Volkswagen | PHAETON - | Repair manual | Volkswagen PHAETON - Repair manual

Front suspension, servicing
Стр. 1 из 6
Volkswagen Phaeton
40 - 2
Front suspension, servicing
VAS 5051, connecting and selecting functions
Special tools, equipment, testers, measuring
instruments and auxiliary items required
„
VAS 5051 Vehicle diagnosis, testing and information
system
„
Diagnostic cable VAS 5051/1 or VAS 5051/3
Warning!
„
During a test drive you must always secure
testing and measuring equipment on the back
seat.
„
These devices may be operated only by a
passenger during a test drive.
Front suspension, servicing
- Connect diagnosis cable connector VAS 5051/1 or VAS
5051/3 to diagnosis connection.
- Switch on tester - arrow - .
The tester is operational when it displays a picture of a car.
- Switch on ignition.
- Touch button/field for "Guided Fault Finding" on screen.
- Select one after another:
„
Brand
„
Type
„
Model year
„
Version
„
Engine code
- Confirm data entered.
Note:
„
Wait until tester has checked all control modules in
vehicle.
- Press Goto button and select "Function/component
selection" function
Follow information given on screen to start the desired
functions.
Front axle, overview
Стр. 2 из 6
Front suspension, servicing
A - Mounting bracket, upper links, air
spring strut, and wheel bearing
housing 40-3, A - Mounting bracket,
upper links, air spring strut and wheel
bearing housings, assembly overview
B - Subframe, lower links, and
stabilizer bar 40-4, B - Subframe,
lower link, and stabilizer bar, assembly
overview
Note:
„
If vehicles with drive axle removed must be moved,
an outer joint must be installed first. Tighten outer
joint to 50 Nm, otherwise the wheel bearings will be
damaged.
„
Welding and straightening work on supporting or
wheel carrying components of suspension is not
permitted.
Стр. 3 из 6
Front suspension, servicing
„
Always replace self-locking nuts.
„
Always replaced corroded nuts/bolts.
Wheel bearing, lifting to curb weight position
Special tools, testers and auxiliary items
required
„
engine/transmission jack V.A.G
1383 A
„
Tightening strap T10038
„
Wheel hub support T10149
Note:
Стр. 4 из 6
Front suspension, servicing
„
Always tighten all connecting bolts to suspension
parts with bonded rubber bushings in curb weight
position (unloaded).
Bonded rubber bushings have a limited twisting range.
Axle components with bonded rubber bushings must be
brought into installation position before tightening, which
corresponds to curb weight position when driving.
Otherwise, if you stress the bonded rubber bushing it will
lead to a shorter life span.
By raising the suspension on one side using the
engine/transmission jack V.A.G 1383 A and support
T10149 , this position will be simulated on the hoist.
- Before beginning assembly, measure dimension - a - from
center of wheel to lower edge of wheelhousing using a tape
measure.
The measurement must be taken in the curb weight
position (unloaded).
- Note measured value. This is needed for tightening bolts
and nuts.
Before the individual suspension is raised on one side, the
vehicle must be secured to the lifting arms on the hoist
using tensioning straps T10038 .
Caution!
If the vehicle is not secured, it may slip off the hoist!
- Turn wheel hub until one of the wheel bolt holes is at 12
o'clock position. .
- Attach Wheel Hub Support T10149 to wheel hub with a
wheel bolt.
Only tighten respective bolts and nuts after dimension
- a - between wheel hub center and lower edge of wheel
housing, measured before beginning of assembly, is
Стр. 5 из 6
Front suspension, servicing
achieved
Topic 40-2 .
- Raise wheel bearing housing using engine/transmission
jack V.A.G 1383 A until dimension - a - is achieved.
Lift wheel bearing housing
Caution!
„
Do not raise or lower the hoist if the
engine/transmission jack is under the vehicle.
„
Do not leave engine/transmission jack V.A.G 1383
A under vehicle any longer than necessary.
- Tighten respective nuts/bolts.
- Lower wheel bearing housing.
- Move engine/transmission jack V.A.G 1383 A below
vehicle away.
- Remove wheel hub support T10149 .
Стр. 6 из 6
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over... Стр. 1 из 29
40 - 3
A - Mounting bracket, upper links, air spring strut
and wheel bearing housings, assembly overview
Note:
„
If a vehicle has to be moved after removing the drive
axle, first install an outer joint and tighten this to 50
Nm, otherwise you will damage the wheel bearings.
„
Welding and straightening work on supporting or
wheel carrying components of the suspension is not
permitted.
„
Always replace self-locking hex head nuts.
„
Always replaced corroded bolts and nuts.
„
Hex socket head bolt
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over... Стр. 2 из 29
„
200 Nm plus an additional
180 ( 1 / 2 turn)
„
Always replace
Vehicle must not be raised
when tightening
„
Torx bolt
„
9 Nm
„
Cover plate
„
Air spring strut
„
„
„
Protective boot must not have
any indentations (be pressed
inward)
„
Removing and installing
40-3, Air spring strut removing
and installing
Wheel acceleration sensor
„
Left front wheel acceleration
sensor G337
„
Right front wheel acceleration
sensor G338
„
Check with Vehicle Diagnosis,
Testing and Information
System VAS 5051 in "Guided
Fault Finding"
Hex bolt
„
„
10 Nm
Air supply line
„
5 Nm
„
Clean connection before
loosening
„
Air escapes when
connections are loosened
„
Protect threaded connection
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over... Стр. 3 из 29
from dirt
„
Multi-point socket head bolt
„
70 Nm
„
M 10 x 20
„
Pre-tighten to 10 Nm in
diagonal sequence
„
Drive axle
„
Hex nut
„
„
„
50 Nm
„
Self-locking
„
Always replace
Upper front link
„
Can only be removed
together with mounting
bracket
„
Mounting bracket, removing
and installing
40-3,
Mounting bracket, removing
and installing
„
Bonded rubber bushings,
replacing 40-3, Upper link
bonded rubber bushing,
replacing
Hex bolt
„
„
Always replace
Mounting bracket
„
Removing and installing
40-3, Mounting bracket,
removing and installing
„
Washer
„
Multi-point socket head bolt
„
Observe tightening sequence
40-3, Tightening sequence,
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over... Стр. 4 из 29
air spring damper to body
„
„
50 Nm plus an additional 90
( 1 / 4 turn)
„
Always replace
Hex nut
„
„
Hex bolt
„
„
„
„
23 Nm
Always replace
Hex nut
( 1 / 4 turn)
„
50 Nm and 90
„
Self-locking
„
Replace after every removal
Upper rear link
„
Can only be removed
together with mounting
bracket
„
Mounting bracket, removing
and installing
40-3,
Mounting bracket, removing
and installing
„
Bonded rubber bushings,
replacing 40-3, Upper link
bonded rubber bushing,
replacing
Hex bolt
„
On aluminum wheel bearing
housings, tighten against
driving direction
„
Tie rod
„
Hex bolt
„
Hex bolt
„
7 Nm
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over... Стр. 5 из 29
„
„
„
Always replace
Hex nut
„
50 Nm
„
Self-locking
„
Always replace
Wheel bearing housing
„
Removing and installing
40-3, Wheel bearing housing,
removing and installing
„
Aluminum or steel, application
Parts catalog
Air spring strut removing and installing
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over... Стр. 6 из 29
Special tools, testers and auxiliary items
required
„
Torque wrench V.A.G 1331
„
Torque wrench V.A.G 1332
„
Engine/transmission jack V.A.G
1383 A
„
Wheel hub support T10149
Removing
Remove air spring strut together with mounting
bracket and upper links.
During assembly work, make sure that no indentations
form on boot of air spring strut!
- Remove front wheel.
- Clean air line connection - arrow - to air spring strut.
- Remove air line - A - from air spring strut and then seal off
both connections.
- Open air line cable ties at air spring strut.
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over... Стр. 7 из 29
- Loosen connecting link to stabilizer bar - 2 - and to lower
link - 1 - .
- Attach Wheel Hub Support T10149 to wheel hub with a
wheel bolt.
- Raise wheel bearing housing with engine/transmission
jack V.A.G 1383 A and Wheel Hub Support T10149 until
connecting link is "stress free" .
- Remove connecting link from stabilizer bar.
- Lower wheel bearing housing.
- Move engine/transmission jack V.A.G 1383 A away from
under vehicle.
- Remove both upper links from wheel bearing housing.
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over... Стр. 8 из 29
- Remove air spring strut from lower link - 1 - .
- Remove Wheel Acceleration Sensor - 1 - from air spring
strut.
- Remove plenum chamber cover.
Repair Manual, Body Exterior, Repair Group 64,
Stationary windows; Plenum chamber cover, removing and
installing
- Unclip cable - 3 - .
- Disconnect strut adjustment switching valve electrical
connector - 2 - .
Vehicles with Adaptive Cruise Control
- Remove Brake Booster Membrane Position Sensor G420
-1-.
Repair Manual, Brake System, Repair Group 47, Brake
booster/brake master cylinder, assembly overview; Brake
Booster Membrane Position Sensor G420, removing and
installing
Left side air spring strut, removing
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over... Стр. 9 из 29
- Turn steering gear left to stop.
Continue removing air spring strut on right side
- Turn steering gear right to stop.
Continue for both sides
- Remove Level Control System Sensor connecting link arrow - from lower link.
- Remove air spring strut multi-point socket head bolts - 1,
2, 3 - from air spring strut.
- Pull wheel bearing housing as far downward as possible
and then remove from air spring strut.
- Remove mounting bracket from air spring strut.
If air spring strut is to be replaced, first read the following
40-3, Air spring strut, filling .
Installing
Installation is in reverse order of removal. Note the
following:
- Check threaded bushings (3 pieces, as part of mounting
bracket) are located properly in body.
- Observe tightening sequence for multi-point socket head
bolts.
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
Стр. 10 из 29
Tightening sequence, air spring damper to body
- Push upper link - 3 - as far down as possible when
tightening.
- Raise wheel bearing housing and then tighten hex bolt - 1
- 40-2, Lift wheel bearing housing
- Check basic setting of level control system Vehicle
Diagnosis, Testing and Information System VAS 5051 .
Tightening torques
Air line to air spring strut
Connecting link to stabilizer bar
5 Nm
90 Nm plus an additional 1 / 4 turn (90
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
1)
Стр. 11 из 29
)
2)
Connecting link to lower link
1)
90 Nm plus an additional 1 / 4 turn (90
)
2)
Upper link to wheel bearing housing
50 Nm
Wheel acceleration sensor to air spring strut
10 Nm
Connecting link from vehicle level sensor to lower
link
8 Nm
Air spring strut to lower link
1)
90 Nm plus an additional 1 / 4 turn (90
)
2)
Mounting bracket to body
1)
50 Nm plus an additional 1 / 4 turn (90
)
Air spring strut to mounting bracket
1) Use
new bolts/nuts
2) Tighten
bolts/nuts in curb weight position
Air spring strut, filling
Special tools, testers and auxiliary items required
„
Adapter T10157
„
Air suspension strut charger VAS 6231 , not depicted
„
Steel gas cylinder filled with Argon or Corgon, not
illustrated
Note:
„
Air spring struts are supplied as replacement parts
with a minimum pressure. By sitting in storage for
20 Nm
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
extended periods this minimum pressure can
diminish (just like a tire). Before the air spring strut is
removed from its packaging, this minimum pressure
must be controlled and restored by "refilling" . Without
this necessary refilling, folds can form in the underfilled air spring boot. These folds cause damage
which can lead to premature failure.
- Remove cover from packaging.
- Remove bolt - arrow - from residual pressure retaining
valve.
- Close steel gas bottle pressure valve.
- Become familiar with the relevant rules for prevention of
accidents for pressurized containers and technical gases.
- Connect air spring filler unit VAS 6231 and adapter
T10157 as shown in the illustration.
„
„
Air spring strut with packaging
Steel gas bottle for argon, corgon with gauges
Стр. 12 из 29
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
„
„
Air spring filler unit VAS 6231
Adapter T10157
- Set flow rate limiter gauge to 2.0 L/min - arrow - .
- Fill gas into air spring strut using several individual
pressure bursts.
The display only shows a correct gas pressure if the
"oscillatory pressure" of the residual pressure retaining
valve is overcome. The "oscillatory pressure" is at approx.
3.5 bar. When the display reaches 3.5 to 4.5 bar, air spring
damper is sufficiently filled with gas.
- Make sure display does not climb over 4.5 bar when
filling.
- Disconnect air spring filler unit VAS 6231 from adapter
T10157 . This dissipates gas above an internal pressure of
3.5 bar.
Minimum pressure is now set. Remove air spring strut from
packaging.
- After installation, first drive the vehicle at high ride height
and then at normal ride height. Repeat this sequence once
more.
Move twice to different ride heights, the gas is replaced
with cleaned air from air supply unit.
Стр. 13 из 29
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
- Install air spring strut
40-3, Installing .
Mounting bracket, removing and installing
Special tools, testers and auxiliary items required
„
Torque wrench V.A.G 1332
Removing
- Remove air spring strut
and installing .
40-3, Air spring strut removing
- Remove mounting bracket from air spring strut - 1 - .
Installing
Installation is in reverse order of removal.
Стр. 14 из 29
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
Стр. 15 из 29
- Install mounting bracket to air spring strut - 1 - .
- Install air spring strut
40-3, Installing .
Tightening torque
Air line to air spring strut
Connecting link to stabilizer bar
1)
5 Nm
90 Nm plus an additional 1 / 4 turn (90
)
2)
Connecting link to lower link
1)
90 Nm plus an additional 1 / 4 turn (90
)
2)
Upper link to wheel bearing housing
50 Nm
Wheel acceleration sensor to air spring strut
10 Nm
Connecting link from vehicle level sensor to lower
link
8 Nm
Air spring strut to lower link
1)
90 Nm plus an additional 1 / 4 turn (90
)
2)
Mounting bracket to body
1)
50 Nm plus an additional 1 / 4 turn (90
)
Air spring strut to mounting bracket
1) Always
use new nuts and bolts
2) Tighten
bolts and nuts in curb weight position
Upper link, removing and installing
Special tools, testers and auxiliary items required
20 Nm
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
„
Torque wrench V.A.G 1332
Removing
- Remove air spring strut
and installing .
40-3, Air spring strut removing
- Compress air spring strut in a vise with protective covers.
- Remove mounting bracket
removing and installing .
40-3, Mounting bracket,
- Remove both links from mounting bracket.
Links, setting
- Set upper front link to dimension - a - and tighten.
Dimension - a - = 81
2 mm
Стр. 16 из 29
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
Стр. 17 из 29
- Set upper rear link to dimension - a - and tighten.
Dimension - a - = 69
2 mm
Installing
Installation is in reverse order of removal, note the
following:
- Attach both links to mounting bracket.
- Adjust both links before tightening.
40-3, Links, setting
Tightening torque
Air line to air spring strut
Connecting link to stabilizer bar
1)
5 Nm
90 Nm plus an additional 1 / 4 turn (90
)
2)
Connecting link to lower link
1)
90 Nm plus an additional 1 / 4 turn (90
)
2)
Upper link to wheel bearing housing
50 Nm
Wheel acceleration sensor to air spring strut
10 Nm
Connecting link from vehicle level sensor to lower
link
8 Nm
Air spring strut to lower link
1)
)
2)
Mounting bracket to body
1)
50 Nm plus an additional 1 / 4 turn (90
)
Air spring strut to mounting bracket
Upper link to mounting bracket
1)
1) Use
90 Nm plus an additional 1 / 4 turn (90
20 Nm
50 Nm plus an additional 1 / 4 turn (90
)
new bolts and nuts
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
2) Tighten
bolts in curb weight position
Upper link bonded rubber bushing, replacing
Special tools, testers and auxiliary items required
„
Assembly tool 3301
„
Front and Rear Bearing Tool 3348
Bonded rubber bushing, removing
Clamp link only in vise with protective covers!
Removing bonded rubber bushing
Стр. 18 из 29
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
Bonded rubber bushing, seating
Bonded rubber bushing installation location
A = 90
5
Seating bonded rubber bushing
- A - Bushing
Wheel bearing housing, removing and installing
Special tools, testers and auxiliary items required
„
Torque wrench V.A.G 1332
Стр. 19 из 29
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
„
Ball joint puller T40010
Removing
During assembly work, make sure that no indentations
form on boot of air spring strut!
- Remove drive axle hex bolt. Vehicle must be on ground to
do this - risk of accident - .
- Remove front wheel.
- Secure brake disc using wheel bolt - arrow - .
- Remove brake caliper and disengage from wire to body
Repair Manual, Brake System, Repair Group 46, Front
brakes, servicing
.
- Remove brake disc and cover plate.
- Loosen lower link hex nut and guide link on wheel bearing
housing 2 turns.
Стр. 20 из 29
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
Стр. 21 из 29
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- Press lower link guide pins away from tapered seat using
ball joint puller T40010 .
Do not damage protective joint boot when doing this!
- Remove level control system sensor connecting link from
lower link - arrow - .
- Separate guide link guide pin from tapered seat using ball
join puller T40010 .
Do not damage protective joint boot when doing this!
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
- Remove hex bolt - 3 - and nut - 4 - .
- Remove tie rod end.
- Remove nut - 1 - and remove hex bolt. Then remove both
links - 2 - upward.
- Remove lower link and guide link from wheel bearing
housing.
- Remove wheel bearing housing.
Installing
Installation is in reverse order of removal, note the
following:
During assembly work, make sure that no indentations
form on boot of air spring strut!
- Insert wheel bearing housing.
- Slide drive axle outer joint into wheel hub and handtighten new hex socket head bolt.
- Insert lower link and guide link guide pins in wheel
bearing housing.
- Insert upper link in wheel bearing housing.
- Press both upper links down as far as possible when
Стр. 22 из 29
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
Стр. 23 из 29
tightening!
- Install tie rod.
- Check basic setting of level control system.
- Measure vehicle after installation.
alignment
44-3, Wheel
Tightening torque
Drive axle to wheel hub
1) .
200 Nm plus an additional 1 / 2 turn (180
)
Brake caliper to wheel bearing housing
Repair Manual, Brake System, Repair Group 46,
Front brakes, servicing
Cover plate to wheel bearing housing
10 Nm
Lower link to wheel bearing housing
120 Nm
Guide link to wheel bearing housing
120 Nm
1)
1)
Connecting link from vehicle level
sensor to lower link
8 Nm
Upper link to mounting bracket
50 Nm
Tie rod to wheel bearing housing
50 Nm
1)
1)
1) Always
use new nuts and bolts
Wheel bearing, assembly overview
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
„
Wheel bearing housing
„
Multi-point socket head bolt
„
80 Nm plus an additional 1 / 4
turn (90
„
„
„
)
Always replace
Wheel bearing
„
Removing and installing
40-3, Wheel bearing,
removing and installing
„
Installed location:
„
Larger diameter of wheel
bearing faces wheel hub
Wheel hub
Стр. 24 из 29
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
„
Pressing out 40-3, Wheel
bearing, removing and
installing
„
Pull off bearing inner ring from
hub 40-3, Pressing off
bearing inner ring
„
Pressing in 40-3, Wheel
bearing, removing and
installing
Wheel bearing, removing and installing
Special tools, testers and auxiliary items
required
„
Thrust plate VW 401
„
Thrust plate VW 402
Стр. 25 из 29
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
„
Punch VW 407
„
Punch VW 412
„
Thrust pad VW 512
Special tools, testers and auxiliary items required
„
Torque wrench V.A.G 1332
„
3 - Separating tool Kukko 17/2
Removing
During assembly work, make sure that no indentations
form on boot of air spring strut!
- Remove drive axle hex bolt.
Note:
„
Only loosen when vehicle is resting on the wheels danger of accident -
Стр. 26 из 29
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
- Remove front wheel.
- Secure brake disc using a wheel bolt - arrow - .
- Remove brake caliper and tie to body using wire.
Repair Manual, Brake System, Repair Group 46, Front
brakes, servicing
.
- Remove ABS speed sensor
Repair Manual, Brake System, Repair Group 46, Front
brakes, servicing
.
- Remove brake disc and cover plate.
- Press drive axle as far out of wheel hub as possible (in
direction of final drive).
- Turn steering gear toward right.
- Remove wheel bearing unit from wheel bearing housing.
Installing
Installation is in reverse order of removal, note the
following:
During assembly work, make sure that no indentations
form on boot of air spring strut!
- Insert wheel bearing unit and tighten.
- Press upper links down as far as possible when
tightening!
Стр. 27 из 29
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
Стр. 28 из 29
Tightening torque
200 Nm plus an additional 1 / 2 turn (180
Drive shaft to wheel hub
1) .
)
Brake caliper to wheel bearing
housing
Repair Manual, Brake System, Repair Group 46, Front
brakes, servicing
Cover plate to wheel bearing housing
Wheel bearing unit to wheel bearing
housing 1)
1) Always
10 Nm
80 Nm plus an additional 1 / 4 turn (90
use new nuts and bolts
Pressing out hub
- Press out wheel hub.
- Insert separating tool in bearing inner race ring groove arrow - and hub and tension threaded spindle.
Note:
„
Use a commercially available separating tool , such
as Kukko 17/2.
- Press bearing inner race off wheel hub.
)
A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...
Pressing off bearing inner ring
Pressing in wheel hub
- Press wheel hub into wheel bearing to stop.
Стр. 29 из 29
B - Subframe, lower link, and stabilizer bar, assembly overview
Стр. 1 из 17
40 - 4
B - Subframe, lower link, and stabilizer bar,
assembly overview
„
„
Subframe
„
Removing and installing
40-4, Subframe, removing
and installing
„
Application
Catalog
See Parts
Hex bolt
„
M 12 x 1.5 x 120
„
70 Nm plus an additional 180
( 1 / 2 turn)
„
Always replace
B - Subframe, lower link, and stabilizer bar, assembly overview
„
Guide link
„
„
„
„
„
„
Removing and installing
40-4, Guide link, removing
and installing
Hex nut
„
120 Nm
„
Self-locking
„
Always replace
Hex nut
„
Lift wheel bearing housing
before fastening 40-2, Lift
wheel bearing housing
„
Self-locking
„
Always replace
Hex nut
„
70 Nm plus an additional 180
( 1 / 2 turn)
„
Lift wheel bearing housing
before fastening 40-2, Lift
wheel bearing housing
„
Self-locking
„
Always replace
Hex bolt
„
M 12 x 1.5 x 70
„
Lift wheel bearing housing
before fastening 40-2, Lift
wheel bearing housing
„
Always replace
Hex nut
„
90 Nm plus an additional 90
( 1 / 4 turn)
Стр. 2 из 17
B - Subframe, lower link, and stabilizer bar, assembly overview
„
„
Self-locking
„
Always replace
Lower link
„
„
„
Removing and installing
40-4, Lower link, removing
and installing
Hex nut
„
120 Nm
„
Self-locking
„
Always replace
Hex head bolt
„
M 12 x 1.5 x 85
„
Lift wheel bearing housing
before fastening 40-2, Lift
wheel bearing housing
„
Always replace
„
Subframe support plate
„
Hex bolt
„
M10 x 25
„
40 Nm plus an additional 90
( 1 / 4 turn)
„
Always replace
„
Washer
„
Hex bolt
„
„
M14 x 1.5 x 90
„
130 Nm plus an additional 90
( 1 / 4 turn)
„
Always replace
Hex nut
Стр. 3 из 17
B - Subframe, lower link, and stabilizer bar, assembly overview
„
„
90 Nm plus an additional 90
( 1 / 4 turn)
„
Self-locking
„
Always replace
Connecting link
„
Left and right connecting links
are identical
Installed location 40-4,
Installed location of connecting
link
Arrow on connecting link points
in direction of travel
Larger diameter of connecting
link is at stabilizer bar and lower
link
„
„
Hex bolt
„
M 12 x 1.5 x 65
„
90 Nm plus an additional 90
( 1 / 4 turn)
„
Lift wheel bearing housing
before fastening 40-2, Lift
wheel bearing housing
„
Always replace
Stabilizer bar
„
„
Multi-point socket head bolt
„
„
50 Nm
Multi-point socket head bolt
„
„
Removing and installing
40-4, Stabilizer bar, removing
and installing
50 Nm
Mounting bracket
Стр. 4 из 17
B - Subframe, lower link, and stabilizer bar, assembly overview
„
Engine carrier
„
Repair Manual, Engine Mechanical,
Fuel Injection Ignition, Repair Group 10,
Engine, removing and installing
„
„
Hex bolt
„
M 12 x 1.5 x 95
„
Always replace
Hex bolt
„
M14 x 1.5 x 135
„
130 Nm plus an additional 90
( 1 / 4 turn)
„
Always replace
„
Washer
„
Subframe support
„
Hex bolt
„
„
M10 × 40
„
50 Nm plus an additional 90
( 1 / 4 turn)
Self-locking hex nut
„
Always replace
Subframe, removing and installing
Special tools, testers and auxiliary items required
Стр. 5 из 17
B - Subframe, lower link, and stabilizer bar, assembly overview
„
Torque wrench V.A.G 1332
„
Engine/transmission jack V.A.G 1383 A
Removing
- Remove stabilizer bar
and installing .
40-4, Stabilizer bar, removing
- Remove front wheels.
- Remove both guide links
and installing .
40-4, Guide link, removing
- Loosen both lower links at subframe.
Стр. 6 из 17
B - Subframe, lower link, and stabilizer bar, assembly overview
- Loosen hex bolt - 1 - but do not remove.
- Disconnect all electrical wires from body to front axle.
- Remove connecting link - arrow - from level control
system sensor to lower link.
- Mark installation position of subframe to body with felt-tip
pen.
- Support subframe with engine/transmission jack V.A.G
1383 A and universal mount.
- Remove hex bolts - 1, 2 - and - 3 - in sequence shown.
- Lower subframe as far as possible and then remove both
lower links from subframe.
- Slowly lower subframe and remove.
Installing
Installation is in reverse order of removal, note the
following:
- When installing subframe, align with help of markings on
body.
- Install subframe with old hex bolts. Replace with new
ones after vehicle alignment.
- When doing so, tighten hex bolts to specified tightening
Стр. 7 из 17
B - Subframe, lower link, and stabilizer bar, assembly overview
Стр. 8 из 17
torque without additional tightening.
- Place vehicle on wheels or raise wheel bearing housing to
tighten lower link and guide link 40-2, Lift wheel bearing
housing
- Check basic setting of self-levelling suspension.
- Measure vehicle after installation
alignment .
44-3, Wheel
Tightening torque
Stabilizer bar to engine carrier
Connecting link to stabilizer bar
1)
50 Nm
90 Nm plus an additional 90
( 1 / 4 turn)
90 Nm plus an additional 90
( 1 / 4 turn)
70 Nm plus an additional 90
( 1 / 4 turn)
2)
Connecting link to lower link
1)
2)
Guide link to subframe
1)
2)
Guide link to wheel bearing housing
Air spring strut to lower link
1)
120 Nm
90 Nm plus an additional 90
( 1 / 4 turn)
2)
Connecting link from vehicle level sensor to lower
link
Subframe to body, bolts M14
1)
Subframe to body, bolts M10
1)
1) Always
use new nuts and bolts
2) Tighten
screws and nuts in curb weight position
Stabilizer bar, removing and installing
Special tools, testers and auxiliary items required
8 Nm
130 Nm plus an additional 90
turn)
40 Nm plus an additional 90
(1/4
( 1 / 4 turn)
B - Subframe, lower link, and stabilizer bar, assembly overview
„
Torque wrench V.A.G 1332
Removing
Note:
„
Vehicle must rest on wheels for removal and
installation of stabilizer bar. Otherwise, there is a risk
that the stabilizer bar or other components may be
damaged.
- Remove front and rear noise insulation.
Repair Manual, Body Exterior, Repair Group 50, Noise
insulation; noise insulation - assembly overview
- Loosen hex bolt - 1 - and remove hex bolt - 2 - .
Стр. 9 из 17
B - Subframe, lower link, and stabilizer bar, assembly overview
- Loosen stabilizer bar - 1 - on both sides.
- Align stabilizer bar so that the multi-point socket head
bolts - arrows - can be turned easily by hand.
- Remove stabilizer bar.
Installing
Installation is in reverse order of removal, note the
following:
- Insert stabilizer bar.
- Install multi-point socket head bolts - arrows - by hand on
both sides.
- Align stabilizer bar - 1 - so that the multi-point socket head
bolts can be turned by hand easily.
- Alternately tighten multi-point socket head bolts to
stabilizer bar mounting bracket.
- Attach stabilizer bar to connecting link.
- Tighten connecting links.
Стр. 10 из 17
B - Subframe, lower link, and stabilizer bar, assembly overview
Стр. 11 из 17
Installed location of connecting link
Tightening torque
Stabilizer bar to engine carrier
Connecting link to stabilizer bar
1)
50 Nm
90 Nm plus an additional 1 / 4 turn (90
)
90 Nm plus an additional 1 / 4 turn (90
)
2)
Connecting link to lower link
1)
2)
1) Always
use new nuts and bolts
2) Tighten
bolts and nuts in curb weight position
Lower link, removing and installing
B - Subframe, lower link, and stabilizer bar, assembly overview
Special tools, testers and auxiliary items
required
„
Torque wrench V.A.G 1332
„
Engine/transmission jack V.A.G
1383 A
„
Wheel hub support T10149
„
Ball joint puller T40010
Removing
- Remove hex bolt for drive axle. (Only loosen when vehicle
is resting on the wheels - danger of accident - ).
- Remove front wheel.
Стр. 12 из 17
B - Subframe, lower link, and stabilizer bar, assembly overview
- Secure brake disk using a wheel bolt - arrow - .
- Remove brake caliper and tie to body using wire.
Repair Manual, Brake System, Repair Group 46, Front
brakes, servicing
- Remove brake disc and cover plate.
- Remove front and rear noise insulation
Repair Manual, Body Exterior, Repair Group 50, Noise
insulation; Noise insulation - assembly overview
.
- Raise wheel bearing housing until connecting link is
"stress free" 40-2, Lift wheel bearing housing
- Loosen connecting link at stabilizer bar - 2 - and to lower
link - 1 - .
- Remove connecting link from stabilizer bar.
- Lower wheel bearing housing.
- Move engine/transmission jack away from under the
Стр. 13 из 17
B - Subframe, lower link, and stabilizer bar, assembly overview
vehicle.
- Remove both upper links from wheel bearing housing.
- Remove hex bolt from lower link guide pin. Then press
guide pin away from tapered seat with ball join puller
T40010 .
Do not damage protective joint boot when doing this!
- Remove Level Control System Sensor connecting link arrow - from lower link.
- Remove air spring strut - 1 - from lower link.
- Turn steering gear toward right.
- Pull wheel bearing housing down as far as possible and
swing lower link out of air spring strut fork.
Стр. 14 из 17
B - Subframe, lower link, and stabilizer bar, assembly overview
Стр. 15 из 17
- Remove lower link from subframe.
- Mark installation position of subframe to body using a felttip pen.
- Lower subframe to remove hex bolt.
- Remove lower link.
Installing
Installation is in reverse order of removal, note the
following:
- Align subframe with help of markings on body.
- Tighten subframe with bolts originally installed. Replace
these with new bolts after vehicle alignment.
- Tighten bolts originally installed to specified torque
without additional tightening.
- Raise wheel bearing housing for fastening to subframe
40-2, Lift wheel bearing housing
- Check basic setting of level control system.
- Measure vehicle after installation
alignment .
44-3, Wheel
Tightening torque
Drive shaft to wheel hub
1) .
200 Nm plus an additional 1 / 2 turn (180
)
Brake caliper to wheel bearing housing
Repair Manual, Brake System, Repair Group 46,
Front brakes, servicing
Cover plate to wheel bearing housing
Connecting link to stabilizer bar
1)
10 Nm
90 Nm plus an additional 1 / 4 turn (90
)
90 Nm plus an additional 1 / 4 turn (90
)
2)
Connecting link to lower link
1)
2)
upper link to mounting bracket
50 Nm
Lower link to wheel bearing housing
120 Nm
1)
1)
Connecting link from vehicle level
sensor to lower link
8 Nm
B - Subframe, lower link, and stabilizer bar, assembly overview
Стр. 16 из 17
90 Nm plus an additional 1 / 4 turn (90
)
Subframe to body, bolts M14
130 Nm plus an additional 1 / 4 turn (90
)
Subframe to body, bolts M10
40 Nm plus an additional 1 / 4 turn (90
)
Lower link to subframe
70 Nm plus an additional 1 / 2 turn (180
)
Air spring strut to lower link
1)
2)
1)
1)
1)
2)
1) Always
use new nuts and bolts
2) Tighten
bolts and nuts in curb weight position
Guide link, removing and installing
Special tools, testers and auxiliary items required
„
Torque wrench V.A.G 1332
„
Ball joint puller T40010
Removing
B - Subframe, lower link, and stabilizer bar, assembly overview
Стр. 17 из 17
- Remove front wheel.
- Loosen guide link hex nut at wheel bearing housing 2
turns.
- Separate guide link guide pins away from tapered seat
using ball joint puller T40010 .
Do not damage protective joint boot when doing this!
- Remove guide link from subframe.
Installing
Installation is in reverse order of removal, note the
following:
- Raise wheel bearing housing for tightening to subframe
40-2, Lift wheel bearing housing
- Measure vehicle after installation
alignment .
44-3, Wheel
Tightening torque
Guide link to subframe
1)
70 Nm plus an additional 1 / 2 turn (180
2)
Guide link to wheel bearing housing
1)
1) Always
use new nuts and bolts
2) Tighten
bolts and nuts in curb weight position
120 Nm
)
Drive shaft, servicing
Стр. 1 из 32
40 - 5
Drive shaft, servicing
Drive axles, overview
I - Drive axle with triple-roller joint AAR
40-5, I 2900, assembly overview
Drive axle with triple-roller joint AAR
2900, assembly overview
II - Drive axle with peened triple-roller
joint AAR 3300i, assembly overview
40-5, II Drive axle with peened triple roller
joint AAR 3300i, assembly overview
Drive axles, removing and Installing
Removing
During assembly work, make sure that no indentations
form on boot of air spring strut!
Drive shaft, servicing
Caution!
Remove drive axle hex bolts (only loosen if vehicle is
standing on wheels -danger accident-).
- Loosen drive axle at transmission flange.
- Remove front wheel.
- Remove noise insulation
Repair Manual, Body Exterior, Repair Group 50, Noise
insulation; Noise insulation - assembly overview
.
- Remove ABS speed sensor.
- Remove cover plate
Repair Manual, Brake System, Repair Group 46, Front
brakes, servicing
.
- Remove both upper links from wheel bearing housing.
- Remove drive axle heat shield - arrows - . The third bolt
can not be seen in illustration.
Left drive axle
- Turn steering gear toward left.
Right drive axle
- Turn steering gear toward right.
Continued for both drive axles
- Disconnect drive axle from transmission flange and
Стр. 2 из 32
Drive shaft, servicing
Стр. 3 из 32
remove.
Installing
Installation is in reverse order of removal, note the
following:
During assembly work, make sure that no indentations
form on boot of air spring strut!
- Press upper links as far down as possible when
tightening!
Tightening torque
Drive axle to wheel hub
1)
200 Nm plus an additional 1 / 2 turn (180
Cover plate to wheel bearing
housing
)
10 Nm
ABS speed sensor to wheel bearing
housing
Repair Manual, Brake System, Repair Group 46, Front
brakes, servicing
Upper link to mounting bracket
1)
50 Nm plus an additional 1 / 4 turn (90
Drive axle to transmission, pretighten
10 Nm
Drive shaft to transmission, tighten
70 Nm
Heat shield to transmission housing
23 Nm
1)
1) Always
use new nuts and bolts
I - Drive axle with triple-roller joint AAR 2900, assembly
overview
)
Drive shaft, servicing
„
Стр. 4 из 32
Hex head bolt
„
Always replace
M16 screw tightening torque:
„
200 Nm plus an additional 1 /
2
„
„
turn (180
)
Outer constant velocity
protective joint boot
„
Check for tears and chafing
„
Before clamping hose clamp,
raise protective joint boot
briefly to balance pressure
40-5, Protective joint boot,
ventilating
„
Different version in rubber or
Hytrel
Clamp
„
Different versions for
protective joint boot in rubber
or Hytrel
„
Always replace
„
Tighten rubber protective joint
boots 40-5, Clamping
sleeves on rubber protective
joint boots are clamped with
Drive shaft, servicing
„
Стр. 5 из 32
Tighten Hytrel protective joint
boots 40-5, Clamping
sleeves on Hytrel protective
joint boots are clamped with
„
Axle shaft
„
Clamp
„
Always replace
„
Tensioning 40-5, Clamping
sleeves on Hytrel protective
joint boots are clamped with
„
Joint piece
„
Multiple point socket head bolt,
70 Nm
„
„
Pre-tighten to 10 Nm
Triple roller star
Chamfer - arrow - faces splines
axle shaft splines
„
„
„
Installed location
5
Topic 40-
Circlip
„
Replace each time it is
removed
„
Insert in shaft groove
O-ring
A new seal is in repair kit and
must be replaced.
„
Cover
„
Replace each time it is
removed
Destroyed when disassembling.
A modified cover is included in
the repair kit.
Drive shaft, servicing
„
Clamp
„
Always replace
„
Tensioning 40-5, Clamp
large clamping sleeve to inner
joint with
„
Different hose clamps are
possible depending on
construction. Can also be
assembled with pliers 3340
Electronic Parts Catalog
"ETKA" .
„
Protective joint boot for triple
roller joint
„
Clamp
„
„
Always replace
„
Tensioning 40-5, Clamp
small clamping sleeve to inner
joint with
Spring washer
„
„
Thrust washer
„
„
„
Installed location 40-5,
Installation location of thrust
washer and spring washer
(wheel side)
Installed location 40-5,
Installation location of thrust
washer and spring washer
(wheel side)
Circlip
„
Always replace
„
Insert before mounting in ring
groove (not visible with joint
installed)
Outer constant velocity joint
„
Replace only as a unit
Стр. 6 из 32
Drive shaft, servicing
„
Pressing off 40-5, Pressing
off outer constant velocity
joint
„
Installing: Drive joint onto
shaft with a plastic hammer
until circlip engages.
„
Checking 40-5, Outer
constant velocity (CV) joint,
checking
Triple-roller joint AAR 2900, disassembling and assembling
Special tools, testers and auxiliary items
required
„
Sleeve VW 416 B
„
Punch VW 412
Стр. 7 из 32
Drive shaft, servicing
„
Sleeve VW 426
„
Sleeve 3110
„
Puller Kukko 12/1
„
Press piece 2050
Special tools, testers and auxiliary items
required
„
CV joint boot clamp tool V.A.G
1275
„
Circlip pliers VW 161 A
„
Pressure spindle 3207
Стр. 8 из 32
Drive shaft, servicing
Стр. 9 из 32
Disassembling
- Line cover.
Note:
„
Use old screw to line cover.
„
When doing so, hold shaft at a 20
angle .
Use a plastic hammer and sleeve 3110 .
- Remove any shavings in cover area.
- Open large clamping sleeve.
- Open small clamping sleeve on shaft and slide protective
joint boot back.
- Identify installation location for parts - 1 - to - 3 - with
lines.
If parts are not marked when assembling, the components
Drive shaft, servicing
are not brought back to their previous installation position
then it is possible that it will be noisy when driving.
A waterproof felt tipped pen is suitable for marking.
- Remove O-ring - arrow - from groove.
1 - Joint piece
2 - Triple roller star
3 - Axle shaft
- Remove circlip.
1 - Pliers (commercially available)
- Remove triple roller star from axle shaft. Use puller Kukko
12/1 (commercially-available) to do this.
- Remove grease in sealing ring groove and on shaft
splines.
- Check roller body and ball cage for wear.
- Clean shaft and housing.
Assembling
- Slide small protective joint boot clamping sleeve onto
shaft.
- Slide new protective joint boot onto shaft.
Стр. 10 из 32
Drive shaft, servicing
- Slide joint onto shaft.
- Slide protective joint boot onto joint.
Mount triple roller star
The chamfer - arrow - on star faces toward shaft, this is
used as an assembly aid.
- Place triple roller star onto shaft corresponding to marking
and drive to stop.
- Install circlip. Ensure proper seating.
- Press half of grease G 000 605 from repair kit into triple
roller joint.
- Slide joint over rollers.
Note:
„
Make sure protective joint boot does not twist.
- Press half of grease G 000 605 from repair kit into rear
side of triple roller joint.
Стр. 11 из 32
Drive shaft, servicing
- Carefully clean sealing ring groove - 4 - .
- Lay O-ring - 1 - in groove - 4 - .
The individual parts are shown disassembled for sake of
better illustration.
1 - Circlip
2 - Cover from repair kit
3 - O-ring
4 - Groove in triple roller joint
- Lay axle shaft in press.
- Lightly press on cover - 1 - from repair kit so circlips from
repair kit can engage.
- Place circlip from repair kit around circumference below
edge.
Note:
„
Make sure you hear circlip engage.
Стр. 12 из 32
Drive shaft, servicing
- Position joint in middle position, see "min" - "max"
position.
Note:
„
When positioning joint in middle position, it is
necessary to bleed protective joint boot, e.g. with a
screwdriver - arrow - .
- Install clamping sleeve - 2 - .
Note:
„
For a better alignment of multi-point socket head
bolts when installing axle shaft, clamping sleeve
connecting tube - 2 - must be between joint
connecting flanges - 1 - .
Стр. 13 из 32
Drive shaft, servicing
Clamp large clamping sleeve to inner joint with pliers V.A.G
1275 .
Clamp small clamping sleeve to inner joint with pliers V.A.G
1275 .
Outer constant velocity joint, servicing
Clamping sleeves on rubber protective joint boots are
clamped with pliers V.A.G 1275 .
Стр. 14 из 32
Drive shaft, servicing
Clamping sleeves on Hytrel protective joint boots are
clamped with clamping tool V.A.G 1682 .
- Install clamping tool V.A.G 1682 as shown in illustration.
When doing so, make sure clamping tool jaws are in
corners - arrow B - of clamping sleeves.
- Clamp clamping sleeve by turning spindle with torque
wrench (when doing so, do not tilt pliers).
„
Torque specification: 20 Nm
„
Use torque wrench with 5 to 50 Nm range (e.g. V.A.G
1331 ).
„
Be sure thread of spindle of clamp tool moves freely.
Grease with MoS 2 grease if necessary.
„
If thread is tight e.g. dirty, the required tensioning
force for the hose clamp will not be achieved in spite
of correct torque specification settings.
Pressing off outer constant velocity joint
Стр. 15 из 32
Drive shaft, servicing
- Clamp drive shaft in vise with protective covers.
- Remove large clamping sleeve and turn back protective
joint boot.
- Screw on pressure spindle 3207 onto guide pins until CV
joint can be removed.
Protective joint boot, ventilating
Only for rubber protective joint boot:
A vacuum can form in joint when installing protective joint
boot.
This vacuum pulls a fold in when driving - arrow - .
Observe the following:
- Before clamping, clamping sleeves, balance pressure by
raising protective joint boot.
Installation location of thrust washer and spring washer
(wheel side)
1 - Spring washer
2 - Thrust washer (plastic)
Стр. 16 из 32
Drive shaft, servicing
Outer constant velocity (CV) joint, checking
In order to replace grease in case of strong soiling, joint
must be disassembled or if journal surface of balls must be
checked for wear and damage.
Removing
- Mark ball hub position to ball cage and housing using an
electric scriber or oil stone, before disassembling.
- Pivot ball hub and ball cage.
- Remove balls one after another.
- Turn cage until two rectangular windows - arrow - contact
joint body.
- Lift out cage together with hub.
Стр. 17 из 32
Drive shaft, servicing
- Swing hub segment into rectangular window on cage.
- Tip hub out of cage.
6 balls for each joint belong to a tolerance group. Check
stub axle, hub, cage and balls for small indentations
(pitting) and signs of seizure. Excessive circumferential
backlash in joint makes itself noticed via tip-in shock, in
such cases joint should be replaced. Flattening and running
marks of balls are no reason to replace joint.
Installing
- Press half of total amount of grease into joint body.
- Insert cage with hub into joint body.
- Press in opposite balls one after the other. Reestablish
old position of ball hub to ball cage and to joint body.
- Insert new circlip in hub.
- Distribute remaining grease in cover.
II Drive axle with peened triple roller joint AAR 3300i,
assembly overview
Стр. 18 из 32
Drive shaft, servicing
Стр. 19 из 32
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi
„
„
Clamp
„
Always replace
„
Tensioning 40-5, Clamp
large clamping sleeve to inner
joint with
Protective joint boot for triple
roller joint
„
„
Protective joint boot must fit in
groove and on joint contour.
Clamp
„
Always replace
„
Tensioning 40-5, Clamp
small clamping sleeve to inner
joint with
Drive shaft, servicing
„
„
„
„
„
Circlip
„
Always replace
„
Insert before mounting in ring
groove (not visible with joint
installed)
Outer constant velocity joint
„
Replace only as a unit
„
Removing
„
Checking 40-5, Outer
constant velocity (CV) joint,
checking
„
installing
Topic 40-5
Topic 40-5
Collar screw
„
Always replace
„
200 Nm plus an additional
180 ( 1 / 2 turn)
Clamp
„
Always replace
„
Tensioning 40-5, Clamping
sleeves on Hytrel protective
joint boots are clamped with
Outer constant velocity
protective joint boot
„
„
Стр. 20 из 32
Check for tears and chafing
Clamp
„
Always replace
„
Tensioning 40-5, Clamping
sleeves on Hytrel protective
joint boots are clamped with
„
Driveshaft
„
Circlip
Drive shaft, servicing
„
„
Application Electronic Parts
Catalog "ETKA"
Triple roller star
Chamfer - arrow - faces splines
axle shaft splines
„
„
Circlip
„
Always replace
„
Insert in shaft groove
Bolt, 70 Nm
„
„
Pre-tighten to 10 Nm
Joint piece
Triple roller joint AAR 3300i, disassembling and assembling
Стр. 21 из 32
Drive shaft, servicing
Special tools, testers and auxiliary items
required
„
Thrust plate VW 401
„
Thrust plate VW 402
„
Punch VW 408 A
„
Punch VW 411
„
Tube VW 416 B
„
Thrust pad VW 447 H
Стр. 22 из 32
Drive shaft, servicing
Special tools, testers and auxiliary items
required
„
CV joint boot clamp tool V.A.G
1275
„
Torque wrench V.A.G 1331
„
Torque wrench V.A.G 1332
„
CV joint boot clamp tool V.A.G
1682
„
Assembly tool T10065
Special tools, testers and auxiliary items required
Стр. 23 из 32
Drive shaft, servicing
„
Slide hammer - complete set VW 771
„
Assembly tool T40018
„
Brass or copper drift
Peened triple roller joint AAR 3301, disassembling
- Clamp joint horizontally in vise.
Note:
„
Use protective vise covers.
„
Make sure joint is not damaged.
- Mark location of joint to axle shaft.
If parts are not marked when assembling, the components
are not brought back to their previous installation position
then it is possible that it will be noisy when driving.
A waterproof felt tipped pen is suitable for marking.
Стр. 24 из 32
Drive shaft, servicing
- Open clamping sleeves - arrows - .
- Slide protective joint boot back.
- Insert assembly device T40018 behind joint.
Guide pins - 1 - must contact joint.
- Bring assembly device T40018 into contact with joint by
turning knurled thumb screws - 2 - .
Note:
„
Secure joint in assembly device T40018 with no play.
„
Only hand-tighten screws - 2 - .
Стр. 25 из 32
Drive shaft, servicing
- Screw slide hammer VW 771 into assembly device
T40018 .
- Remove joint horizontally with slide hammer VW 771 .
Lower joint in assembly device T40018 .
- Identify installation location for parts - 1 - and - 2 - with
lines.
If parts are not marked when assembling, the components
are not brought back to their previous installation position
then it is possible that it will be noisy when driving.
A waterproof felt tipped pen is suitable for marking.
1 - Axle shaft
2 - Triple roller star
- Remove grease with a lint-free cloth.
- Remove circlip with pliers - 1 - (commercially-available).
Стр. 26 из 32
Drive shaft, servicing
- Press triple roller star off axle shaft.
Assembly tool T10065/4 must not be applied to roller body.
- Remove protective joint boot.
- Remove grease on shaft splines.
- Check roller body and ball cage for wear.
- Clean axle shaft and housing.
Triple roller joint AAR 3300i, assembling
- Slide new protective joint boot onto axle shaft.
- Press circlip - 1 - onto center of splines.
Стр. 27 из 32
Drive shaft, servicing
- To press on circlips - 1 - , use special tool shown in
illustration.
Instead of T10065/2 conical axle shafts, cylindrical axle
shafts T10065/3 are used Topic 40-5 .
Triple roller star, pressing onto axle shaft
This illustration only applies to conical axle shafts arrow - .
The chamfer on star faces toward axle shaft, this is used as
an assembly aid.
- Use special tool shown in illustration.
Special tool T10065/2 must not come in contact with roller
body.
- Place triple roller star onto shaft corresponding to marking
and drive to stop.
Circlip must engage audibly, triple roller star must lie
against circlip with no gap.
Стр. 28 из 32
Drive shaft, servicing
This illustration is only for cylindrical axle shaft - arrow
-.
The chamfer on star faces toward axle shaft, this is used as
an assembly aid.
- Use special tool shown in illustration.
Special tool T10065/3 must not come in contact with roller
body.
- Place triple roller star onto shaft corresponding to marking
and drive to stop.
Circlip must engage audibly, triple roller star must lie
against circlip with no gap.
- Install circlip with pliers - 1 - (commercially-available).
- Press half of high-temperature grease from repair kit into
triple roller joint.
- Lightly lubricate roller body.
Make sure roller body does not tilt!
Стр. 29 из 32
Drive shaft, servicing
- Press joint over triple roller bar with a plastic hammer.
- Press rest of grease into protective joint boot.
- Ensure correct seating of boot on joint.
Boot must fit in groove and on joint contour.
- Position joint in middle position, see "min - max" position.
Note:
„
When positioning joint in middle position, it is
necessary to bleed protective joint boot, e.g. with a
screwdriver - arrow - .
- Install clamping sleeve.
Note:
Стр. 30 из 32
Drive shaft, servicing
„
For a better alignment of multi-point socket head
bolts when installing axle shaft, clamping sleeve
connecting tube - 2 - must be between joint
connecting flanges - 1 - .
- Clamp clamping sleeves on triple roller joint 40-5,
Clamp small clamping sleeve to inner joint with
Outer constant velocity joint, servicing
Outer CV joint, removing
- Clamp axle shaft in vise with protective covers.
- Open both clamping sleeves and remove protective joint
boot from CV joint.
- Strike a copper or brass drift - A - on CV joint inner race
with a hammer.
- Remove joint and protective joint boot.
Outer CV joint, installing
- Guide protective joint boot with small clamping sleeve
onto joint.
Joints and protective joint boots must be free of grease.
Стр. 31 из 32
Drive shaft, servicing
- Always replace circlip - 1 - .
- Position protective joint boot in outer groove - arrow B - .
Inner groove - arrow A - must remain visible "identifying
groove" (for correct installation of protective joint boot).
- Press half of grease from repair kit into inner joint.
- Screw old axle shaft screw into joint as shown in
illustration.
- Drive joint onto axle shaft with a plastic hammer until
circlip engages.
- Press rest of grease into protective joint boot.
- Slide protective joint boot onto joint.
- Ensure correct seating of protective joint boot on joint.
Protective joint boot must fit in groove and on joint contour.
- Clamp clamping sleeves onto outer joint 40-5,
Clamping sleeves on Hytrel protective joint boots are
clamped with
Стр. 32 из 32
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