Volkswagen Workshop Service and Repair Manuals

Removing and installing suspension strut

Special tools and workshop equipment required

t	Torque wrench -V.A.G 1332-

t	Spreader -3424-

t	Engine and gearbox jack -V.A.G 1383 A-

t	Support -T10149-

t  Remover -3283 A-

t  Shock absorber set -T10001- Carry out the following work: Removing –  Lift vehicle far enough to take weight off front axle. –  Loosen twelve-point nut for drive shaft.   Caution Wheel bearings must not be subjected to load after bolt securing drive shaft to wheel hub has been loosened. If wheel bearings are loaded with weight of vehicle, wheel bearings will be damaged and service life of wheel bearings will be considerably reduced. It is not permissible to turn drive shaft bolt more than 90° anti-clockwise if vehicle is standing on its wheels. Do not attempt to move the vehicle without the drive shafts fitted as this would damage the wheel bearing. If a vehicle nevertheless has to be moved, comply with the following: t  Install an outer joint instead of the drive shaft. t  Tighten outer joint to 120 Nm. –  Loosen wheel bolts. –  Raise vehicle. –  Remove wheel.

–  Unscrew nut -arrow- and pull coupling rod -1- out from suspension strut.

–  Remove clip for brake line -1- and brake line -2- and unhook brake line from suspension strut -arrows-. –  Pull connector off ABS speed sensor. –  Remove speed sensor wire -3- from suspension strut.

–  Remove nuts -arrows-. –  Pull swivel joint out of suspension link. –  Pull outer joint of drive shaft out of wheel hub. If the drive shaft cannot be pulled out of the wheel bearing by hand, use press tool -3283 A-.

Before using press tool -3283 A- ensure that thrust piece -1- is inserted.

Using press tool -3283 A-: –  Secure press tool -3283 A--1- with two wheel bolts to wheel hub.

–  It is essential to follow specified sequence. I -  Tighten knurled nut -1- hand-tight. II -  Only turn press tool -3283 A- by means of bolt -2- using a spanner in order to press out drive shaft.   Note At the end of the procedure or for pressing out drive shaft further the spindle must be moved to its original position in order to deploy the hydraulic force! –  Secure drive shaft to body with wire. –  Bolt swivel joint to suspension link again.

–  Use wheel bolt to attach engine and gearbox jack -V.A.G 1383 A- with support -T10149- to wheel hub.   WARNING t  Do not lift or lower vehicle while engine and gearbox jack -V.A.G 1383 A- is under vehicle. The vehicle could slip off the lifting platform. t  Do not leave engine and gearbox jack -V.A.G 1383 A- under vehicle longer than necessary.

–  Separate threaded connection between wheel bearing housing and suspension strut -arrow-.

–  Insert spreader -3424- in slot in wheel bearing housing. –  Turn ratchet handle through 90° and pull off from spreader -3424-. –  Press brake disc towards suspension strut by hand. Otherwise the shock absorber tube can cant in the bore of the wheel bearing housing. –  Pull wheel bearing housing downwards off shock absorber tube and lower with engine and gearbox jack -V.A.G 1383 A- until shock absorber tube is free. –  Firmly tie wheel bearing housing to subframe. –  Remove support -T10149- from wheel hub and remove engine and gearbox jack -V.A.G 1383 A- from beneath vehicle.   WARNING Do not leave engine and gearbox jack -V.A.G 1383 A- under vehicle longer than necessary. –  Remove plenum chamber cover → General body repairs, exterior; Rep. gr.50.

–  Unbolt upper shock absorber mounting and remove spring strut downwards. 1 -  Ratchet, commercially available 2 -  -T10001/8- 3 -  -T10001/11- 4 -  -T10001/5- Installing

–  Use wheel bolt to attach engine and gearbox jack -V.A.G 1383 A- with support -T10149- to wheel hub. –  Place suspension strut on wheel bearing housing and fix in place with the multi-point socket head bolt and a new nut. The tip of the multi-point socket head bolt must point in the direction of travel. –  Remove spreader -3424-. –  Raise wheel bearing housing using engine and gearbox jack until suspension strut lies against inner suspension turret.

–  Position stop on suspension strut turret and tighten nuts for upper shock absorber mounting to tightening torque. 1 -  Torque wrench -V.A.G 1332- 2 -  -T10001/8- 3 -  -T10001/11- 4 -  -T10001/5- –  Remove support -T10149- from wheel hub and remove engine and gearbox jack -V.A.G 1383 A- from beneath vehicle.   WARNING Do not leave engine and gearbox jack -V.A.G 1383 A- under vehicle longer than necessary.

–  Tighten threaded connection between wheel bearing housing and suspension strut -arrow-

–  Remove nuts -arrows-. –  Pull swivel joint out of suspension link.

Make sure that deflector ring -1- is clipped completely onto outer joint.   Note t  The lugs of deflector ring -1- must face towards outer joint. t  Deflector ring -1- must lie on contact surface of outer joint -arrow-.   Note

If deflector ring -1- is not positioned correctly or if it fell off outer joint, it must be driven onto outer joint to stop using thrust piece -T10049-. –  Fit drive shaft into wheel bearing.

–  Bolt swivel joint to suspension link with new nuts -arrows-. Use new nuts. Ensure that bellows are not damaged or twisted. Continue installation in reverse order. –  Install plenum chamber cover → General body repairs, exterior; Rep. gr.50. –  Install wheel and tighten bolts or nuts → Chapter. –  Tighten twelve-point nut for drive shaft.   Note During this step, vehicle must not be standing on its wheels or wheel bearing will be damaged.

Specified torques

Component	Specified torque
Coil spring strut to body t  Use new nuts.	60 Nm
Suspension strut to wheel bearing housing t  Use new bolts and nuts.	70 Nm + 90° further
Swivel joint to suspension link t  Use new bolts.	100 Nm
Coupling rod to suspension strut t  Use new nuts.	40 Nm
12-point nut on drive shaft t  Use new nuts.	50 Nm + 45° further