Volkswagen Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ 3186 Special socket 21 mm AF
• ◆ VW 401 Press plate
• ◆ 3254 Open jaw spanner 50 mm AF
• ◆ VW 408 A Press tool
• ◆ VW 295a Adapter

Special tools and workshop equipment required

• ◆ 3253/1 Tube
• ◆ VW 402 Press piece
• ◆ 30-11 Thrust plate
• ◆ 3260 Pad
• ◆ VW 408 A Press tool

Special tools and workshop equipment required

• ◆ VW 407 Press tool
• ◆ 3118 Tube
• ◆ 3253/7 Disk

Notes:

• ◆ If a vehicle has to be moved after removing the drive shaft, first install outer joint and tighten to 50 Nm otherwise the wheel bearing will be damaged.
• ◆ It is not permitted to carry out welding and straightening operations on load bearing suspension components or those components which locate the wheels.
• ◆ Always renew self-locking nuts.
• ◆ Always renew corroded nuts/bolts.

• Hexagon head bolt
• ◆ 20 Nm and turn 90° further
• ◆ Renew each time after removing
• ◆ Mark installation position =>Fig. 1
• Plate with nuts

• Bolt
• ◆ Adjusting camber
  
• ◆ Mark position before loosening
• Hexagon socket head bolt, 10 Nm
• Speed sensor
• Protective cap
• Bracket
• Bracket
• Self-locking nut, 95 Nm
• ◆ Renew each time after removing
• Track rod

• Wheel bearing housing
• ◆ Coat hole surfaces completely with Molykote grease =>Fig.5
• ◆ Standard with 16V -74 kW vehicles as from 06.96.
• The caster angle does not change with the introduction of this wheel bearing housing.
• With the introduction of the 88 kW GTI the wheel bearing housing was modified which changed the caster angle.
• This, along with a different installation position for the ball joint, increased the caster by 1°.

• Wheel bearing housing
• ◆ Coat hole surfaces completely with Molykote grease =>Fig.5

• Self-locking nut, 35 Nm
• ◆ Splitting ball joint =>Fig. 8
• ◆ Renew each time after removing
• Circlip
• ◆ Ensure correctly seated
• Hexagon bolt, 10 Nm
• Splash plate

• Wheel bearing
• ◆ Pressing out =>Fig.4
• ◆ Renew, as it is destroyed during pressing out
• ◆ Pressing in =>Fig.6
• Cross-head screw
• Wheel bolt, 110 Nm
• Self-locking 12-point nut
• ◆ Tightening
  
• ◆ Renew each time after removing
• Ventilated brake disc
• ◆ For vehicles from 01.95: 239.00 ø
• ◆ Brake disc:256.00 mm øfor 16V vehicles

• Brake disc
• ◆ For vehicles up to 12.94
• Cross-head screw
• Wheel hub
• ◆ Pressing out =>Fig.2
• ◆ Pressing in =>Fig.7
• ◆ Pulling off bearing inner race
  =>Fig.3
• ◆ Pulling drive shaft out from wheel hub and pressing in =>Removing and installing drive shafts Page 40-49
• Speed sensor rotor
• ◆ Only on vehicles with ABS
• Wheel hub with speed sensor rotor
• ◆ Rotor is welded to wheel hub

→ Fig.1     Separating ball joint/wishbone connection

• ‒ Mark installation position of bolts.
• ‒ Remove bolts (arrows).

→ Fig.2     Pressing wheel hub out of wheel bearing housing

→ Fig.3     Pulling bearing race out of hub

Remove speed sensor rotor if fitted (on vehicles with ABS).

Only use puller with leg clamp e.g. Kukko 204-2 (commercial type).

→ Fig.4     Pressing wheel bearing out of wheel bearing housing

Fist remove securing ring.

→ Fig.5     Coating hole surface with Molykote grease

Use grease sachet from repair set.

→ Fig.6     Pressing wheel bearing into wheel bearing housing

• ‒ Install circlip.

→ Fig.7     Pressing hub into wheel bearing

→ Fig.8     Pressing track rod ball joint off steering arm

•      1 -     Ball joint splitter (commercial type) e.g. Kukko No. 128/2