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Project 46 How to Diagnose and Repair the Drive Flange Shaft on a 2003 VW Golf TDI 5-Speed

 

Overview

 

Note

 

The steps discussed below are the techniques,and  approach used to fix the drive flange transaxle on the 2003 VW Golf TDI. For other service procedures, a Bentley or a factory service manual should be consulted.

 

The focus of this project is to to discuss in detail a drive flange repair on VW's equipped with the 5-speed transaxle. Owners should not ignore unusual noises and vibrations from the engine compartment. The problem could be caused by bolts (6) securing the drive flange to the transaxle backing out. Loose bolts will cause the drive axle shaft to wobble and distort the bolt holes in the drive flange shaft.

 

At highway speeds (between 60 to 75mph), the bolts will snap securing the drive flange shaft to the transaxle resulting in serious damage. The vehicle will have to be towed and the owner will be faced with an out-of-pocket expense of several thousand dollars.

 

In this case, the owner of the vehicle noticed the noise at a low speed. There was no major damage to the transaxle. A used drive flange was not available at local salvage yards for this repair. The part at the local VW dealer was priced at $300.00. The part was also not in stock. It would have to be back ordered with a waiting time up to five (5) days.

 

Note

 

When attempting this repair, an air compressor and a 1/2-inch square drive impact wrench should be used to remove the transaxle lock nut. A 30mm 1/2-inch square drive socket is used with the impact wrench. When re-assembling, the lock nut must be tightened so that there is no movement of the nut. There should be no play in the axle. A lock nut that is not tightened properly will result in pre-mature failure of the wheel bearing. A 1/2-inch square drive breaker bar, 30mm socket, and a cheater pipe can be used to loosen the lock nut.

 

Other special tools required for this project are: (1) metric tap and die set and (2) three (3) jaw puller.

 

Below are the steps and tools used to remove the drive axle and make the repair with a bolt kit for less than $10.00. To repair the problem at a dealership would be an out-of-pocket expense of over $800.00..

 

Repair Steps

 

Step 1 - Using a hoisting device, place a jack stand under the vehicle subframe. Figure 46-1 shows the wheel removed, jack stand, and placement of a hoisting device.

 

Figure 46-1 Placing a Hoisting Device Under Vehicle

 

Step 2 - Connect a 1/2-inch square drive breaker bar to a 12-inch 1/2inch square drive extension.

Step 3 - Insert a 12mm internal wrench (tri-square) into the shank of a 3/8-inch square drive deep socket. Figure 46-2 shows the tool setup for the removal of the drive flange bolts.

 

Figure 46-2 Drive Flange Removal Tools

 

Step 4 -  Loosen the bolts (6) connected to the drive frange. (See Figure 46-3).

 

 

Figure 46-3 Loosening Drive Flange Bolts

 

Step 5 - Remove drive flange bolts and set aside. Figure 46-4 shows the drive flange with the mounting bolts removed.

 

Figure 46-4 Removing Drive Flange Bolts

 

Step 6 - Remove the drive axle lock nut using a 1/2-inch square drive impact wrench or breaker bar.

Step 7 - Insert a 30mm 1/2-inch square drive socket onto the shaft of the impact wrench. Figure 46-5 shows the lock nut being removed with an impact wrench.

 

 

Figure 46-5 Removing Axle Lock Nut

 

Step 8 - Using a 1/2-inch square drive ratchet and 1/2-inch square drive 13mm socket, remove the bolts securing the ball joints on the drivers side and passenger side of vehicle (See Figure 46-6).

 

 

Figure 46-6 Removing Bolt to Ball Joint

 

Step 9 - Using a 3/8-inch square drive ratchet, 15mm thin jaw open end wrench, and 3/8-inch square drive 13mm socket remove the bolts securing the caliper assembly and set aside (See Figure 46-7).

 

 

Figure 46-7 Removing Caliper Assembly

 

Step 10 - Using a phillips screw driver with a No. 2 bit, remove the screw securing the brake rotor (See Figure 46-8).

 

 

Figure 46-8 Removing Screw to Rotor

 

Step 11 - Remove the brake rotor from the axle and set aside.

 

Step 12 - Position a 3-jaw gear puller around the brake rotor hub (See Figure 46-9).

 

 

Figure 46-9 Placing Gear Puller on brake hub

 

Step 13 - Position the point of the gear puller in the center of the axle shaft.

 

Step 14 - Using a 1/2-inch square drive ratchet and 19mm 1/2-inch square drive socket turn the puller bolt in a clockwise direction (See Figure 46-10).

 

 

Figure 46-10 Turning Gear Puller Bolt on Axle Shaft

 

Note

Turning the gear puller pushes the axle shaft from the brake assemby so that the axle can be removed from the vehicle.

 

Step 15 - Remove the axle assembly from the vehicle and set aside (See Figure 46-11).

 

 

 

Figure 46-11 Removed Drive Axle

 

Step 16 - Using a 3/8-inch square drive ratchet, T30 torx 3/8-inch square drive socket, and 12-inch 3/8-inch square drive extension remove the bolt securing the drive flange to the axle shaft (See Figure 46-12). Figure 46-13 shows the drive flange removed. Figure 46-14 shows the damaged holes in drive flange that have to be straightened with an electric drill and drill bit.

 

 

Figure 46-12 Drive Flange Bolt Removed

 

 

 

Figure 46-13 Drive Flange Shaft Removed

 

 

Figure 46-14 Damaged Bolt Holes in Drive Flange

 

Step 17 - Using an electric drill and the appropriate size drill bit, straighten the damaged bolt holes in the drive flange.

 

Step 18 - Using an 6.0 metric tap, and adjustable tap wrench chase the threads in the axle assembly (See Figure 46-15)

 

.

 

Figure 46-15 Cleaning Threads on Drive Axle

 

Step 19 - Coat Locktite (Blue) on the threads of the six (6) replacement bolts for the drive flange (See Figure 46-16).

 

 

Figure 46-16 Applying Locktite to Drive Flange Bolts

 

Step 20 - Install the drive flange into the splines of the drive axle.

 

Step 21 - Install the bolt to the assembled drive flange that was previoiusly removed (See Figure 46-17).

 

 

Figure 46-17 Installing Drive Flange Shaft Bolt

 

Step 21- Install the drive axle assembly as shown in Figure 46-18.

 

 

 

Figure 46-18 Installing Drive Axle in Vehicle

 

Step 22 - Install the replacement bolts into the drive flange shaft and tighten. (See Figure 46-19).

 

 

Figure 46-19 Installing Drive Flange Bolts

 

Finishing Up

 

Step 23 - Install the axle lock nut that was previously removed (See Figure 46-20).

 

 

Figure 46-20 Installing Axle Lock Nut

 

Note

 

Tighten the lock nut with the inpact wrench until the nut no longer moves. There should be no play in the axle. A lock nut that is not tightened properly will lead to early bearing failure.

 

Step 24 - Install the rotor to the brake assembly.

 

Step 25 - Install the screw with a phillips screwdriver that was previously removed.

 

Step 26 - Install the caliper assembly that was previously removed (See Figure 46-21).

 

 

Figure 46-21 Installed Caliper Assembly

 

Step 27 - Install the bolts that were previously removed to the ball joints (See Figure 46-22).

 

 

Figure 46-22 Installing Bolts to Ball Joints

 

Step 28 - Install wheels to vehicle and torque to 89 ftlbs.

 

Step 29 - Lift vehicle with a lifting device.

 

Step 30 - Remove jack stands.

 

Step 31 - Remove wheel chocks.

 

Step 32 - Gather and put away all shop and hand tools used for the job.

 

Step 33 - Road test vehicle.

 

Tools and Equipment

 

Air compressor

1/2-inch square drive impact wrench

30mm 1/2-inch square drive socket

1/2-inch square drive breaker bar

Cheater pipe

Metric tap and die set

3-jaw gear puller

Lifting device

Jack stands

Wheel chocks

12-inch 1/2-inch square drive extension

12mm internal wrench

3/8-inch square deep socket

1/2-inch square drive ratchet

1/2-inch square drive 13mm socket

3/8-inch square drive ratchet

15m open end thin jaw wrench

3/8-inch square drive socket

Phillips screwdriver with #2 bit

19mm 1/2-inch square drive socket

T30 torx 3/8-inch square drive socket

3/8 electric drill

6.0 metric tap

Adjustable tap wrench

Blue locktite sealer

Six (6) replacement bolts

1/2-inch square drive torque wrench