Subframe, Stabilizer Bar, Control Arm

Volkswagen Passat B6 - Subframe, stabilizer bar, control arm Стр.
1 из 42
40 - 4
Subframe, stabilizer bar, control arm

Subframe, stabilizer bar, control arm, assembly overview
Caution!
Welding and straightening operations are not

permitted on load-bearing or wheel-controlling
components.
Always replace self-locking nuts.
Always replaced corroded bolts/nuts.
Nut
Torque specification Topic

40-3
Subframe, stabilizer bar, control arm Стр. 2 из 42
When tightening,
counterhold at inner multi-
point fitting of joint pin
Self-locking
Replace each time it is

removed
Stabilizer bar
Different versions
Application Electronic
Parts Catalog "ETKA"
Removing and installing

40-4, Stabilizer bar,
removing and installing
Connecting link
Attaches stabilizer bar to

suspension strut
Hex nut

40-3
When tightening,
counterhold at inner multi-
point fitting of joint pin
Self-locking

removed
Mounting bracket
Locating 40-4, Locating

mounting bracket
With bonded rubber bushing
Hex head bolt

40-3

removed
Hex head bolt

40-3

removed
Hex head bolt

40-3
Left Front Level Control System

Sensor G78
Can be checked in Guided

Fault Finding using
Vehicle Diagnosis, Testing
and Information System VAS
5051
Control arm
If ball joint is damaged,

replace together

40-4, Control arm with
mounting bracket, removing
and installing
Mount, replacing 40-4,

Bonded rubber bushing for
control arm, replacing
Nut

40-3
Self-locking

removed
Ball joint
Checking 40-4, Ball joint,

checking

40-4, Ball joint, removing
and installing
If control arm is damaged,

replace together
Nut

40-3
Self-locking

removed
Nut

40-3
Hex head bolt

40-3

removed
Hex head bolt

40-3

removed
Hex head bolt

40-3

removed
Only tighten in curb weight

position 40-2, Lifting
wheel bearing to curb weight

position
Hex head bolt

40-3
First tighten when pendulum

support is fastened to
transmission

removed
Lower bonded rubber bushing

for support
Pressing out and in 40-4,

Subframe, servicing
Pendulum support
First fasten to transmission,

then to subframe
Different versions
Hex head bolt

40-3

removed
Hex head bolt

40-3

removed
Shield
Torx bolt

40-3
Hex head bolt

40-3

removed
Subframe

40-4, Subframe, removing
and installing
Different versions
Upper bonded rubber bushing

for support
Pressing out and in 40-4,

Subframe, servicing
Thread in side rail, servicing
Under certain conditions, it is possible to service thread in

weld nuts in side rail
Repair Manual, Body Collision Repair, Repair Group 50,

Repairing threads
Subframe, locating
Special tools, testers and auxiliary items required

Locating pins T10096
Engine/transmission jack V.A.G 1383 A
Locating pins T10096 , installing
To attach subframe to consoles, locating pins T10096

must be screwed into positions: - 1 - , - 8 - , - 9 - and -
16 - one after the other.
Note:
The locating pins T10096 must only be tightened to

20 Nm, otherwise the threads of the locating studs
will be damaged.
Locating mounting bracket
- Replace mounting bracket bolts one after the other on

both sides with locating pins T10096 and tighten them to
20 Nm.
Subframe, locating
- Replace front bolts of subframe one after the other with

locating pins T10096 and tighten to 20 Nm.
The position of front axle is now fixed.
Continue with removing stabilizer bar Topic 40-4 .
Continue with removing steering gear Topic 48-5 .

Continue with removing subframe Topic 40-4 .
Locating pins T10096 , removing
Removal is performed in reverse order. Make sure that the

locating pins T10096 are replaced one after the other with
new bolts.
- Perform a test drive after completing repair. If steering

wheel is crooked, perform a vehicle alignment 44-7,
Wheel alignment .
Torque specifications 40-3, Front axle, torque

specifications
Subframe, removing and installing
Torque wrench V.A.G 1331
Removing
Note:
The subframe is removed together with the control

arms.
- Remove lower sound insulation
Repair Manual, Body Exterior, Repair Group 50, Sound

insulation, assembly overview
- Remove wheels.
- Remove nuts - arrows - on left and right side of

vehicle.
- Pull control arm out from ball joint.
- Remove exhaust system bracket from subframe.
- Remove bolts - arrows - from heat shield.
Vehicles with auxiliary heater

- Remove bolts - arrows A - from heat shield.
- Remove bracket - 2 - from subframe.
- Remove bolt - arrow B - and push exhaust pipe of

auxiliary heater - 1 - upward.
Continued for all vehicles
- Remove heat shield from subframe.
- Remove connecting link from stabilizer bar.
- Remove support from transmission, removing bolt - 13 -

.
- Subframe, locating 40-4, Subframe, locating .
- Remove bolts for:
the steering gear - 3 - and - 6 -
the stabilizer bar - 11 - and - 14 -
and the subframe - 4 - and - 5 - .
- Lower subframe using engine/transmission jack V.A.G

1383 A .
- Secure steering gear to body.
Installing
Installation is carried out in reverse order.
- Tighten bolts, torque specifications 40-3, Front axle,

torque specifications .
- Install wheels, torque specifications 44-2, Torque

specification for mounting wheels .
- Install and tighten sound insulation, torque specifications

- Perform a test drive after completing repair. If steering

wheel is crooked, perform a vehicle alignment 44-7,
Wheel alignment .
Subframe, servicing
Special tools, testers and auxiliary items

required
Installation Device 3372
Thrust plate VW 401
Punch VW 407
Arbor 50 mm Dia. VW432
Assembly tool T10214

Tube from assembly tool T10244/3
Pressing out bonded rubber bushing
- Remove subframe 40-4, Subframe, removing and

installing .
- Attach assembly tool T10267 - 4 - to subframe. Secure

securing stud with securing pin.
Punch VW 407
Press piece 3372/1
Thrust plate VW 401
Tube T10244/3
- Press out both bonded rubber bushings as shown in

illustration.
Note:
The flattened side of the press piece 3372/1 must

face toward insert - A - of the assembly tool
T10267 , otherwise the insert can be damaged.
The tube T10244/3 has a larger and a smaller

diameter. The subframe must rest on the larger
diameter of the tube T10244/3 .
Pressing in bonded rubber bushing
- Fasten both bonded rubber bushings with original bolt,

thereby cut-outs - arrows - must lie exactly across from
one another.
- Place bolted bonded rubber bushings into larger diameter

of tube T10214/2 with bolt head facing downward.
Arbor 50 mm Dia. VW 432

Thrust piece T10214/3 without bolts
Bonded rubber bushing
Tube T10214/2
Tube T10214/1
Thrust plate VW 401
- Press bonded rubber bushing - 1 - in until dimension - a

- is achieved.
Dimension - a - = 2 - 3 mm.
- Align tube T10214/2 with pressed in bonded rubber

bushings on subframe. Thereby, position edges of inner
core of bonded rubber bushing - 1 - on an imaginary line
that runs parallel to edge of assembly tool T10267 - 2 - .
The dimension - a - must be identical on left and right, so

that it is ensured to be parallel.
- Place subframe onto smaller diameter of tube

T10244/3 .
- Press mounting onto stop and continue pressing until a

force of 20 kN is achieved.
Punch VW 407
Press piece T10214/3
Tube T10214/2
Tube T10214/1
- Remove assembly tool T10267 from subframe and

check fit of pressed-in bonded rubber bushing.
The outer diameter - 1 - of both bonded rubber

bushings must not project more than 2 mm into area
of support opening.
The cut-outs of bonded rubber bushings must be

located centrally in subframe opening.
A gap - arrow - between bonded rubber bushings is

permissible.
- Install subframe 40-4, Installing .
Ball joint, checking
Checking axial play
- Forcefully pull control arm down in direction of - arrow -

and press up again.
Checking radial play
- Forcefully push lower part of wheel inward and outward

in direction of - arrow - .
Note:
There must be no perceptible or visual "play" when

carrying out both tests.
Observe ball joint during checks.
Take into account possible existing wheel bearing

play or "play" in upper suspension strut mounting.
Check rubber boot for damage, replace ball joint if

necessary.
Ball joint, removing and installing

required
Ball joint puller 3287A
Engine/transmission jack V.A.G

1383 A
Angle wrench V.A.G 1756

Removing
- Loosen drive axle hex bolt 40-7, Fastening drive axle

bolt, loosening and tightening .
- Remove wheel.
- Remove nuts - arrows - .
- Pull drive axle slightly out of wheel hub.
- Pull ball joint out from control arm.
- Move control arm downward as far as possible.
- Install ball joint puller - 3287 A - as shown in illustration

and press out ball joint.
Note:
Place engine/transmission jack V.A.G 1383 A , or

similar, underneath to ensure safety (danger of
accident through falling parts when pressing out the
ball joint).
To protect ball joint threads and for safety reasons

leave nut on a few turns.
Installing
- Install ball joint in wheel bearing housing.
- Insert drive axle into wheel hub.
- Install new self-locking nut, and counter-hold with internal

Torx bit T40 .
- Tighten nuts - arrows - .
Note:
Check boot for damage or twisting.
- Install and fasten wheel, torque specification 44-2,

Torque specification for mounting wheels .
- Tighten drive axle hex bolt.
Note:
The vehicle must not be sitting on its wheels,

otherwise the wheel bearing can be damaged.

specifications
Control arm with mounting bracket, removing and

installing

Locating Pins T10096
Removing
- Remove wheel.

insulation - Assembly overview
.
- Pull wheel bearing housing with ball joint out from control
arm.
- Locate position for mounting bracket 40-4, Locating

mounting bracket
- Replace bolt - 1 - for left side, - 8 - for right side with

locating pins T10096 and tighten locating fixture to 20
Nm.
Note:
The locating pins T10096 must only be tightened to

20 Nm, otherwise the threads of the locating studs
will be damaged.
- Remove position - 10 - for left side of vehicle, position -

15 - for right side of vehicle.
- If equipped, remove connecting link for Left Front Level

Control System Sensor G78 from control arm.
- Remove bolts - 1 - .
- Remove control arm with mounting bracket.
Installing
- Place control arm with mounting bracket into subframe.
- Set positions - 10 - and - 15 - in place, but do not

tighten.
- Install and fasten bolts - 1 - .
- Replace locating pins T10096 with a new bolt, and

fasten. Torque specification 40-3, Front axle, torque
specifications .
- Fasten control arm to ball joint - arrows - .
- Fasten control arm to console at - 10 - and - 15 - in curb

weight position 40-2, Lifting wheel bearing to curb

weight position .
Further installation is in reverse order of removal.
- Install lower sound insulation.

Note:

specifications
Removing (left side for vehicles with DSG or automatic

transmission)
Additional tools
Engine/transmission jack VAG 1383A
- Remove left front wheel.
- Remove lower noise insulation
Repair Manual, Body Exterior, Repair Group 50, Noise

insulation - assembly overview
.
- Remove bracket for exhaust system from subframe.
Vehicles with front wheel drive
- Remove bolts - arrows - from heat shield.
Vehicles with auxiliary heater
- Remove bolts - arrows A - from heat shield.
- Remove bracket - 2 - from subframe.
- Remove bolt - arrow B - and slide exhaust pipe of

auxiliary heater - 1 - upward.
Continued for all vehicles
- Remove heat shield from subframe.

- Remove pendulum support from transmission, remove

bolts - 13 - to do so.
- Remove connecting link of Left Front Level Control

System Sensor G78 from transverse link, if present.

- Loosen bolt - 15 - .
- Now remove bolts for:
Steering gear - 3 - and - 6 -
Stabilizer bar - 11 - and - 14 -
- Subframe, locating 40-4, Subframe, locating
- Place engine/transmission jack VAG1383A under

subframe.
- Place, for example, a piece of wood - 1 - between

engine/transmission jack VAG 1383A and subframe.
- Remove bolts - 2 - , - 4 - , and - 5 - and lower the

subframe with the consoles as far as required.
- When doing this, pry alignment bushings of steering gear

out of left console.
- Remove bolt - 15 - and remove transverse link from

console.
Installing (left side for vehicles with DSG or automatic

transmission)
Further installation is in reverse sequence to removal.
Note:
Make sure alignment bushings of steering gear fit

correctly in console!
Tightening torques of front axle 40-3, Front axle, torque

specifications
Tightening torques of steering 48-3, Steering, torque

specifications
- Install lower noise insulation
Repair Manual, Body Exterior, Repair Group 50, Noise

Note:
- Perform road test after repair work; if steering wheel is

crooked while doing so, vehicle alignment must be
performed 44-7, Wheel alignment .
Bonded rubber bushing for control arm, replacing

required
Tube T10219/1
Drift T10219/2
Thrust plate VW 402
Punch VW 411
Pressing out bonded rubber bushing
- Press out bonded rubber bushings as shown in

illustration.
Punch VW 411
Tube T10219/1
Thrust plate VW 402
Pressing in bonded rubber bushing
To prevent damaging bonded rubber bushing when

pressing in, it must be set in place crooked. When pressing
in, the bonded rubber bushing will straighten itself out.
- Apply assembly lube G 294 421 A1 onto outside of

bonded rubber bushing.
- Set bonded rubber bushing in place on an angle (in

direction of control arm), thereby the lip - arrow - must
slide into hole as shown in illustration.
Drift T10219/2
Tube T10219/1
Thrust plate VW 402
- Press bonded rubber bushing in far enough until center -

1 - and hole of control arm - 2 - are at same height.
- Press bushing back slightly in control arm.
Tube T10219/1
Thrust plate VW 402
Dimension - a - and - b - must be the same.
Mounting bracket with bushing for control arm, replacing
Pressing off mounting bracket with bushing from control arm


required
Guide Pin VW 439
Thrust plate VW 401
Thrust plate VW 402
The bonded rubber bushing is only available as a

replacement part with mounting bracket.
- Press mounting bracket with bonded rubber bushing off

from control arm.
Note:
When pressing out, hold the control arm tightly
Thrust plate VW 401

Guide Pin VW 439
Thrust plate VW 402
Pressing mounting bracket with bushing onto control arm
Thrust plate VW 401
Tube Trans. Drive Shaft VW 426

- Coat hex of control arm with thinned assembly lube G

294 421 A1 (1:20).
- Carefully press bushing onto control arm up to stop.
Tube Trans. Drive Shaft VW 426

Mounting bracket with bonded rubber bushing
Control arm
Thrust plate VW 401
- Perform a test drive after repair. If steering wheel is

crooked, perform a vehicle alignment 44-7, Wheel
alignment .
Stabilizer bar, removing and installing
Removing

required
Locating pins T10096
Engine/transmission jack V.A.G

1383 A
Ball joint puller 3287 A
- Remove front wheels.

- Remove nuts - arrows - and remove footwell trim - 1 -

.
- Remove bolt - 1 - and pull off universal joint - 2 - from

steering gear.

- Disconnect connecting links from stabilizer bar.

- Unfasten nuts - arrows - on left and right side of

vehicle.
- Loosen nuts for tie rod ends on both sides, but do not
remove.
To protect threads, leave nut on stud a few turns.
- Press off tie rod end from wheel bearing housing using
ball joint puller 3287A .
- Subframe with consoles, locating 40-4, Subframe,

locating .
- Unfasten stabilizer bar from subframe - 11 - and - 14 -

.
- Remove support from transmission, removing bolts - 13 -

.
- Place engine/transmission jack V.A.G 1383 A under

subframe.
- Place, for example, a piece of wood - 1 - between

engine/transmission jack V.A.G 1383 A and subframe.
- Loosen bolts - 4 - and - 5 - , and lower subframe with

consoles slightly. When doing this, observe electrical
wiring.
- Push stabilizer bar toward right, as seen in driving

direction.
- Now, lift stabilizer bar - 1 - toward front, over subframe -

2 - and down, while turning stabilizer bar slightly.
Installing
Further installation is in reverse order of removal.
Front axle, torque specifications 40-3, Front axle, torque

specifications
Steering, torque specifications 48-3, Steering, torque

specifications
- Install lower sound insulation

Note:
Coat steering gear O-ring seals with lubricant, e.g.

liquid soap, before installing steering gear.
After installation of steering gear to the universal

joint shaft ensure that the seal lies against the
assembly plate without kinking and opening to the
footwell is correctly sealed. Water ingress and/or
noises may be the result.
Make sure sealing surfaces are clean.
- After installation, the basic setting must be performed for

Steering Angle Sensor G85 Vehicle Diagnosis, Testing
and Information System VAS 5051 .
- Perform a test drive after repair. If steering wheel is

crooked, perform a vehicle alignment 44-7, Wheel
alignment .

Subframe, Stabilizer Bar, Control Arm

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Subframe, Stabilizer Bar, Control Arm

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Volkswagen Passat B6 - Subframe, stabilizer bar, control arm Стр.

Subframe, stabilizer bar, control arm

 Welding and straightening operations are not

 Always replace self-locking nuts.

 Always replaced corroded bolts/nuts.

 Torque specification Topic

 Replace each time it is

 Removing and installing

 Attaches stabilizer bar to

 Torque specification Topic

 Replace each time it is

 Locating 40-4, Locating

 With bonded rubber bushing

 Hex head bolt

 Torque specification Topic

 Replace each time it is

 Hex head bolt

 Torque specification Topic

 Replace each time it is

 Hex head bolt

 Torque specification Topic

 Left Front Level Control System

 Can be checked in Guided

 If ball joint is damaged,

 Removing and installing

 Mount, replacing 40-4,

 Torque specification Topic

 Replace each time it is

 Checking 40-4, Ball joint,

 Removing and installing

 If control arm is damaged,

 Torque specification Topic

 Replace each time it is

 Torque specification Topic

 Hex head bolt

 Torque specification Topic

 Replace each time it is

 Hex head bolt

 Torque specification Topic

 Replace each time it is

 Hex head bolt

 Torque specification Topic

 Replace each time it is

 Only tighten in curb weight

wheel bearing to curb weight

 Hex head bolt

 Torque specification Topic

 First tighten when pendulum

 Replace each time it is

 Lower bonded rubber bushing

 Pressing out and in 40-4,

 First fasten to transmission,

 Hex head bolt

 Torque specification Topic

 Replace each time it is

 Hex head bolt

 Torque specification Topic

 Replace each time it is

 Torque specification Topic

 Hex head bolt

 Torque specification Topic

 Replace each time it is

 Removing and installing

Welding and straightening operations are not

Always replace self-locking nuts.

Always replaced corroded bolts/nuts.

Torque specification Topic

Replace each time it is

Removing and installing

Attaches stabilizer bar to

Torque specification Topic

Replace each time it is

Locating 40-4, Locating

With bonded rubber bushing

Hex head bolt

Torque specification Topic

Replace each time it is

Hex head bolt

Torque specification Topic

Replace each time it is

Hex head bolt

Torque specification Topic

Left Front Level Control System

Can be checked in Guided

If ball joint is damaged,

Removing and installing

Mount, replacing 40-4,

Torque specification Topic

Replace each time it is

Checking 40-4, Ball joint,

Removing and installing

If control arm is damaged,

Torque specification Topic

Replace each time it is

Torque specification Topic

Hex head bolt

Torque specification Topic

Replace each time it is

Hex head bolt

Torque specification Topic

Replace each time it is

Hex head bolt

Torque specification Topic

Replace each time it is

Only tighten in curb weight

Hex head bolt

Torque specification Topic

First tighten when pendulum

Replace each time it is

Lower bonded rubber bushing

Pressing out and in 40-4,

First fasten to transmission,

Hex head bolt

Torque specification Topic

Replace each time it is

Hex head bolt

Torque specification Topic

Replace each time it is

Torque specification Topic

Hex head bolt

Torque specification Topic

Replace each time it is

Removing and installing

Upper bonded rubber bushing

Pressing out and in 40-4,

Locating pins T10096

Engine/transmission jack V.A.G 1383 A

The locating pins T10096 must only be tightened to

Torque wrench V.A.G 1331

Torque wrench V.A.G 1332

The subframe is removed together with the control

the steering gear - 3 - and - 6 -

the stabilizer bar - 11 - and - 14 -

and the subframe - 4 - and - 5 - .

Installation Device 3372

Thrust plate VW 401

Arbor 50 mm Dia. VW432

Assembly tool T10214

Assembly tool T10267

Tube from assembly tool T10244/3

The flattened side of the press piece 3372/1 must

The tube T10244/3 has a larger and a smaller