Rear axle beam - removal and refitting

Suspension and steering / Rear axle beam - removal and refitting

Note: If the axle beam is suspected of being distorted, then it should be checked in position by a VW garage using optical alignment equipment
Modification: On 1988 models, the rear suspension mounting bracket bolts incorporate a modified shoulder. Their tightening torque is reduced to that specified.

Removal
1 Remove the rear stub axles.

2 Support the weight of the trailing arms with axle stands (see “Jacking and vehicle support”) then disconnect the struts/shock absorbers by removing the lower mounting bolts.

3 On models fitted with a brake pressure regulator unit, unbolt the spring bracket from the axle beam (see illustration).

9.3 Brake pressure regulator unit showing spring bracket

4 Disconnect the handbrake cables from the axle beam and from the left-hand side and underbody bracket.

5 Remove the brake fluid reservoir filler cap and tighten it down onto a piece of polythene sheet in order to reduce the loss of hydraulic fluid.

6 Lower the axle beam and disconnect the brake hydraulic hoses. Plug the hoses to prevent the ingress of dirt.

7 Support the weight of the axle beam with axle stands then unscrew and remove the pivot bolts and lower the axle beam to the ground. Note that the pivot bolt heads face as shown (see illustration).

9.7 Axle beam pivot bolt head fitting position

8 If the bushes are worn renew them. Using a two-arm puller, force the bushes from the axle beam. Dip the new bushes in soapy water before pressing them in from the outside with the puller. Locate the bush so that the segments which protrude point in the direction of travel (see illustration). When fitted, the cylindrical bush section should protrude by 8 mm.

9.8 Rear axle bonded rubber bush orientation

Protruding segments to face forwards

9 If the mounting bracket is removed, note its fitted position relative to the axle. If the bolts shear during removal, the stud will have to be accurately drilled out and the resultant hole tapped for a 12 mm x 1.5 thread. Be careful to drill in the centre of the broken stud since misalignment of the hole will in turn mean misalignment of the axle. Unless you have experience in this type of work it is best entrusted to a trained mechanic.

10 When the mounting bracket is refitted, its inclination angle to the axle beam should be 12° ± 2°.

Refitting
11 Refitting is a reversal of removal whilst noting the following.

12 When the axle is fitted into position with the mountings under tension, locate the securing bolts then align the right side mounting so that the bolts are centralised in the slotted holes. Now on the left-hand side, use a couple of suitable levers and press the mounting to the rubber bush so that a minimal gap exists on the inside (see illustration). The respective retaining bolts can now be tightened to the specified torque wrench setting.

9.12 Rear axle refitting

Check that clearance (arrowed) is minimal on left-hand mounting inner side

13 On completion, bleed the brake hydraulic system.