle in vise using protective jaws.

- Remove clamp and push back boot.
- Screw in 3207 pressure spindle with M14-thread end into joint until CV
joint is pressed off splined shaft.

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11/20/2002