Service

Workshop Manual
Transporter 2004 ➤
Transporter 2010 ➤
Running gear, axles, steering
Edition 12.2018

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
40 - Front suspension
42 - Rear suspension
44 - Wheels, tyres, vehicle geometry
48 - Steering

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2018 Volkswagen AG, Wolfsburg K0058980320

 Transporter 2004 ➤ , Transporter 2010 ➤
Running gear, axles, steering - Edition 12.2018

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Raising wheel suspension to unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Lifting rear axle in unladen state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Check list for evaluating running gear on accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . 7

40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Assembly overview - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Removing and installing subframe without steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Renewing anti-roll bar bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.5 Removing and installing coupling rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6 Repairing thread in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.7 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.8 Renewing bonded rubber bushes in subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3 Suspension strut, upper suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Assembly overview - suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4 Lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1 Assembly overview - lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.2 Removing and installing lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.3 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.4 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.5 Renewing bonded rubber bush for lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5 Wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.1 Assembly overview - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.3 Renewing wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.1 Overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.2 Assembly overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.3 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.4 Repairing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.5 Removing and installing jointed shaft support bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

1 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.1 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.1 Assembly overview - rear final drive carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.2 Renewing front bonded rubber bushes in rear final drive carrier . . . . . . . . . . . . . . . . . . . . 118
3 Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.1 Assembly overview - anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.2 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Contents i
 Transporter 2004 ➤ , Transporter 2010 ➤
Running gear, axles, steering - Edition 12.2018

3.3 Renewing anti-roll bar bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4 Suspension link, track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.1 Assembly overview - suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.2 Renewing bonded rubber bush for suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5 Suspension strut, shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.1 Assembly overview - suspension strut, shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . 136
5.2 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.3 Removing and installing spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6 Wheel bearing assembly, trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.1 Assembly overview - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.2 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.1 Assembly overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.2 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.3 Repairing inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.4 Renewing boot on outer joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.5 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.1 Fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.2 Removing tyre from wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.3 Fitting tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.4 Tyre sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.5 Tyre sealant disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.6 Models with breakdown set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.7 Protecting wheel centring seat against corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2 Tyre Pressure Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.1 General mode of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.2 Perform basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.1 Notes for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.2 Conditions for testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.3 Models with electronic stabilisation program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.4 Specifications for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.5 Wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.6 Necessity of wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.7 Explanatory notes on production control numbers (PR no.) . . . . . . . . . . . . . . . . . . . . . . . . 172
3.8 Adjusting camber at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.9 Adjusting toe at rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.10 Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.1 Assembly overview - steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.2 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.3 Removing and installing intermediate steering shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.4 Removing and installing protective sleeve for intermediate steering shaft . . . . . . . . . . . . . . 191
2 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.1 Assembly overview - steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.2 Removing and installing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.3 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.4 Repairing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.5 Checking rack seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

ii Contents
 Transporter 2004 ➤ , Transporter 2010 ➤
Running gear, axles, steering - Edition 12.2018

3 Hydraulic power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

3.1 Assembly overview - vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
3.2 Checking hydraulic fluid level of power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3.3 Bleeding steering system after repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3.4 Check steering for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3.5 Checking delivery pressure of vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3.6 Removing and installing vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Contents iii
 Transporter 2004 ➤ , Transporter 2010 ➤
Running gear, axles, steering - Edition 12.2018

iv Contents
 Transporter 2004 ➤ , Transporter 2010 ➤
Running gear, axles, steering - Edition 12.2018

00 – Technical data
1 General information
(VRL012527; Edition 12.2018)
⇒ “1.1 General information”, page 1

1.1 General information

Information concerning wheel and tyre combinations, winter
tyres, snow chains and recommended tyre manufacturers can be
found in the folder “Fault finding wheels, tyres”.
⇒ ElsaWin; Internet (globe); Language flag; Technical Informa‐
tion; Wheel and Tyre Guide

1. General information 1
 Transporter 2004 ➤ , Transporter 2010 ➤
Running gear, axles, steering - Edition 12.2018

2 Repair instructions
⇒ “2.1 Raising wheel suspension to unladen position”,
page 2
⇒ “2.2 Lifting rear axle in unladen state”, page 4

2.1 Raising wheel suspension to unladen position

Special tools and workshop

equipment required

♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use

engine and gearbox jack - VAS 6931-
♦ Tensioning strap - T10038-
♦ Support - T10149-

2 Rep. gr.00 - Technical data

 Transporter 2004 ➤ , Transporter 2010 ➤
Running gear, axles, steering - Edition 12.2018

Caution

Tighten bolted connections on components with bonded rub‐

ber mountings only if the vehicle is standing on its wheels and
is unladen or if the vehicle is raised and is in the unladen po‐
sition (normal position) .
All bolts on running gear components with bonded rubber
bushes may be tightened only when the component is in the
unladen position (normal position).
The bonded rubber bushes are otherwise constantly tensioned
and have a shorter service life.

Bonded rubber bushes can be twisted only to a limited extent.

Axle components with bonded rubber bushes must therefore be
brought to a position equivalent to the unladen (normal) position
before being tightened.
To simulate this position on the lifting platform, raise the respec‐
tive suspension with the engine and gearbox jack - V.A.G 1383
A- or engine and gearbox jack - VAS 6931- and support -
T10149- .
– Before starting work (while vehicle is still standing on its
wheels), measure distance -a- from centre of wheel to lower
edge of wheel housing.
The measurement must be performed in the unladen position
(normal position).
– Note measured value. This will be needed when the bolts and
nuts are tightened.
Before the respective wheel suspension is raised, the vehicle
must be strapped to the lifting platform arms using tensioning
straps - T10038- .

WARNING

If the vehicle is not strapped down, it could slip off the lifting
platform.

Raise wheel suspension:

– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt.
Nuts and bolts in question are only allowed to be tightened when
dimension -a- between the centre of wheel hub and bottom edge
of wheel housing, measured before starting work, has been at‐
tained ⇒ page 3 .

2. Repair instructions 3
 Transporter 2004 ➤ , Transporter 2010 ➤
Running gear, axles, steering - Edition 12.2018

– Raise wheel bearing housing using engine and gearbox jack

- V.A.G 1383 A- or engine and gearbox jack - VAS 6931- until
dimension -a- is attained.

WARNING

♦ Never raise or lower the vehicle while the engine and

gearbox jack is positioned beneath the vehicle.
♦ Do not leave the engine and gearbox jack - V.A.G 1383
A- or engine and gearbox jack - VAS 6931- under the ve‐
hicle longer than necessary.

– Tighten respective nuts and bolts.

– Lower wheel bearing housing.
– Pull out engine and gearbox jack - V.A.G 1383 A- or engine
and gearbox jack - VAS 6931- from underneath the vehicle.
– Detach support - T10149- .
Specified torque
♦ ⇒ “1.1 Fitting wheels”, page 159

2.2 Lifting rear axle in unladen state

4 Rep. gr.00 - Technical data

 Transporter 2004 ➤ , Transporter 2010 ➤
Running gear, axles, steering - Edition 12.2018

Special tools and workshop

equipment required

♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use

engine and gearbox jack - VAS 6931-
♦ Tensioning strap - T10038-
♦ Support - T10149-
All bolts on running gear components with bonded rubber bushes
must be tightened only in the unladen position (normal position).
Bonded rubber bushes can be twisted only to a limited extent.
Axle components with bonded rubber bushes must therefore be
brought to a position equivalent to the unladen (normal) position
before being tightened.
Otherwise, the bonded rubber bush would be subject to torsion
loading, shortening its service life.
To simulate this position on the lifting platform, raise the respec‐
tive axle with the engine and gearbox jack - V.A.G 1383 A- or
engine and gearbox jack - VAS 6931- and support - T10149- .

2. Repair instructions 5
 Transporter 2004 ➤ , Transporter 2010 ➤
Running gear, axles, steering - Edition 12.2018

– Measure distance -a- from centre of wheel to edge of wheel

housing using, for example, a measuring tape ⇒ page 6 .
Dimension -a- from lower edge of wheel housing to centre of
wheel
The measurement must be performed in the unladen position
(normal position).
– Note measured value. This will be needed when the bolts and
nuts are tightened.
Before the axle on one side is raised, the vehicle must be strapped
to the lifting platform arms using tensioning strap - T10038- .
If the vehicle is not strapped down, there is a danger that the ve‐
hicle will slip off the lifting platform!
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- with a wheel bolt.
Threaded connections may be tightened only when dimension
-a- between the centre of wheel hub and lower edge of wheel
housing, measured before starting work, has been attained.

Measuring dimension -a-

– Raise wheel bearing housing using engine and gearbox jack
until dimension -a- is attained.

WARNING

♦ Never raise or lower the vehicle while the engine and

gearbox jack is positioned beneath the vehicle.
♦ Do not leave the engine and gearbox jack under the ve‐
hicle for longer than necessary.

– Tighten respective nuts and bolts.

– Lower wheel bearing housing.
– Pull engine and gearbox jack out from underneath vehicle.
– Remove support - T10149- .
Specified torque
♦ ⇒ “1.1 Fitting wheels”, page 159

6 Rep. gr.00 - Technical data

 Transporter 2004 ➤ , Transporter 2010 ➤
Running gear, axles, steering - Edition 12.2018

3 Evaluating accident vehicles

⇒ “3.1 Check list for evaluating running gear on accident vehi‐
cles”, page 7

3.1 Check list for evaluating running gear on

accident vehicles
Damage to running gear may go unnoticed during repairs to load-
bearing and suspension parts of accident vehicles. Under certain
circumstances, this undiscovered damage could lead to serious
consequential damage during later vehicle operation. Therefore,
the following parts of accident vehicles must be examined in the
manner and order described independent of wheel alignment
which may have to be performed. If no deviations from specifica‐
tions are measured during wheel alignment, there are no defor‐
mations of the running gear.
Visual and functional examination of steering system
♦ Visual examination for deformation and cracks
♦ Examination for play in track rod joints and steering rack
♦ Visual examination for tears in boots
♦ Examine electrical and hydraulic lines and hoses for chafing,
cuts and kinks.
♦ Check of hydraulic lines, threaded connections and steering
rack for leaks.
♦ Check of steering rack and lines for secure seating.
♦ Check for flawless function from lock to lock by moving the
steering from stop to stop. In the process, the steering wheel
must turn with a constant force without resistance.
Visual inspection and functional check of running gear
• Adhere to the sequence of the following inspection steps!
♦ Check all components shown in the assembly overviews for
deformation, cracks and other damage.
♦ Renew damaged parts.
♦ Align wheels on a Volkswagen AG-approved wheel alignment
stand
Visual and functional check of wheels and tyres
♦ Check for true running and imbalance ⇒ VW ServiceNet;
Technical information; Reference guides; Wheel and Tyre
Guide; General; Roughness due to wheels and tyres .
♦ Check tyres for cuts and impact damage in the tread and on
the flanks. ⇒ VW ServiceNet; Technology; Guides; Wheels
and tyres guide; General; Tyre damage
♦ Check tyre pressure; see tyre pressure sticker in fuel tank flap
or ⇒ Maintenance ; Booklet
If rim of wheel and/or tyre is damaged, renew these components.
This also applies if the circumstances of the accident and the
damage to the vehicle indicate possible damage which is not visi‐
ble.
A further factor in the decision is the age of the tyre. Tyres should
not be older than 6 years.

3. Evaluating accident vehicles 7

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If in doubt, the following applies:

• Whenever a safety risk cannot be excluded, the tyre(s) must
be renewed.
Complete vehicle
Check other vehicle systems as well, for example:
♦ Brake system including ABS
♦ Visual and functional examination of exhaust system and pas‐
senger protection
Specifications for testing and adjusting can be found in the re‐
spective workshop manual in ELSA.
The accident vehicle check described here applies to the running
gear. It makes no claim to completeness for the overall vehicle.
Electronic vehicle systems
Safety-relevant systems like, for example, ABS/EDL, airbag sys‐
tems, electronically regulated suspension systems, electrome‐
chanical or electrohydraulic steering and other driver assist
systems must be read with the ⇒ Vehicle diagnostic tester for fault
messages which may have been saved. If faults are saved in the
event memories of the systems mentioned above, repair the faults
according to the instructions in workshop manuals in ELSA. Fol‐
lowing repairs, read event memories of the affected systems
again to ensure that complete function has been restored.

8 Rep. gr.00 - Technical data

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40 – Front suspension
1 Front axle
⇒ “1.1 Overview - front axle”, page 9

1.1 Overview - front axle

I - Assembly overview - sub‐

frame ⇒ page 10
II - Assembly overview - wheel
bearing assembly
⇒ page 54
III - Assembly overview - sus‐
pension strut ⇒ page 31

1. Front axle 9
 Transporter 2004 ➤ , Transporter 2010 ➤
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2 Subframe
⇒ “2.1 Assembly overview - subframe”, page 10
⇒ “2.2 Removing and installing subframe without steering rack”,
page 13
⇒ “2.3 Removing and installing anti-roll bar”, page 16
⇒ “2.4 Renewing anti-roll bar bushes”, page 18
⇒ “2.5 Removing and installing coupling rod”, page 20
⇒ “2.6 Repairing thread in longitudinal member”, page 20
⇒ “2.7 Fixing position of subframe”, page 21
⇒ “2.8 Renewing bonded rubber bushes in subframe”,
page 26

2.1 Assembly overview - subframe

Caution

Bonded rubber bushes can be twisted only to a limited extent.

Tighten bolted connections on components having bonded
rubber mountings only if the vehicle is standing on its wheels
and is unladen or if the vehicle is raised and is in the unladen
position (normal position) ⇒ page 2 .

WARNING

♦ It is not permitted to weld or straighten load-bearing or

wheel-guiding components of the suspension.
♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.

10 Rep. gr.40 - Front suspension

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1 - Subframe
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Fix in position before re‐
moval ⇒ page 21 .
2 - Bolt
❑ Renew after removal
❑ 110 Nm +120°
❑ Tighten only when the
vehicle is standing on its
wheels and is unladen
or when the vehicle is
raised and has been put
in the unladen position
⇒ page 2 .
3 - Nut
❑ Renew after removal
4 - Rear bonded rubber bush
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Pressing out and in
⇒ page 51
❑ Observe installation po‐
sition for bush with »kid‐
ney-shaped« notch
⇒ page 51 .
❑ Tighten only when the
vehicle is standing on its
wheels and is unladen
or when the vehicle is
raised and has been put
in the unladen position
⇒ page 2 .
5 - Suspension link

Note

Altered suspension links are used

from CW 22/2011 onwards Alloca‐
tion ⇒ Electronic parts catalogue
“ETKA” .
❑ If damaged, also renew swivel joint.
6 - Swivel joint
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ Renew together with suspension link if suspension link is damaged
7 - Bolt
❑ Renew after removal
❑ 90 Nm +45°
8 - Nut
❑ Renew after removal
❑ When tightening, counterhold on multipoint socket of joint pin of swivel joint
❑ 60 Nm +90°
9 - Front bonded rubber bush
❑ Pressing out and in ⇒ page 48

2. Subframe 11
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Running gear, axles, steering - Edition 12.2018
❑ Tighten only when the vehicle is standing on its wheels and is unladen or when the vehicle is raised and
has been put in the unladen position ⇒ page 2 .
10 - Washer
11 - Bolt
❑ Renew after removal
❑ Initial tightening torque: 50 Nm
❑ 150 Nm +180°
12 - Coupling rod
❑ Removing and installing ⇒ page 20
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
13 - Nut
❑ Renew after removal
❑ When tightening, counterhold on multipoint socket of joint pin of coupling rod
❑ 60 Nm +45°
14 - Coupling rod
❑ Altered version; note installation position ⇒ page 13
❑ Removing and installing ⇒ page 20
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ A mixed installation (left/right) is permissible for older vehicles.
15 - Anti-roll bar
❑ Removing and installing ⇒ page 16
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
16 - Clip
17 - Bolt
❑ 110 Nm
18 - Rubber mounting
❑ Removing and installing ⇒ page 18
19 - Bolt
❑ Renew after removal
❑ 20 Nm +90°
20 - Bonded rubber bush
21 - Bonded rubber bush
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ Pressing out and in ⇒ page 26
❑ Note installation position ⇒ page 26
22 - Bolt
❑ Renew after removal
23 - Console
24 - Nut
❑ Renew after removal
❑ 20 Nm +180°

12 Rep. gr.40 - Front suspension

 Transporter 2004 ➤ , Transporter 2010 ➤
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Installation position for the coupling rod:

Note

When fitting the modified coupling rod, please check for correct
installation position.

– Fit the coupling rod -1- so that the open side of the U-form
profile points towards the engine (engine compartment).

2.2 Removing and installing subframe with‐

out steering rack

Note

♦ Subframe is removed complete with suspension links and anti-

roll bar.
♦ Suspension struts with wheel bearing housings as well as
steering rack remain on vehicle.

Special tools and workshop equipment required

♦ Tensioning strap - T10038-

♦ Socket, multi-point bit XZN 14 - T10061-

2. Subframe 13
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♦ Locating pins - T10227-

♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use

engine and gearbox jack - VAS 6931-

14 Rep. gr.40 - Front suspension

 Transporter 2004 ➤ , Transporter 2010 ➤
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♦ Rear axle support - T10552-

Removing
– Loosen wheel bolts.
– Raise vehicle ⇒ Maintenance ; Booklet 20.1 ; Description of
work; Raising vehicle with lifting platform and trolley jack .
– Remove front wheels.
– Unscrew nut -arrow- and pull coupling rod -1- off suspension
strut.
– Remove front engine mounting from subframe ⇒ Rep. gr. 10 ;
Assembly mountings; Removing and installing engine mount‐
ing .
– Remove rear engine mounting from subframe ⇒ Rep. gr. 10 ;
Assembly mountings; Removing and installing engine mount‐
ing .

– Remove nuts -arrows-

– Secure steering rack to body on both sides.

Caution

♦ The protective boot for the intermediate steering shaft and

hydraulic lines must not be over-extended or strained.

Vehicles with left/right vehicle level sender

– Unscrew nut -1-.
– Pull front left vehicle level sender - G78- / front right vehicle
level sender - G289- -2- out of suspension link -3-.

2. Subframe 15
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Continued for all vehicles

– Using socket, multi-point bit XZN 14 - T10061- -2-, unscrew
bolts -1- from swivel joint -3-.

Note

Depending on engine, various brackets are mounted on the sub‐

frame, for example, brackets for the exhaust system, which must
be unbolted in order to remove the subframe.

– Fix subframe in position ⇒ page 21 .

– Use tensioning straps - T10038- or -T10552/3- -3- to locate

and secure subframe -1- on rear axle support - T10552- -2- as
shown in figure.
– Carefully lower subframe with engine and gearbox jack - VAS
6931- .

Note

♦ When lowering the subframe, ensure that it does not catch

anywhere or come into contact with other components.
♦ The engine and gearbox jack - VAS 6931- may only be moved
with the subframe on the rear axle support - T10552- in the
lowest position.

– Secure steering rack to body.

Installing
Install in the reverse order of removal, observing the following:
– Remove locating pins - T10227- ⇒ page 25 .
If components such as subframe or suspension link have been
»renewed«, it may be necessary to carry out wheel alignment.
To determine whether wheel alignment is necessary, refer to table
⇒ page 170 .
If an off-centre steering wheel is determined during the road test
even though locating pins - T10227- were used, check the wheel
alignment. In this case the wheel alignment test results must be
archived in the vehicle files.
To determine whether wheel alignment is necessary, refer to table
⇒ page 170 .
Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159
♦ ⇒ “2.1 Assembly overview - steering rack”, page 194
♦ ⇒ “3.1 Assembly overview - vane pump”, page 207

2.3 Removing and installing anti-roll bar

Special tools and workshop equipment required

16 Rep. gr.40 - Front suspension

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♦ Socket, multi-point bit XZN 14 - T10061-

♦ Torque wrench - V.A.G 1332-

Removing

Note

The following procedure is described for one side of the vehicle.

The procedure for the other side of the vehicle is identical.

– Remove wheels.
– If present, detach lower trim on wheel housing liner. To do this,
remove bolts -1- and nut -2-, and remove trim -arrow-.

2. Subframe 17
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– Separate threaded connection between coupling rod and anti-

roll bar by removing nut -arrow-.

– Unscrew threaded connections of anti-roll bar/subframe

-arrows- using socket and multi-point bit - T10061- .
– Then remove anti-roll bar -1- to the left.
Installing
Install in the reverse order of removal, observing the following:

Note

♦ Tighten bolted connections to the anti-roll bar only if the vehi‐

cle is standing on its wheels and is unladen or if the vehicle is
raised and is in the unladen position (normal position)
⇒ page 2 .
♦ When tightening the nut -arrow-, counterhold on the multipoint
socket of the joint pin of the coupling rod.

Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159

2.4 Renewing anti-roll bar bushes

Special tools and workshop equipment required
♦ Socket, multi-point bit XZN 14 - T10061-

18 Rep. gr.40 - Front suspension

 Transporter 2004 ➤ , Transporter 2010 ➤
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♦ Torque wrench - V.A.G 1332-

Removing

Note

The following procedure is described for one side of the vehicle.

The procedure for the other side of the vehicle is identical.

– Remove wheels.
– If present, detach lower trim on wheel housing liner. To do this,
remove bolts -1- and nut -2-, and remove trim -arrow-.

– Unscrew threaded connections of anti-roll bar/subframe

-arrows- using socket and multi-point bit - T10061- .
– Then pull anti-roll bar -1- forwards slightly and remove rubber
bush -2-.
Installing
Install in the reverse order of removal, observing the following:

Note

♦ Thoroughly clean contact surfaces before installing new rub‐

ber bushes.
♦ Ensure that the outer edge of rubber bush lies against stop.
♦ Depending on version, the stop can be located on the left or
on the right of rubber bush.

Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159

2. Subframe 19
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2.5 Removing and installing coupling rod

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

Removing

Note

The following procedure is described for one side of the vehicle.

The procedure for the other side of the vehicle is identical.

– Remove wheel.
– Separate threaded connections between coupling rod and
strut as well as between coupling rod and anti-roll bar. Then
remove coupling rod -1-.
Installing
Install in the reverse order of removal, observing the following:

Note

♦ Tighten bolted connections to the anti-roll bar only if the vehi‐

cle is standing on its wheels and is unladen or if the vehicle is
raised and is in the unladen position (normal position)
⇒ page 2 .
♦ When tightening the nuts -arrows-, counterhold on the multi‐
point socket of the joint pin of the coupling rod.

Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159

2.6 Repairing thread in longitudinal member

Repairing the thread in welded nuts in the longitudinal member is
possible under certain conditions. ⇒ Body Repairs; Rep. gr. 50

20 Rep. gr.40 - Front suspension

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2.7 Fixing position of subframe

Note

♦ Certain repairs on vehicles require the removal of the sub‐

frame or the entire front axle.
♦ The original position of the subframe relative to the body can
be attained with the aid of locating pins - T10227- .

Special tools and workshop equipment required

♦ Tensioning strap - T10038-

♦ Locating pins - T10227-

♦ Torque wrench - V.A.G 1331-

2. Subframe 21
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♦ Torque wrench - V.A.G 1332-

♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use

engine and gearbox jack - VAS 6931-

♦ Rear axle support - T10552-

Assembly and preparation of engine and gearbox jack - VAS

6931- with rear axle support - T10552-
– Adjust both mounting pins, support and mounting block on rear
axle support - T10552- to specified dimensions as follows.

Note

Please use the dimensions specified in the text and never use the
values shown on the folding rule in the illustrations.

22 Rep. gr.40 - Front suspension

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– Adjust mounting pins -T10552/1- -1- on left and right to di‐

mension -a- (40 mm with cap -2- screwed on).
– Tighten union caps of mounting pins.

– Adjust height of mounting pins -2- by hand on left and right at

threaded sleeve -1- to dimension -a- (175 mm).
– Adjust support -T10552/2- -1- to dimension -a- (680 mm).

– Tighten bolt -2- in support using hexagon key to specified tor‐

que.
– Adjust support pin -1- to dimension -a- (530 mm).

– Tighten bolts -2-.

– Align rear axle support - T10552- above engine and gearbox
jack - VAS 6931- in such a way that mounting block points
downwards.
– Place rear axle support - T10552- with mounting block on en‐
gine and gearbox jack - VAS 6931- .

2. Subframe 23
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– Tighten bolt -2- with hexagon key -1- to secure rear axle sup‐
port - T10552- on engine and gearbox jack - VAS 6931- to
specified torque.
Further steps on vehicle
– Loosen wheel bolts.
– Raise vehicle ⇒ Maintenance ; Booklet 20.1 ; Description of
work; Raising vehicle with lifting platform and trolley jack .
– Remove front wheels.

– Unscrew nut -arrow- and pull coupling rod -1- off suspension
strut.
– Remove front engine mounting from subframe ⇒ Rep. gr. 10 ;
Assembly mountings; Removing and installing engine mount‐
ing .
– Remove rear engine mounting from subframe ⇒ Rep. gr. 10 ;
Assembly mountings; Removing and installing engine mount‐
ing .

– Remove nuts -arrows-

– Secure steering rack to body on both sides.

Caution

♦ The protective boot for the intermediate steering shaft and

hydraulic lines must not be over-extended or strained.

Vehicles with left/right vehicle level sender

– Unscrew nut -1-.
– Pull front left vehicle level sender - G78- / front right vehicle
level sender - G289- -2- out of suspension link -3-.
Continued for all vehicles

24 Rep. gr.40 - Front suspension

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– Loosen nut -1- on swivel joint but do not remove it completely.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Press suspension link off swivel joint using ball joint puller -
T10187- -2-.
– Unscrew nut -1-.

Note

Depending on engine, various brackets are mounted on the sub‐

frame, for example, brackets for the exhaust system, which must
be unbolted in order to remove the subframe.

Installing locating pins

– Position engine and gearbox jack - VAS 6931- with attached
rear axle support - T10552- beneath subframe.
– Allow rear axle support - T10552- to move upwards with en‐
gine and gearbox jack - VAS 6931- .

– Insert front supports -3- in mounting holes -arrows- in sub‐

frame -1- onto stop, free of stress, and position rear support
-2- under transverse reinforcement of subframe -1-.

Note

When positioning the rear axle support - T10552- in the subframe

with the engine and gearbox jack - VAS 6931- , make sure that
the vehicle is not raised as well under any circumstances.

– Replace 4 bolts of subframe one after the other diagonally with

locating pins - T10227- .

Note

♦ Observe specified torques of locating pins - T10227- because

otherwise, the threads of the locating pins will be damaged.
♦ Fixing of the subframe is completed when all of 4 subframe
bolts have been replaced one after the other with the locating
pins - T10227- .
♦ The position of the subframe is now fixed.

Removing locating pins

Remove in reverse order, observing the following:

Note

The engine and gearbox jack - VAS 6931- may only be moved
with the subframe on the rear axle support - T10552- in the lowest
position.

2. Subframe 25
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– Use tensioning straps - T10038- or -T10552/3- -3- to locate

and secure subframe -1- on rear axle support - T10552- -2- as
shown in figure.

– Carefully allow subframe -1- placed on rear axle support -

T10552- -2- to move upwards against underbody with engine
and gearbox jack - VAS 6931- -3-.

Note

When positioning the rear axle support - T10552- in the subframe

with the engine and gearbox jack - VAS 6931- , make sure that
the vehicle is not raised as well under any circumstances.

– One after the other, replace locating pins - T10227- with 4 new
bolts.
If an off-centre steering wheel is determined during the road test
even though locating pins - T10227- were used, check the wheel
alignment. In this case the wheel alignment test results must be
archived in the vehicle files.
To determine whether wheel alignment is necessary, refer to table
⇒ page 170 .
Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
Component Specified torque
Locating pins - T10227- 20 Nm
Bolt for securing rear axle sup‐ 30 Nm
port - T10552- on engine and
gearbox jack - VAS 6931-
Bolt securing support on rear 30 Nm
axle support - T10552-

2.8 Renewing bonded rubber bushes in subframe

26 Rep. gr.40 - Front suspension

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Special tools and workshop

equipment required

♦ Thrust plate - 30 - 205-

♦ Hydraulic cylinder - VAS 6178-
♦ Thrust piece - 3351/1- from puller - 3351-
♦ Assembly tool - T10205-
♦ Foot pump - VAS 6179-
Removing
– Remove assembly carrier ⇒ page 13 .

WARNING

For the following assembly work, place the subframe on a

workbench or the workshop floor.

2. Subframe 27
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– Fit tools as shown in illustration.

1- Threaded rod M20 - T10205/8-1-
2- Nut M20 - T10205/8-2-
3- Thrust head - T10205/13-
4- Hydraulic cylinder - VAS 6178-
5- Support - T10205/4-
6- Tube - T10205/5-
7- Press tool - T10205/3-
8- Nut M20 - T10205/8-2-
– Pulling out bonded rubber bush.

Note

The following work is necessary only if the bush jacket remains

in the axle beam.

Pulling out bush jacket:

– Fit tools as shown in illustration.

Note

Fit lower nut (item 8) with collar pointing downwards.

1- Threaded rod M20 - T10205/8-1-

2- Nut M20 - T10205/8-2-
3- Thrust head - T10205/13-
4- Hydraulic cylinder - VAS 6178-
5- Support - T10205/4-
6- Tube - T10205/5-
7- Thrust plate - 30 - 205-
8- Nut M20 - T10205/8-2-
– Pull out bush jacket.
Installing
– Mark installation position on side of bonded rubber bush and
subframe using a felt-tip pen ⇒ page 26 .
– Coat rubber bead with tyre fitting paste.

28 Rep. gr.40 - Front suspension

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– Fit bonded rubber bush and tools as shown in illustration.

Note

Fit lower nut (item 7) with collar pointing downwards.

1- Threaded rod M20 - T10205/8-1-

2- Nut M20 - T10205/8-2-
3- Thrust head - T10205/13-
4- Hydraulic cylinder - VAS 6178-
5- Support - T10205/4-
6- Thrust plate - 3351/1- from puller - 3351-
7- Nut M20 - T10205/8-2-
– Align bonded rubber bush using the marks which have been
made.
– Initially press in bush only until rubber bead has slid completely
into subframe.

Note

It is still possible to correct the installation position by turning the

bush.

– Check the installation position and correct if necessary before

pressing the bush in any further.
– Press bonded rubber bush in to stop.

Installation position for front bonded rubber bush

2. Subframe 29
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Installation position for rear bonded rubber bush

Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10

30 Rep. gr.40 - Front suspension

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3 Suspension strut, upper suspension

link
⇒ “3.1 Assembly overview - suspension strut”, page 31
⇒ “3.2 Removing and installing suspension strut”, page 33
⇒ “3.3 Repairing suspension strut”, page 40

3.1 Assembly overview - suspension strut

1 - Protective cap
2 - Nut
❑ Renew after removal
❑ 80 Nm
3 - Stop
4 - Suspension turret
5 - Nut
❑ 80 Nm
6 - Suspension strut mounting
7 - Upper spring plate
8 - Buffer stop
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
❑ Press into upper spring
plate
⇒ Item 7 (page 31) to
stop.
9 - Deep groove ball thrust
bearing
10 - Protective cover
11 - Coil spring
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
❑ Removing and installing
⇒ page 40
❑ On installation, turn low‐
er end of spring to stop
in suspension strut
plate.
12 - Protective cap
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
13 - Damper
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
❑ Removing and installing suspension strut ⇒ page 33
❑ Repairing suspension strut ⇒ page 40
14 - Damper
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
❑ Removing and installing suspension strut ⇒ page 33
❑ Repairing suspension strut ⇒ page 40

3. Suspension strut, upper suspension link 31

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15 - Buffer stop
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
❑ Compress together with support ring ⇒ Item 16 (page 32) and then press both parts into upper spring
plate ⇒ Item 7 (page 31) to stop.
16 - Support ring
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
❑ Compress together with bump stop ⇒ Item 15 (page 32) and then press both parts into upper spring plate
⇒ Item 7 (page 31) to stop.

32 Rep. gr.40 - Front suspension

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3.2 Removing and installing suspension

strut
⇒ “3.2.1 Removing and installing suspension strut, suspension
strut secured with clamp”, page 33
⇒ “3.2.2 Removing and installing suspension strut, suspension
strut secured with bolts”, page 38

3.2.1 Removing and installing suspension strut, suspension strut secured with
clamp

3. Suspension strut, upper suspension link 33

 Transporter 2004 ➤ , Transporter 2010 ➤
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Special tools and workshop

equipment required

34 Rep. gr.40 - Front suspension

 Transporter 2004 ➤ , Transporter 2010 ➤
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♦ Spreader - 3424-
♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-
♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use
engine and gearbox jack - VAS 6931-
♦ Shock absorber tool set - T10001-
♦ Support - T10149-
♦ Ball joint puller - T40010-
♦ Ejector - T10103-
♦ Adapter - T 10103/1-
Removing
– Remove plenum chamber bulkhead ⇒ Rep. gr. 50 ; Plenum
chamber bulkhead; Assembly overview - plenum chamber
bulkhead .
– Loosen 12-point nut -1- of axle shaft -2-.
– Remove wheel ⇒ “1.1 Fitting wheels”, page 159 .

3. Suspension strut, upper suspension link 35

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– Unbolt coupling rod -1- from suspension strut.

– Swing coupling rod towards rear.
– Press brake line out of retainer on suspension strut.
– Pull off connector for front left brake pad wear sender - G34- /
rear right brake pad wear sender - G37- ⇒ Brake systems;
Rep. gr. 46 ; Brake mechanism; Front brake; Removing and
installing brake pads .
– Pull off connector for front right speed sensor - G45- / front left
speed sensor - G47- ⇒ Brake systems; Rep. gr. 45 ; ABS,
ACC, TCS, EDL, ESP; Sensors; Removing and installing
speed sensors on front axle .
– Push wire for front left brake pad wear sender - G34- / rear
right brake pad wear sender - G37- out of retainer on suspen‐
sion strut.
– Push wire for front right speed sensor - G45- / front left speed
sensor - G47- out of retainer on suspension strut.
– Remove brake caliper ⇒ Brake system; Rep. gr. 46 ; Brake
mechanism; Front brake; Removing and installing brake cali‐
per .
– Secure brake caliper to vehicle with wire.

Note

Observe the following procedure to prevent damage to the drive

shaft caused by overstretching.

– Turn wheel hub until one of the wheel bolt holes is at the top.

– Attach support - T10149- to wheel hub using wheel bolt.

– Support wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- or engine and gearbox jack - VAS 6931- .

WARNING

♦ Never raise or lower the vehicle while the engine and

gearbox jack is positioned beneath the vehicle.
♦ Do not leave the engine and gearbox jack - V.A.G 1383
A- or engine and gearbox jack - VAS 6931- under the ve‐
hicle longer than necessary.

– Loosen nut on swivel joint but do not remove completely.

– Push suspension link off swivel joint using puller - T 40010- .
– Unscrew nut.
– Pull suspension link off swivel joint.

36 Rep. gr.40 - Front suspension

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– Push drive shaft out of wheel hub using remover - T 10103-

and adapter - T 10103/1- .
– Secure drive shaft to body.
– Press off track rods using ball joint puller - T40010- .

– Separate threaded damper connection on body.

1 - Commercially available ratchet handle
2 - T10001/8
3 - T10001/11
4 - T10001/5
– Lower engine and gearbox jack - V.A.G 1383 A- or engine and
gearbox jack - VAS 6931- as far as necessary.
– Remove shock absorber with wheel bearing housing.
– Place shock absorber with wheel bearing housing on a suita‐
ble surface.

– Unscrew nut -1- from wheel bearing housing -3-.

– Pull out bolts -2-.

– Open wheel bearing housing -1- with spreader - 3424- at po‐

sition -A-.
– Remove shock absorber -2- in -direction of arrow B-.
Installing
Install in the reverse order of removal, observing the following:
♦ Check alignment of suspension strut relative to wheel bearing
housing.

3. Suspension strut, upper suspension link 37

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When installing, the metal tab on suspension strut must slip into
groove -arrow A- in wheel bearing housing.
– If necessary, turn suspension strut further until this position is
reached.
– Insert wheel bearing housing far enough that suspension strut
sits on stop -arrow B- in wheel bearing housing.
– Insert suspension strut.

– Secure threaded connection of shock absorber on body.

1 - Commercially available ratchet handle
2 - T10001/8
3 - T10001/11
4 - T10001/5
If components such as damper have been renewed, it may be
necessary to carry out wheel alignment.
For information on the necessity of wheel alignment refer to
⇒ page 170 .
Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159
♦ ⇒ “6 Drive shaft”, page 67
♦ Install brake caliper ⇒ Brake systems; Rep. gr. 46 ; Brake
mechanism; Front brake; Removing and installing brake cali‐
per .
♦ Plenum chamber bulkhead; Assembly overview - plenum
chamber bulkhead ⇒ Rep. gr. 50 ; Plenum chamber bulkhead

3.2.2 Removing and installing suspension strut, suspension strut secured with
bolts

38 Rep. gr.40 - Front suspension

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Special tools and workshop

equipment required

♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-
♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use
engine and gearbox jack - VAS 6931-
♦ Shock absorber tool set - T10001-
♦ Support - T10149-
Removing
– Remove plenum chamber bulkhead ⇒ Rep. gr. 50 ; Plenum
chamber bulkhead; Assembly overview - plenum chamber
bulkhead .
– Remove wheel.
– Unbolt coupling rod from suspension strut and swing back.
– Press brake line out of retainer on suspension strut.
– Pull of connectors for brake pad wear indicator and ABS speed
sensor.
– Press wires for brake pad wear indicator and ABS speed sen‐
sor out of bracket on suspension strut.
– Turn wheel hub until one of the wheel bolt holes is at the top.

3. Suspension strut, upper suspension link 39

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– Attach support - T10149- to wheel hub using wheel bolt.

– Support wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- or engine and gearbox jack - VAS 6931- .

WARNING

♦ Never raise or lower the vehicle while the engine and

gearbox jack is positioned beneath the vehicle.
♦ Do not leave the engine and gearbox jack - V.A.G 1383
A- or engine and gearbox jack - VAS 6931- under the ve‐
hicle longer than necessary.

– Separate threaded damper connection on body.

1 - Commercially available ratchet handle
2 - T10001/8
3 - T10001/11
4 - T10001/5
– Unbolt suspension strut from wheel bearing housing.
– Lower engine and gearbox jack - V.A.G 1383 A- or engine and
gearbox jack - VAS 6931- as far as necessary, and remove
suspension strut.
Installing
Install in the reverse order of removal, observing the following:
If components such as damper have been renewed, it may be
necessary to carry out wheel alignment.
To determine whether wheel alignment is necessary, refer to table
⇒ page 170 .
Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159
♦ Plenum chamber bulkhead; Assembly overview - plenum
chamber bulkhead ⇒ Rep. gr. 50 ; Plenum chamber bulkhead

3.3 Repairing suspension strut

40 Rep. gr.40 - Front suspension

 Transporter 2004 ➤ , Transporter 2010 ➤
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Special tools and workshop

equipment required

♦ Torque wrench - V.A.G 1332-

♦ Spring compressor - V.A.G 1752/1-
♦ Spring retainer - V.A.G 1752/5-
♦ Shock absorber tool set - T10001-
Removing coil spring
– Clamp spring compressor - V.A.G 1752/1- in bench vice.

WARNING

When compressing coil springs, always ensure that the spring

coils are correctly positioned in the spring retainer.

3. Suspension strut, upper suspension link 41

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– Insert suspension strut in spring compressor and tighten until

upper spring plate is relieved.
1 - Commercially available ratchet handle
2 - T10001/8
3 - T10001/11
4 - T10001/5
5 - V.A.G 1752/1
6 - V.A.G 1752/5
– Unscrew hexagon nut from piston rod.
– Remove suspension strut mounting, upper spring plate with
bump stop and deep groove ball thrust bearing with protective
boot from piston rod.
– Remove coil spring with spring compressor from shock ab‐
sorber.
Installing coil spring
Install in the reverse order of removal, observing the following:
– Ensure that protective boot is correctly seated in deep groove
ball thrust bearing.

Note

During assembly, do not kink protective boot; if this occurs, im‐

mediately press protective boot out again.

– Ensure that bump stop is correctly seated in upper spring

plate.
– Before releasing spring compressor, turn lower end of spring
to stop in spring plate.
– Pull lower end of protective boot down far enough that the
locking lugs of the protective cap engage in the groove of the
protective boot.
Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “3.1 Assembly overview - suspension strut”, page 31
♦ ⇒ “1.1 Fitting wheels”, page 159
♦ ⇒ “6 Drive shaft”, page 67

42 Rep. gr.40 - Front suspension

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4 Lower suspension link, swivel joint

⇒ “4.1 Assembly overview - lower suspension link, swivel joint”,
page 43
⇒ “4.2 Removing and installing lower suspension link”,
page 44
⇒ “4.3 Checking swivel joint”, page 46
⇒ “4.4 Removing and installing swivel joint”, page 46
⇒ “4.5 Renewing bonded rubber bush for lower suspension link”,
page 48

4.1 Assembly overview - lower suspension link, swivel joint

1 - Subframe
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Fix in position before re‐
moval ⇒ page 21 .
2 - Bolt
❑ Renew after removal
3 - Rear bonded rubber bush
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Pressing out and in
⇒ page 48
❑ Observe installation po‐
sition for bush with »kid‐
ney-shaped« notch
⇒ page 51 .
4 - Suspension link
❑ If damaged, also renew
swivel joint.
❑ Removing and installing
⇒ page 44
5 - Nut
❑ Renew after removal
❑ 110 Nm +120°
6 - Bolt
❑ Renew after removal
7 - Front bonded rubber bush
❑ Pressing out and in
⇒ page 48
8 - Bracket
❑ For front left vehicle lev‐
el sender - G78-
9 - Nut
❑ Renew after removal
❑ 110 Nm +120°
10 - Swivel joint
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ Renew together with suspension link if suspension link is damaged

4. Lower suspension link, swivel joint 43

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❑ Checking swivel joint ⇒ page 46 .
❑ Removing and installing ⇒ page 46
11 - Bolt
❑ Renew after removal
❑ 90 Nm +45°
12 - Nut
❑ Renew after removal
❑ 60 Nm +90°

4.2 Removing and installing lower suspen‐

sion link
Special tools and workshop equipment required
♦ Ball joint puller - T10187-

♦ Torque wrench - V.A.G 1332-

Removing

Note

If the suspension link is deformed, the swivel joint must be re‐

newed together with the suspension link.

– Loosen wheel bolts.

– Raise vehicle ⇒ Maintenance ; Booklet 20.1 ; Description of
work; Raising vehicle with lifting platform and trolley jack .
– Remove wheel.

44 Rep. gr.40 - Front suspension

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Vehicles with left/right vehicle level sender

– Unscrew nut -1-.
– Pull front left vehicle level sender - G78- / front right vehicle
level sender - G289- -2- out of suspension link -3-.
Continued for all vehicles

– Loosen nut -1- on swivel joint but do not remove it completely.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Press suspension link off swivel joint using ball joint puller -
T10187- -2-.
– Unscrew nut -1-.

– Unscrew nut -arrow-.

– Remove bolt -1-.
– Unscrew nut -2-.
– Remove bolt -3-.
– Remove suspension link -4- from subframe.
Installing
Install in the reverse order of removal, observing the following:

Note

Tighten only when the vehicle is standing on its wheels and is

unladen or when the vehicle is raised and has been placed in the
unladen position ⇒ page 2 .

– Install front wheel and tighten.

Specified torques
♦ ⇒ “4.1 Assembly overview - lower suspension link, swivel
joint”, page 43
♦ ⇒ “1.1 Fitting wheels”, page 159

4. Lower suspension link, swivel joint 45

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4.3 Checking swivel joint

Checking axial play
– Forcefully pull suspension link down and press up again.

Checking radial play

– Press lower part of wheel forcefully outwards and inwards.

Note

♦ There should be no tangible or visible “play” during both tests.

♦ Observe swivel joint while performing tests.
♦ Take into account possible existing wheel bearing play or
“play” in upper suspension strut mounting.
♦ Check rubber boot for damage and renew swivel joint if nec‐
essary.

4.4 Removing and installing swivel joint

Special tools and workshop equipment required
♦ Socket, multi-point bit XZN 14 - T10061-

♦ Ball joint puller - T10187-

46 Rep. gr.40 - Front suspension

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♦ Torque wrench - V.A.G 1332-

Removing

Note

If the suspension link is deformed, the swivel joint must be re‐

newed together with the suspension link.

– Loosen wheel bolts.

– Raise vehicle ⇒ Maintenance ; Booklet 20.1 ; Description of
work; Raising vehicle with lifting platform and trolley jack .
– Remove wheel.
Vehicles with left/right vehicle level sender
– Unscrew nut -1-.
– Pull front left vehicle level sender - G78- / front right vehicle
level sender - G289- -2- out of suspension link -3-.
Continued for all vehicles

– Loosen nut -1- on swivel joint but do not remove it completely.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Press suspension link off swivel joint using ball joint puller -
T10187- -2-.
– Unscrew nut -1-.
– Pull suspension link off swivel joint.

4. Lower suspension link, swivel joint 47

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– Unscrew bolts -arrows- using socket - T10061- -1-.

– Remove swivel joint -2-.
Installing
Install in the reverse order of removal, observing the following:

Note

The lever of the vehicle level sender must point towards the out‐
side of the vehicle.

– Install wheel and tighten.

Specified torques
♦ ⇒ “4.1 Assembly overview - lower suspension link, swivel
joint”, page 43
♦ ⇒ “1.1 Fitting wheels”, page 159

4.5 Renewing bonded rubber bush for lower

suspension link
⇒ “4.5.1 Renewing bonded rubber bush for lower suspension link,
front bonded rubber bush”, page 48
⇒ “4.5.2 Renewing bonded rubber bush for lower suspension link,
rear bonded rubber bush”, page 51

4.5.1 Renewing bonded rubber bush for lower suspension link, front bonded rub‐
ber bush

48 Rep. gr.40 - Front suspension

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Special tools and workshop

equipment required

♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-
♦ Press tool - VW 408 A-
♦ Thrust plate - VW 447 i-
♦ Bolt from fitting tool - 10 - 203-
♦ Tube - 3296-

♦ Thrust piece from assembly tool - 3346-

4. Lower suspension link, swivel joint 49

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Removing
– Remove lower suspension link ⇒ page 44 .

Caution

♦ When bending up metal collar, do not damage suspension

link.

WARNING

♦ Wear safety goggles and protective gloves.

– To support the suspension link, use a sharp -chisel- to bend

up metal collar -1- in area -a-.

– Press out bonded rubber bush.

Installing
– Coat rubber bead of bonded rubber bush with tyre fitting paste.

– Press bush -A- into suspension link -B- by hand as far as pos‐
sible.

50 Rep. gr.40 - Front suspension

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– Press in bonded rubber bush -A- onto stop.

– Press in bonded rubber bush further with bolt -A- from fitting
tool - 10 - 203- .

Note

This causes the rubber bead to »pop« out of the suspension link.

4.5.2 Renewing bonded rubber bush for lower suspension link, rear bonded rub‐
ber bush

4. Lower suspension link, swivel joint 51

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Special tools and workshop

equipment required

♦ Thrust plate - VW 401-

♦ Press tool - VW 409-
♦ Press tool - VW 411-
♦ Fitting tool - 2003/3-
♦ Thrust piece from assembly tool - 3346-
♦ Assembly tool - 3347-

♦ Thrust piece - 3416/1-

52 Rep. gr.40 - Front suspension

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Removing
– Remove lower suspension link ⇒ page 44 .
– Position listed tools as shown in diagram.
– Press out bonded rubber bush.
Installing

Note

Note the installation position before pressing in bonded rubber

bushes with »kidney-shaped« recess.

Installation position for left side

In the suspension link's installation position, the larger »kidney-
shaped« recess -A- must point to the centre of the vehicle.
The markings -arrows- must align.

Installation position for right side

In the suspension link's installation position, the larger »kidney-
shaped« recess -A- must point to the centre of the vehicle.
The markings -arrows- must align.

– Position listed tools as shown in diagram.

– Press in bonded rubber bush -A-.

4. Lower suspension link, swivel joint 53

 Transporter 2004 ➤ , Transporter 2010 ➤
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5 Wheel bearing
⇒ “5.1 Assembly overview - wheel bearing”, page 54
⇒ “5.2 Removing and installing wheel bearing housing”,
page 55
⇒ “5.3 Renewing wheel bearing”, page 61

5.1 Assembly overview - wheel bearing

Note

♦ Note allocation ⇒ Electronic parts catalogue (ETKA) .

♦ Observe the different torque specifications for each of the two wheel bearing housing versions.
♦ For vehicles manufactured from 01.06.2015: If a new wheel bearing housing is installed, the installation of
a new track rod ball joint is compulsory.

1 - Wheel bearing housing

❑ Note allocation ⇒ Elec‐
tronic parts catalogue
(ETKA)
❑ Removing and installing
⇒ page 55
For vehicles manufactured
from 01.06.2015: If a new
wheel bearing housing is in‐
stalled, the installation of a new
track rod ball joint is compul‐
sory.

2 - Cover plate
3 - Bolt
❑ 10 Nm
4 - Bolt
❑ 15 Nm
5 - Brake disc
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
6 - Twelve-point nut
❑ Renew after removal
❑ Initially tighten to
200 Nm and then slack‐
en off 180°
❑ Final torque setting:
200 Nm
7 - Wheel bearing
❑ Renew after removal
❑ Removing and installing
⇒ page 61
8 - Wheel bearing housing
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
❑ Removing and installing ⇒ page 55

54 Rep. gr.40 - Front suspension

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For vehicles manufactured from 01.06.2015: If a new wheel bearing housing is installed, the installation of a
new track rod ball joint is compulsory.

9 - Nut
❑ Renew after removal
10 - Bolt
❑ Renew after removal
❑ 150 Nm +90°
11 - Nut
❑ Renew after removal
❑ 60 Nm +90°
12 - Drive shaft
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
❑ Removing and installing ⇒ “6 Drive shaft”, page 67
❑ Repairing
⇒ “6.4.1 Repairing drive shaft (with constant velocity joint), vehicles with 5-speed manual gearbox”, page
98
13 - Nut
❑ Renew after removal
14 - Suspension strut
❑ Allocation ⇒ Electronic parts catalogue (ETKA)
❑ Assembly overview ⇒ page 31
15 - Bolt
❑ Renew after removal
❑ Initial tightening torque: 50 Nm
❑ 75 Nm +180°
16 - Bolt
❑ 8 Nm
17 - Speed sensor
18 - Track rod ball joint

5.2 Removing and installing wheel bearing

housing
Special tools and workshop equipment required
♦ Spreader - 3424-

5. Wheel bearing 55
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♦ Adapter - T10103/1-

♦ Bolts - T10103/2-
♦ Ball joint puller - T10187-

♦ Ejector - T10520-

♦ Torque wrench - V.A.G 1332-

56 Rep. gr.40 - Front suspension

 Transporter 2004 ➤ , Transporter 2010 ➤
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♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use

engine and gearbox jack - VAS 6931-

Removing
– Loosen nut for drive shaft.

Caution

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.
Wheel bearings must not be subjected to load after bolt secur‐
ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° 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 must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.

Note

For vehicles manufactured from 01.06.2015: If a new wheel bear‐

ing housing is installed, the installation of a new track rod ball joint
is compulsory.

– Loosen wheel bolts.

– Raise vehicle ⇒ Maintenance ; Booklet 20.1 ; Description of
work; Raising vehicle with lifting platform and trolley jack .
– Remove wheel.
– Detach brake caliper and tie to body with wire ⇒ Brake system;
Rep. gr. 46 ; Front brakes; Assembly overview - front brakes .
– Remove ABS speed sensor ⇒ Brake system; Rep. gr. 45 ;
Sensors; Removing and installing speed sensor on front axle
-G45- / -G47- .
– Remove brake disc ⇒ Brake system; Rep. gr. 46 ; Front
brakes; Assembly overview - front brakes
– Remove bracket for brake line and wires from wheel bearing
housing, and lay it to one side.
– Remove splash plate from wheel bearing housing.

5. Wheel bearing 57
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– Loosen nut -1- on track rod ball joint but do not remove com‐
pletely.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Press track rod off wheel bearing housing using ball joint puller
- T10187- -2-.
– Unscrew nut -1-.

Vehicles with left/right vehicle level sender

– Unscrew nut -1-.
– Pull front left vehicle level sender - G78- / front right vehicle
level sender - G289- -2- out of suspension link -3-.

Continued for all vehicles

– Loosen nut -1- on swivel joint but do not remove it completely.

Caution

To protect thread, leave nut screwed a few turns onto joint pin.

– Press suspension link off swivel joint using ball joint puller -
T10187- -2-.
– Unscrew nut -1-.
– Pull suspension link off swivel joint.

Before using press tool - T10520- ensure that thrust piece -1- is
inserted.

58 Rep. gr.40 - Front suspension

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Using ejector - T10520- :

– Use bolts - T 10103/1- to secure adapter - T10103/2- -1- to
wheel bearing.
– To press out drive shaft -3-, secure ejector - T10520- -2- to
wheel hub using 4 wheel bolts -3-.

– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
shaft with ejector - T10520- .

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 apply
the hydraulic force.

– Secure drive shaft to body with wire.

– Place engine and gearbox jack - VAS 6931- or engine and
gearbox jack - V.A.G 1383 A- under wheel bearing housing.

Clamped suspension strut

– Unscrew nut -1- from wheel bearing housing -3-.
– Pull out bolts -2-.

– Open wheel bearing housing -1- with spreader - 3424- at po‐

sition -A-.

5. Wheel bearing 59
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Note

Make sure that the spreader - 3424- is only inserted into the wheel bearing housing. Insert sufficiently to ensure
that the metal tab of the suspension strut is not damaged.

– Turn ratchet handle through 90° and detach from spreader -

3424- .
– Pull wheel bearing housing -1- in opposite
-direction of arrow B- downwards off shock absorber -2-.

60 Rep. gr.40 - Front suspension

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Bolted suspension strut

– Remove nuts -arrows-
– Pull out bolts -2-.
– Pull wheel bearing housing from suspension strut.
Continued for all vehicles

Note

If wheel bearing housing is renewed, swivel joint must be trans‐

ferred. Always use new bolts.

Installing
Install in the reverse order of removal, observing the following:

Caution

For vehicles manufactured from 01.06.2015: If a new wheel

bearing housing is installed, the installation of a new track rod
ball joint is compulsory.

Clamped suspension strut

When installing, the metal tab on suspension strut must slip into
groove -arrow A- in wheel bearing housing.
– If necessary, turn suspension strut further until this position is
reached.
– Insert wheel bearing housing far enough that suspension strut
sits on stop -arrow B- in wheel bearing housing.
Specified torques
♦ ⇒ “5.1 Assembly overview - wheel bearing”, page 54
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “3.1 Assembly overview - vane pump”, page 207
♦ ⇒ “6 Drive shaft”, page 67
♦ Speed sensor bolt ⇒ Brake system; Rep. gr. 45 ; Sensors;
Assembly overview - speed sensor on front axle
♦ Bolts for splash plate, brake caliper, brake disc ⇒ Brake sys‐
tem; Rep. gr. 46 ; Front brakes; Assembly overview - front
brakes

5.3 Renewing wheel bearing

Note

The wheel bearings must always be renewed after removal.

5. Wheel bearing 61
 Transporter 2004 ➤ , Transporter 2010 ➤
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WARNING

♦ Danger of accident through falling parts.

♦ You may be injured through falling parts.
♦ Place engine and gearbox jack - V.A.G 1383 A- or engine
and gearbox jack - VAS 6931- below wheel bearing hous‐
ing throughout the entire process.

Special tools and workshop

equipment required

♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use

engine and gearbox jack - VAS 6931-
♦ Hydraulic cylinder - VAS 6178-
♦ Pressure application device - V.A.G 1389/1- discontinued, use
foot pump - VAS 6179- if necessary
♦ Remover - T10103- and adapter for remover - T10103/2-
♦ Assembly tool - T10205-
♦ Ball joint puller - T40010-

62 Rep. gr.40 - Front suspension

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♦ Pressure gauge with connection line - VAS 6179/1-

Removing
– Loosen twelve-point nut on wheel hub.

Caution

♦ The wheel bearing can be damaged by the weight of the

vehicle if the nut ⇒ Item 6 (page 54) is loosened.
♦ Do not loosen the nut ⇒ Item 6 (page 54) if the vehicle is
standing on its wheels.

– Remove front wheel.

– Remove brake caliper complete with brake carrier and secure
to vehicle ⇒ Brakes - mechanism; Rep. gr. 46 ; Removing
and installing brake caliper, floating caliper disc brake .
– Remove brake disc ⇒ Brakes - mechanism; Rep. gr. 46 ;
Removing and installing brake disc .
– Remove ABS speed sensor ⇒ Anti-lock brake system; Rep.
gr. 45 ; Sensors; Removing and installing speed sensor on
front axle .
– Unbolt suspension link from swivel joint.
– Push suspension link off swivel joint using puller - T40010- .

5. Wheel bearing 63
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– Using remover - T 10103- and adapter - T 10103/1- push drive

shaft out of wheel hub.
– Secure drive shaft to body.
– To stabilise the wheel bearing housing, insert swivel joint back
in wheel bearing housing, and tighten swivel joint nut hand-
tight.

Note

The illustration below shows the rear axle. This is not relevant for
describing the procedure.

– Centre gripping pieces - T10205/12- »behind« wheel hub -1-

using wheel bolts-2-.

Note

Wheel bolts -2- must not protrude from backs of gripping pieces
- T10205/12- .

– Place engine and gearbox jack - V.A.G 1383 A- or engine and

gearbox jack - VAS 6931- under wheel bearing housing.

– Tools as shown in illustration:

1- Threaded rod M20 - T10205/8-1-
2- Nut M20 - T10205/8-2-
3- Thrust head - T10205/13-
4- Hydraulic cylinder - VAS 6178-
5- Bell - T10205/2-
6- Gripping pieces - T10205/12-
7- Press tool - T10205/3-
8- Nut M20 - T10205/8-2-
9- Threaded rod M20 - T10205/8-1-

64 Rep. gr.40 - Front suspension

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– Press wheel bearing unit with wheel bearing out of wheel

bearing housing, holding the tools steady.

Note

When setting bell - T10205/2- -1- in place, ensure that the wheel
bolts -arrows- are in the positions shown.

Installing
Install in the reverse order of removal, observing the following:

Note

♦ The wheel bearings must always be renewed after removal.

♦ The illustration below shows the rear axle. This is not relevant
for describing the procedure.
♦ Wheel bolts -2- must not protrude from rear of wheel bearing
unit -1-.
♦ The gripping pieces - T10205/11- should prevent the retaining
ring from slipping down the wheel bearing during the pressing
in sequence

– Centre gripping pieces - T10205/11- »behind« new wheel

bearing unit -1- using wheel bolts -2-.

5. Wheel bearing 65
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Note

The guide - T10205/15- must always be installed with the recess

facing towards the wheel bearing.

– Fit wheel bearing unit and wheel bearing together with the
tools on the wheel housing as shown in illustration.
1 - Threaded rod M20 - T10205/8-1-
2 - Nut M20 - T10205/8-2-
3 - Thrust head - T10205/13-
4 - Hydraulic cylinder - VAS 6178-
5 - Bell - T10205/2-
6 - Gripping pieces - T10205/11-
7 - Threaded rod M20 - T10205/8-1-
8 - Nut M20 - T10205/8-2-
9 - Guide - T10205/15-
– Connect pressure gauge with connection line - VAS 6179/1-
between hydraulic cylinder - VAS 6178- and hydraulic line of
pressure application device - V.A.G 1389/1- or foot pump -
VAS 6179- .
The pressures described below apply to the hydraulic press -
VAS 6178- only.
When pressing in, the pressure reading taken shortly before the
end of pressing must be between 90 and 140 bar.
The maximum pressure must not exceed 310 bar.
– Press in wheel bearing until circlip engages audibly.
Ensure the wheel bearing does not cant when pressing in.
– Install drive shaft ⇒ page 67 .
– Install ABS speed sensor ⇒ Anti-lock brake system; Rep. gr.
45 ; Sensors; Removing and installing speed sensor on front
axle .
– Install brake disc ⇒ Brakes - mechanism; Rep. gr. 46 ; Re‐
moving and installing brake disc .
– Install brake caliper complete with brake carrier ⇒ Brakes -
mechanism; Rep. gr. 46 ; Removing and installing brake
caliper, floating caliper disc brake .
– Install wheel and tighten.
Specified torques
♦ ⇒ “1.1 Fitting wheels”, page 159
♦ ⇒ “6 Drive shaft”, page 67

66 Rep. gr.40 - Front suspension

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6 Drive shaft
⇒ “6.1 Overview - drive shaft”, page 67
⇒ “6.2 Assembly overview - drive shaft”, page 68
⇒ “6.3 Removing and installing drive shaft”, page 77
⇒ “6.4 Repairing drive shaft”, page 98
⇒ “6.5 Removing and installing jointed shaft support bearing”,
page 112

6.1 Overview - drive shaft

1 - Assembly overview - drive

shafts (with constant velocity
joint) for vehicles with 5-speed
manual gearbox ⇒ page 68
Vehicles with 4-cylinder en‐
gine only
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing
⇒ page 77
❑ Repairing drive shaft
⇒ page 98
2 - Assembly overview - drive
shafts (with constant velocity
joint) for vehicles with 6-speed
manual gearbox and four-
wheel drive ⇒ page 77
Only vehicles with 4-cylinder
and 5-cylinder engine
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing
⇒ page 80
❑ Repairing drive shaft
⇒ page 102
3 - Assembly overview - drive
shafts (with triple roller joint
AAR 3700i + AAR 4100i) for
vehicles with 6-speed gear‐
box / automatic gearbox and
four-wheel drive ⇒ page 70
Vehicles with 5-cylinder and 6-
cylinder engines only
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing ⇒ page 85
❑ Repairing drive shaft ⇒ page 108
4 - Assembly overview - drive shaft (with triple roller joint AAR 3700i/SX) for vehicles with dual clutch gearbox
⇒ page 75
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ Removing and installing ⇒ page 91

6. Drive shaft 67
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6.2 Assembly overview - drive shaft

⇒ “6.2.1 Assembly overview - drive shafts (with constant velocity
joint) for vehicles with 5-speed manual gearbox”, page 68
⇒ “6.2.2 Assembly overview - drive shafts (with constant velocity
joint) for vehicles with 6-speed manual gearbox and four-wheel
drive”, page 70
⇒ “6.2.3 Assembly overview - drive shafts (with triple roller joint
AAR 3700i + AAR 4100i) for vehicles with 6-speed manual gear‐
box, automatic gearbox and four-wheel drive”, page 72
⇒ “6.2.4 Assembly overview - drive shafts (with triple roller joint
AAR 3700i/SX) for vehicles with dual clutch gearbox”,
page 75

6.2.1 Assembly overview - drive shafts (with

constant velocity joint) for vehicles with
5-speed manual gearbox
Vehicles with 4-cylinder engine only

Note

During start of production, construction was changed from »bon‐

ded« drive shafts (outer joint inserted in wheel hub with locking
fluid) to »unbonded« drive shafts (outer joint pressed into wheel
hub). Procedures for repair work and what must be observed are
described in this chapter.

Caution

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.

68 Rep. gr.40 - Front suspension

 Transporter 2004 ➤ , Transporter 2010 ➤
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1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing and installing
⇒ page 98
❑ Procedure for vehicles
with bonded drive
shafts: clean and de‐
grease splines and ap‐
ply locking fluid ⇒ Elec‐
tronic Parts Catalogue
(ETKA) .
2 - Twelve-point nut
❑ Renew after removal
❑ Initially tighten to
200 Nm and then slack‐
en off 180°
❑ Final torque setting:
200 Nm
3 - Retaining ring
❑ Renew after removal
❑ Insert in groove in shaft
4 - Clip
❑ Renew after removal
❑ 25 Nm
5 - Boot
❑ Removing and installing
⇒ page 98
❑ For outer constant ve‐
locity joint.
❑ Check for splits and
chafing
6 - Clip
❑ Renew after removal
7 - Drive shafts
❑ Removing and installing drive shafts ⇒ page 77
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
8 - Boot
❑ Before installing, apply sealant to sealing surface ⇒ Electronic Parts Catalogue (ETKA) .
❑ For left inner constant velocity joint.
❑ Check for splits and chafing
❑ Drive off constant velocity joint with a drift
❑ Removing and installing ⇒ page 98
9 - Inner constant velocity joint
❑ For left drive shaft
❑ Renew only as complete unit
❑ Removing and installing ⇒ page 98
10 - Retaining ring
❑ Renew after removal
❑ Remove and install using circlip pliers - VW 161 A- .
11 - Protective cap
❑ Drive off constant velocity joint with a drift

6. Drive shaft 69
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❑ Before installing, apply sealant - D 454 300 A2- to sealing surface
12 - Multi-point socket head bolt
❑ Renew after removal
❑ 50 Nm +90°
❑ For left drive shaft
13 - Locking plate
❑ For left drive shaft
14 - Boot
❑ Before installing, apply sealant to sealing surface ⇒ Electronic Parts Catalogue (ETKA) .
❑ For right inner constant velocity joint.
❑ Check for splits and chafing
❑ Drive off constant velocity joint with a drift
15 - Retaining ring
❑ Renew after removal
❑ Remove and install using circlip pliers - VW 161 A- .
16 - Inner constant velocity joint
❑ Renew only as complete unit
❑ For right drive shaft
17 - Bolt
❑ 20 Nm +90°
❑ For right drive shaft
18 - Support ring
❑ For right drive shaft
❑ Removing and installing ⇒ page 112
19 - Protective cap
❑ For right drive shaft

6.2.2 Assembly overview - drive shafts (with

constant velocity joint) for vehicles with
6-speed manual gearbox and four-
wheel drive
Only vehicles with 4-cylinder and 5-cylinder engine

Note

During start of production, construction was changed from »bonded« drive shafts (outer joint inserted in wheel
hub with locking fluid) to »unbonded« drive shafts (outer joint pressed onto wheel hub). Procedures for repair
work and what must be observed are described in this chapter.

Caution

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.

70 Rep. gr.40 - Front suspension

 Transporter 2004 ➤ , Transporter 2010 ➤
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1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing and installing
⇒ page 102
❑ Procedure for vehicles
with bonded drive
shafts: clean and de‐
grease splines and ap‐
ply locking fluid ⇒ Elec‐
tronic Parts Catalogue
(ETKA) .
2 - Twelve-point nut
❑ Renew after removal
❑ Initially tighten to
200 Nm and then slack‐
en off 180°
❑ Final torque setting:
200 Nm
3 - Retaining ring
❑ Renew after removal
❑ Insert in groove in shaft
4 - Clip
❑ Renew after removal
❑ 25 Nm
5 - Boot
❑ For outer constant ve‐
locity joint.
❑ Check for splits and
chafing
❑ Removing and installing
⇒ page 102
6 - Clip
❑ Renew after removal
❑ 25 Nm
7 - Drive shafts
❑ Removing and installing drive shafts ⇒ page 80
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
8 - Clip
❑ Renew after removal
❑ 25 Nm
9 - Boot
❑ Check for splits and chafing
10 - Clip
❑ Renew after removal
❑ 25 Nm
11 - Retaining ring
❑ Renew after removal
❑ Remove and install using circlip pliers - VW 161 A- .
12 - Inner constant velocity joint
❑ For right drive shaft

6. Drive shaft 71
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❑ Renew only as complete unit
13 - Bolt
❑ 20 Nm +90°
❑ For right drive shaft
14 - Support ring
❑ For right drive shaft
❑ Removing and installing ⇒ page 112
15 - Protective cap
❑ For right drive shaft
16 - Inner constant velocity joint
❑ For left drive shaft
❑ Renew only as complete unit
❑ Also for right drive shaft on vehicles with all-wheel drive

6.2.3 Assembly overview - drive shafts (with

triple roller joint AAR 3700i + AAR 4100i)
for vehicles with 6-speed manual gear‐
box, automatic gearbox and four-wheel
drive
Vehicles with 5-cylinder and 6-cylinder engines only

Note

During start of production, construction was changed from »bonded« drive shafts (outer joint inserted in wheel
hub with locking fluid) to »unbonded« drive shafts (outer joint pressed onto wheel hub). Procedures for repair
work and what must be observed are described in this chapter.

Caution

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.

72 Rep. gr.40 - Front suspension

 Transporter 2004 ➤ , Transporter 2010 ➤
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1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing and installing
⇒ page 108
❑ For vehicles with bon‐
ded drive shafts: clean
and degrease splines
and apply locking fluid
⇒ Electronic Parts
Catalogue (ETKA) .
2 - Twelve-point nut
❑ Renew after removal
❑ Initially tighten to
200 Nm and then slack‐
en off 180°
❑ Final torque setting:
200 Nm
3 - Retaining ring
❑ Renew after removal
❑ Insert in groove in shaft
4 - Clip
❑ Renew after removal
❑ 25 Nm
❑ Tightening hose clip
⇒ page 109
5 - Boot
❑ For outer constant ve‐
locity joint.
❑ Check for splits and
chafing
❑ Removing and installing
⇒ page 108
6 - Clip
❑ Renew after removal
❑ 25 Nm
❑ Tightening hose clip ⇒ page 109
7 - Drive shafts
❑ Removing and installing drive shafts ⇒ page 85
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
8 - Clip
❑ Renew after removal
❑ 25 Nm
❑ Tighten clamp using hose clip pliers - V.A.G 1275-
9 - Inner joint boot
❑ Check for splits and chafing
10 - Clip
❑ Renew after removal
❑ 25 Nm
❑ Tighten clamp using hose clip pliers - V.A.G 1275-

6. Drive shaft 73
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11 - Triple roller star with rollers

12 - Retaining ring
❑ Remove and install using circlip pliers - VW 161 A- .
13 - Triple roller shaft
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ For right drive shaft
14 - Support ring
❑ For right drive shaft
❑ Removing and installing ⇒ page 112
15 - Sleeve
❑ For right drive shaft
16 - Protective cap
❑ For right drive shaft
17 - Inner triple roller joint AAR 3700i + AAR 4100i
❑ For left drive shaft
❑ Renew only as complete unit
❑ For right drive shaft on vehicles with four-wheel drive
❑ Dismantling and assembling triple roller joint AAR 3700i + AAR 4100i for drive shaft ⇒ page 109
❑ Distinguishing features of triple roller joints AAR 3700i + AAR 4100i
18 - Bolt
❑ 20 Nm +90°
❑ For right drive shaft

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6.2.4 Assembly overview - drive shafts (with triple roller joint AAR 3700i/SX) for
vehicles with dual clutch gearbox

Caution

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.

1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing and installing
⇒ page 104
❑ For vehicles with bon‐
ded drive shafts: clean
and degrease splines
and apply locking fluid
⇒ Electronic Parts
Catalogue (ETKA) .
2 - Twelve-point nut
❑ Renew after removal
❑ Initially tighten to
200 Nm and then slack‐
en off 180°
❑ Final torque setting:
200 Nm
3 - Retaining ring
❑ Renew after removal
❑ Insert in groove in shaft
4 - Clip
❑ Renew after removal
❑ 25 Nm
❑ Tightening hose clip
⇒ page 105
5 - Boot
❑ For outer constant ve‐
locity joint.
❑ Check for splits and
chafing
❑ Removing and installing
⇒ page 104
6 - Clip
❑ Renew after removal
❑ 25 Nm
❑ Tightening hose clip ⇒ page 105
7 - Drive shafts
❑ Removing and installing drive shafts ⇒ page 91
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
8 - Clip
❑ Renew after removal
❑ 25 Nm

6. Drive shaft 75
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❑ Tightening hose clip ⇒ page 107
9 - Inner joint boot
❑ Check for splits and chafing
10 - Clip
❑ Renew after removal
❑ 25 Nm
❑ Tightening hose clip ⇒ page 107
11 - Triple roller star with rollers
❑ Removing and installing ⇒ page 106
12 - Retaining ring
❑ Remove and install using circlip pliers - VW 161 A- .
13 - Triple roller shaft
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ For right drive shaft
14 - Support ring
❑ For right drive shaft
❑ Removing and installing ⇒ page 112
15 - O-ring
❑ Renew after removal
16 - Inner triple roller joint
❑ For left drive shaft
❑ Renew only as complete unit
❑ For right drive shaft on vehicles with all-wheel drive
❑ Dismantling and assembling triple roller joint AAR 3700i/SX for drive shaft ⇒ page 106 .
17 - Bolt
❑ Bearing securing bolt for right drive shaft
❑ 20 Nm +90°

76 Rep. gr.40 - Front suspension

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6.3 Removing and installing drive shaft

⇒ “6.3.1 Removing and installing drive shafts (with constant ve‐
locity joint), for vehicles with 5-speed manual gearbox”,
page 77
⇒ “6.3.2 Removing and installing drive shafts (with constant ve‐
locity joint), for vehicles with 6-speed manual gearbox and four-
wheel drive”, page 80
⇒ “6.3.3 Removing and installing drive shafts (with triple roller joint
AAR 3700i + AAR 4100i), vehicles with 6-speed manual gearbox,
automatic gearbox and all-wheel drive”, page 85
⇒ “6.3.4 Removing and installing drive shafts (with triple roller joint
AAR 3700i/SX), vehicles with dual clutch gearbox”, page 91

6.3.1 Removing and installing drive shafts (with constant velocity joint), for vehi‐
cles with 5-speed manual gearbox

Special tools and workshop

equipment required

♦ Torque wrench - V.A.G 1332-

♦ Ejector - T10103-
♦ Adapter - T10103/1-
♦ Bolts for adapter - T10103/2-

6. Drive shaft 77
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♦ Ball joint puller - T40010-

♦ Locking fluid - D 185 400 A2-
♦ Lubricating grease ⇒ Electronic parts catalogue “ETKA”
– Loosen twelve-point nut on wheel bearing.

WARNING

When bolt is loosened or tightened, vehicle must be standing

on its wheels.
Danger of accidents.

– Raise vehicle.
– Remove front wheels.
Removing left drive shaft:
– Unbolt drive shaft from gearbox flange.
Removing right drive shaft:
– Remove support bearing ⇒ Item 18 (page 70) .
Continued procedure for both sides:
– Unbolt suspension link from swivel joint.

– Using ball joint puller - T 40010- , pull suspension link from

swivel joint.

– Press drive shaft out of wheel hub using remover - T 10103-

and adapter - T 10103/1- .

Note

When pressing out drive shaft, ensure that there is sufficient

clearance to all other parts.

– Pull off connector for brake pad wear indicator and speed sen‐
sor.
– Unclip both wires from the retainer on suspension strut and lay
them to side.

78 Rep. gr.40 - Front suspension

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– Pull wheel bearing housing outwards and lay an appropriate

wooden block between body and suspension strut.
Removing right drive shaft:
– Pull right drive shaft off stub shaft.
Continued procedure for both sides:
– Remove drive shafts.
Installing
Installing left drive shaft:

– Bolt inner joint of drive shaft onto gearbox flange

⇒ Item 12 (page 70) .
Installing right drive shaft:

– Grease the area between -A- and -B- »abundantly« with lu‐
bricating grease ⇒ Electronics Parts Catalogue “ETKA” .
– Set stub shaft on greased splines of final drive.
– Bolt on support bearing ⇒ Item 18 (page 70) .
Continued procedure for both sides of vehicle with »bonded«
drive shafts:

6. Drive shaft 79
 Transporter 2004 ➤ , Transporter 2010 ➤
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– Completely remove residual locking fluid from splines of drive

shaft -arrow A- and from contact surface/gap -arrow B- of
wheel hub.
– Apply locking fluid ⇒ Electronic Parts Catalogue (ETKA) »all
around« drive shaft splines.
– Insert drive shaft into wheel bearing.
– Tighten twelve-point nut by hand (do not completely tighten).
– Remove wooden block from between body and suspension
strut.
– Insert swivel joint into suspension link and bolt on suspension
link.
– Route wiring harness neatly along suspension strut and re‐
store electrical connections.
– Position front wheels.
– Lower vehicle onto its wheels.
– Tighten front wheels.
– Tighten twelve-point nut.

Note

Tighten twelve-point nut immediately following installation of drive

shaft so that locking fluid does not harden first.

Continued procedure for both sides of vehicle with »unbonded«

drive shafts:
– Insert drive shaft into wheel bearing.
– Tighten twelve-point nut by hand (do not completely tighten).
– Remove wooden block from between body and suspension
strut.
– Insert swivel joint into suspension link and bolt on suspension
link.
– Route wiring harness neatly along suspension strut and re‐
store electrical connections.
– Position front wheels.
– Lower vehicle onto its wheels.
– Tighten front wheels.
– Tighten twelve-point nut.
Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “6.2 Assembly overview - drive shaft”, page 68
♦ ⇒ “1.1 Fitting wheels”, page 159

6.3.2 Removing and installing drive shafts

(with constant velocity joint), for vehicles
with 6-speed manual gearbox and four-
wheel drive
Special tools and workshop equipment required

80 Rep. gr.40 - Front suspension

 Transporter 2004 ➤ , Transporter 2010 ➤
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♦ Torque wrench - V.A.G 1332-

♦ Ejector - T10103-

♦ Ball joint puller - T40010A-

♦ Locking fluid - D 185 400 A2-

Removing
– Loosen drive shaft nut on wheel hub.

WARNING

When bolt is loosened or tightened, vehicle must be standing

on its wheels.
Danger of accidents.

– Raise vehicle.
– Remove front wheels.
Removing left drive shaft
– Lever off inner joint of drive shaft from gearbox with a tyre lev‐
er .

6. Drive shaft 81
 Transporter 2004 ➤ , Transporter 2010 ➤
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Note

Do not damage protective cap on inner CV joint.

Removing right drive shaft, vehicles without all-wheel drive

– Unscrew support bearing ⇒ Item 18 (page 70) .
Continuation for both sides
– Unbolt suspension link from swivel joint.
– Push suspension link off swivel joint using puller - T 40010A- .

– Using remover - T 10103- and adapter - T 10103/1- push drive

shaft out of wheel hub.
– Separate electrical connector for brake pad wear indicator and
speed sensor.
– Unclip lines from retainer on suspension strut.

– Pull wheel bearing housing outwards.

– Place a suitable wooden block between the body and sus‐
pension strut.
Removing right drive shaft, vehicles without all-wheel drive
– Pull down drive shaft from support shaft.
Removing right drive shaft, vehicles with all-wheel drive
– Pull off drive shaft from gearbox.
Continuation for both sides
– Remove drive shaft.
Installing
Install in the reverse order of removal, observing the following:
– Check O-rings on both sides of splines, renew if damaged.

82 Rep. gr.40 - Front suspension

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Installing left drive shaft

– Remove retaining ring -B-.
– Install new retaining ring -A-.

– Apply grease to gearbox shaft between -arrow A- and

-arrow B- ⇒ Electronic parts catalogue “ETKA” .
– Mesh outer and inner splines of joint body and gearbox.

– Grip drive shaft by hand and push in direction of -B- to stop.

– Now push joint body with a jolt so that it engages in retaining
ring.
The retaining ring must be felt to engage.

Installing right drive shaft, vehicles without all-wheel drive

– Remove retaining ring -B-.
– Install new retaining ring -A-.

6. Drive shaft 83
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– Apply grease to gearbox shaft between -arrow A- and

-arrow B- ⇒ Electronic parts catalogue “ETKA” .
– Push drive shaft on splines of final drive.
– Tighten support bearing ⇒ Item 18 (page 70) .
Installing right drive shaft, vehicles with all-wheel drive
– Fit new retaining ring into groove of joint pin.
– Mesh outer and inner splines of joint body and gearbox.
– Grip drive shaft by hand and push onto gearbox shaft as far
as stop.
– Now push joint body with a jolt so that it engages in retaining
ring.
The retaining ring must be felt to engage.
Continuation for both sides with bonded drive shafts

84 Rep. gr.40 - Front suspension

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– Completely remove residual locking fluid from splines of drive

shaft -arrow A- and from contact surface/gap -arrow B-.
– Apply locking fluid to splined area of drive shaft ⇒ Electronic
parts catalogue (ETKA) .
– Fit drive shaft in wheel hub.
– Screw drive shaft nut on wheel hub finger-tight.
– Remove wooden block between body and suspension strut.
– Fit swivel joint in suspension link.
– Tighten suspension link.
– Clip in electrical wiring connections on suspension strut.
– Join electrical connectors.
– Fit wheels ⇒ page 159 .
– Tighten drive shaft nut on wheel hub.

Note

Tighten drive shaft nut immediately after installing so that locking

fluid does not harden beforehand.

Continuation for both sides with unbonded drive shafts

– Fit drive shaft in wheel hub.
– Screw drive shaft nut on wheel hub finger-tight.
– Remove wooden block between body and suspension strut.
– Fit swivel joint in suspension link.
– Tighten suspension link.
– Clip in electrical wiring connections on suspension strut.
– Join electrical connectors.
– Fit wheels ⇒ page 159 .
– Tighten drive shaft nut on wheel hub.
Specified torques
♦ ⇒ “6.3 Removing and installing drive shaft”, page 77
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159

6.3.3 Removing and installing drive shafts (with triple roller joint AAR 3700i + AAR
4100i), vehicles with 6-speed manual gearbox, automatic gearbox and all-
wheel drive

6. Drive shaft 85
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Special tools and workshop

equipment required

♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-
♦ Press tool - VW 408 A-
♦ Press tool - VW 411-
♦ Tube - VW 416 B-
♦ Thrust plate - VW 447 H-

86 Rep. gr.40 - Front suspension

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♦ Snap ring pliers - VW 161 A-

♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-
♦ Clamp tensioner - V.A.G 1682-
♦ Assembly tool - T10065-

♦ Hose clip pliers - V.A.G 1275-

6. Drive shaft 87
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♦ Remover - T10103- , adapter - T10103/1- , bolts for adapter -

T10103/2-

♦ Ball joint puller - T40010-

♦ Locking fluid ⇒ Electronic parts catalogue (ETKA)

♦ Lubricating grease ⇒ Electronic Parts Catalogue “ETKA”
Procedure for both sides:
– Loosen twelve-point nut on wheel hub.

WARNING

When bolt is loosened or tightened, vehicle must be standing

on its wheels.
Danger of accidents.

– Raise vehicle.
– Remove front wheels.
– Lever triple roller joint of drive shaft off gearbox using a tyre
fitting lever .

Note

Do not damage the protective cap on the inner constant velocity

joint.

Removing right drive shaft »only vehicles without all-wheel drive«:

– Remove support bearing ⇒ Item 18 (page 70) .
Continued procedure for both sides:
– Unbolt suspension link from swivel joint.

88 Rep. gr.40 - Front suspension

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– Using ball joint puller - T 40010- , pull suspension link from

swivel joint.

– Press drive shaft out of wheel hub using remover - T 10103-

and adapter - T 10103/1- .

Note

When pressing out drive shaft, ensure that there is sufficient

clearance to all other parts.

– Pull off connector for brake pad wear indicator and speed sen‐
sor.
– Unclip both wires from the retainer on suspension strut and lay
them to side.

– Pull wheel bearing housing outwards and lay an appropriate

wooden block between body and suspension strut.
– Remove drive shaft.

Note

♦ When removing drive shafts, make sure that triple roller star
with rollers is not pulled out of triple roller joint.
♦ If triple roller star with rollers has slipped out, joint protective
boot must be opened and triple roller star with rollers must be
re-inserted in triple roller joint.

Installing
Install in the reverse order of removal, observing the following:

Note

Before installing drive shafts, ensure that the O-rings on both

sides of the gearbox splines are not damaged; renew them if nec‐
essary.

6. Drive shaft 89
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– Replace »old« retaining ring -B- with a »new one« -A-.

– Grease the area between -A- and -B- »abundantly« with lu‐
bricating grease ⇒ Electronics Parts Catalogue “ETKA” .
– Set drive shaft on splines of final drive.

– With a forceful »jolt«, push drive shaft as far as possible in

direction -B- of gearbox.

Note

♦ Ensure that the inner joint has been driven onto the stub shaft
to stop. If necessary, repeat the procedure.
♦ The retaining ring must be »felt« to engage.

Installing right drive shaft »vehicles without all-wheel drive only«:

– Grease the area between -A- and -B- »abundantly« with lu‐
bricating grease ⇒ Electronics Parts Catalogue “ETKA” .
– Set stub shaft on greased splines of final drive.
– Bolt on support bearing ⇒ Item 18 (page 70) .
Continued procedure for both sides of vehicle with »bonded«
drive shafts:

90 Rep. gr.40 - Front suspension

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– Completely remove residual locking fluid from splines of drive

shaft -arrow A- and from contact surface/gap -arrow B- of
wheel hub.
– Apply locking fluid ⇒ Electronic Parts Catalogue (ETKA) »all
around« drive shaft splines.
– Insert drive shaft into wheel hub.
– Tighten twelve-point nut by hand (do not completely tighten).
– Remove wooden block from between body and suspension
strut.
– Insert swivel joint into suspension link and bolt on suspension
link.
– Route wiring harness neatly along suspension strut and re‐
store electrical connections.
– Position front wheels.
– Lower vehicle onto its wheels.
– Tighten front wheels.
– Tighten twelve-point nut.

Note

Tighten twelve-point nut immediately following installation of drive

shaft so that locking fluid does not harden first.

Continued procedure for both sides of vehicle with »unbonded«

drive shafts:
– Insert drive shaft into wheel hub.
– Tighten twelve-point nut by hand (do not completely tighten).
– Remove wooden block from between body and suspension
strut.
– Insert swivel joint into suspension link and bolt on suspension
link.
– Route wiring harness neatly along suspension strut and re‐
store electrical connections.
– Position front wheels.
– Lower vehicle onto its wheels.
– Tighten front wheels.
– Tighten twelve-point nut.
Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159

6.3.4 Removing and installing drive shafts (with triple roller joint AAR 3700i/SX),
vehicles with dual clutch gearbox

6. Drive shaft 91
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Special tools and workshop

equipment required

♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-
♦ Press tool - VW 408 A-
♦ Press tool - VW 411-
♦ Tube - VW 416 B-
♦ Thrust plate - VW 447 H-

92 Rep. gr.40 - Front suspension

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♦ Snap ring pliers - VW 161 A-

♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-
♦ Clamp tensioner - V.A.G 1682-
♦ Assembly tool - T10065-

♦ Remover - T10103- , adapter - T10103/1- , bolts for adapter -

T10103/2-

6. Drive shaft 93
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♦ Ball joint puller - T40010-

♦ Wedge - T10161-

♦ Lubricating grease ⇒ Electronic parts catalogue “ETKA”

Procedure for both sides:
– Loosen twelve-point nut on wheel hub.

WARNING

When bolt is loosened or tightened, vehicle must be standing

on its wheels.
Danger of accidents.

– Raise vehicle.
– Remove front wheels.
– Unscrew nut from swivel joint arrows on suspension link.
– Using ball joint puller - T 40010- , pull suspension link from
tapered seat of swivel joint.
– Pull suspension link down and guide swivel joint out of sus‐
pension link.

94 Rep. gr.40 - Front suspension

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– Mount adapter - T 10103/1- and remover - T 10103- on wheel

hub.
– Press drive shaft out of wheel hub splines using remover - T
10103- .

Note

When pressing out drive shaft, ensure that there is sufficient

clearance to all other parts.

– Pull off connector for brake pad wear indicator and speed sen‐
sor.
– Unclip both wires from the retainer on suspension strut and lay
them to side.

6. Drive shaft 95
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– Pull wheel bearing housing outwards and lay an appropriate

wooden block between body and suspension strut.
– Press drive shaft in -direction of arrow B- and remove external
push rod joint of drive shaft from wheel bearing housing.
Removing right drive shaft »only vehicles without all-wheel drive«:
– Remove support bearing ⇒ Item 17 (page 76) .
– Pull right-hand-side drive shaft out of gearbox splines and re‐
move complete drive shaft.
Continued procedure for left side:
– Lever triple-roller joint of drive shaft off gearbox housing using
wedge - T10161- .
– Pull drive shaft out of gearbox splines and remove complete
drive shaft.

Note

♦ When removing drive shafts, make sure that triple roller star
with rollers is not pulled out of triple roller joint.
♦ If triple roller star with rollers has slipped out, joint protective
boot must be opened and triple roller star with rollers must be
re-inserted in triple roller joint.

Installing
Install in the reverse order of removal, observing the following:
Procedure for both sides:

Note

Before installing drive shafts, ensure that the O-rings on both

sides of the gearbox splines are not damaged. Renew them if
necessary.

Installing left drive shaft:

– Replace »old« retaining ring of drive shaft with a »new one«.

Note

Insert »new« retaining ring directly into groove of drive shaft. It is

not permitted for retaining ring to be pushed over splines. This will
overstretch retaining ring and render it unusable.

– Grease the final drive at the gearbox »abundantly« with lubri‐

cating grease ⇒ Electronic Parts Catalogue“ETKA” .
– Fit drive shaft into splines of final drive.

96 Rep. gr.40 - Front suspension

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– With a forceful »jolt«, push drive shaft as far as possible in

direction -B- of gearbox.

Note

♦ Make sure that inner joint has been inserted as far as stop.
♦ The retaining ring must be »felt« to engage.

Installing right drive shaft »vehicles without all-wheel drive only«:

– Grease the final drive at the gearbox »abundantly« with lubri‐
cating grease ⇒ Electronic Parts Catalogue“ETKA” .
– Insert stub shaft on greased splines of final drive.
– Bolt on support bearing.
Continued procedure for both sides:
– Insert drive shaft into wheel hub.
– Tighten twelve-point nut by hand (do not completely tighten).
– Remove wooden block from between body and suspension
strut.
– Insert swivel joint into suspension link and bolt on suspension
link.
– Route wiring harness neatly along suspension strut and re‐
store electrical connections.
– Position front wheels.
– Lower vehicle onto its wheels.
– Tighten front wheels.
– Tighten twelve-point nut.
Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159

6. Drive shaft 97
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6.4 Repairing drive shaft

⇒ “6.4.1 Repairing drive shaft (with constant velocity joint), vehi‐
cles with 5-speed manual gearbox”, page 98
⇒ “6.4.2 Repairing drive shaft (with constant velocity joint), vehi‐
cles with 6-speed manual gearbox and all-wheel drive”,
page 102
⇒ “6.4.3 Repairing outer CV joint of drive shaft (with triple roller
joint AAR 3700i/SX), vehicles with dual clutch gearbox”,
page 104
⇒ “6.4.4 Dismantling and assembling triple roller joint AAR 3700i/
SX of drive shaft, vehicles with dual clutch gearbox”, page 106
⇒ “6.4.5 Repairing outer CV joint of drive shaft (with triple roller
joint AAR 3700i + AAR 4100i), vehicles with 6-speed manual
gearbox, automatic gearbox and all-wheel drive”, page 108
⇒ “6.4.6 Dismantling and assembling triple roller joint AAR 3700i
+ AAR 4100i of drive shaft, vehicles with 6-speed manual gear‐
box, automatic gearbox and all-wheel drive”, page 109

6.4.1 Repairing drive shaft (with constant ve‐

locity joint), vehicles with 5-speed man‐
ual gearbox
Remove outer constant velocity joint of drive shafts:
– Remove drive shaft ⇒ page 77 .
– Loosen clamp for boot -1- and pull boot back onto drive shaft
-4-.
– Remove remaining grease with a clean cloth.

– Drive outer constant velocity shaft -3- off drive shaft -4- with a
plastic mallet -2-.

Note

♦ The outer constant velocity joint is secured to the drive shaft

with a retaining ring -2-.
♦ Renew the retaining ring every time it is removed -2-.

98 Rep. gr.40 - Front suspension

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Install outer constant velocity joint of drive shafts:

– Push boot -3- onto drive shaft -1-.
– Renew retaining ring -2-.
– Drive clean outer constant velocity joint -4- onto drive shaft
-1- with a plastic mallet until retaining ring engages -2-.
– Inject 70 grammes of lubricating grease ⇒ Electronic parts
catalogue “ETKA” into outer constant velocity joint through the
ball tracks.
– Fill boot of joint with 70 grammes of lubricating grease ⇒
Electronic parts catalogue “ETKA” .
– Install boot professionally.

Tightening large clip on outer constant velocity joint:

– Apply clamp tensioner - V.A.G 1682- as shown in illustration.
Ensure edges of tool lie in corners of ear -B- on clip.
– Tighten clip by turning spindle -A- with a torque wrench - V.A.G
1331- -C-.

Tightening small clip on outer joint:

– Apply clamp tensioner - V.A.G 1682- as shown in illustration.
Ensure edges of tool lie in corners of ear -B- on clip.
– Tighten clip by turning spindle -A- with a torque wrench - V.A.G
1331- -C-.

Note

♦ Due to the hard material of the joint boot and, consequently,

to the use of a stainless steel clamp, it is possible to tension
the clamps only with clamp tensioner - V.A.G 1682- .
♦ The clamp tensioner - V.A.G 1682- must not be twisted or
canted as it is tightened.

6. Drive shaft 99
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Removing inner constant velocity joint of left drive shaft:

– Remove drive shaft ⇒ page 77 .
– Clamp drive shaft in vice with protective jaw covers.
– Using, e.g. a brass or copper drift, drive off the outer protective
cap.

Note

The outer protective cap for the inner constant velocity joint must
be renewed every time it is removed.

– Remove retaining ring ⇒ Item 10 (page 69) .

– Loosen boot clamp and push boot back onto drive shaft.
– Remove grease with a clean cloth.

– Assemble tools as shown in figure.

– Press inner constant velocity joint off drive shaft while sup‐
porting the drive shaft from below.
Installing inner constant velocity joint of left drive shaft:
– Push protective boot onto drive shaft.

– Position tools as shown in figure.

– Press inner constant velocity joint onto drive shaft to stop.

100 Rep. gr.40 - Front suspension

 Transporter 2004 ➤ , Transporter 2010 ➤
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– Fit a »new« retaining ring.

– Check that retaining ring is properly seated.
– Fill boot of joint with 60 gm of lubricating grease ⇒ Electronic
Parts Catalogue “ETKA” .
– Install boot professionally.

Tightening clamp on inner constant velocity joint:

– Apply clamp tensioner - V.A.G 1682- as shown in illustration.
Ensure edges of tool lie in corners of ear -B- on clip.
– Tighten clip by turning spindle -A- with a torque wrench - V.A.G
1331- -C-. Tightening torque is 25 Nm.

Note

♦ Due to the hard material of the joint boot and, consequently,

to the use of a stainless steel clamp, it is possible to tension
the clamps only with clamp tensioner - V.A.G 1682- .
♦ The clamp tensioner - V.A.G 1682- must not be twisted or
canted as it is tightened.

– Inject 60 gm of lubricating grease ⇒ Electronic Parts Cata‐

logue “ETKA” into inner constant velocity joint through the ball
track.
– Clean contact surface of inner constant velocity joint for in‐
stallation of protective cap.

– Apply sealant ⇒ Electronic Parts Catalogue (ETKA) to contact

surface -shaded area- of new protective cap as shown
-arrow-.

Note

♦ Apply a continuous bead of sealant measuring 2 - 3 mm in

diameter.
♦ The cap must be positioned very precisely.

– Align the cap precisely to the bolt holes before setting it in po‐
sition because it cannot be turned after it has been driven on.
– Drive protective cap onto drive shaft using a plastic mallet
without damaging the drive shaft.
– Remove any sealant which may be pressed out.
– Install drive shaft ⇒ page 77 .

6. Drive shaft 101

 Transporter 2004 ➤ , Transporter 2010 ➤
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Removing inner constant velocity joint of right drive shaft:

– Remove drive shaft ⇒ page 77 .
– Clamp drive shaft in vice with protective jaw covers.
– Loosen boot clamp and pull boot back onto drive shaft.
– Remove grease with a clean cloth.
– Using retaining ring pliers - VW 161A- , force open retaining
ring -1- as far as possible -2- and hold retaining ring in this
position.
– Remove inner constant velocity joint -4- from drive shaft -3-.
Installing inner constant velocity joint of right drive shaft:
– Installation is carried out in the reverse order of removal.
Observe the following when doing this:
Inject 60 grammes of lubricating grease ⇒ Electronic parts cata‐
logue “ETKA” into inner constant velocity joint through the ball
tracks.
Fill boot of joint with 60 gm of lubricating grease ⇒ Electronic
Parts Catalogue “ETKA” .
Specified torques
♦ ⇒ “6.2 Assembly overview - drive shaft”, page 68
♦ ⇒ “1.1 Fitting wheels”, page 159
♦ ⇒ “2.1 Assembly overview - subframe”, page 10

6.4.2 Repairing drive shaft (with constant ve‐

locity joint), vehicles with 6-speed man‐
ual gearbox and all-wheel drive
Remove outer constant velocity joint of drive shafts:
– Remove drive shaft ⇒ page 77 .
– Loosen clamp for boot -1- and pull boot back onto drive shaft
-4-.
– Remove remaining grease with a clean cloth.

– Drive outer constant velocity shaft -3- off drive shaft -4- with a
plastic mallet -2-.

Note

♦ The outer constant velocity joint is secured to the drive shaft

with a retaining ring -2-.
♦ Renew the retaining ring every time it is removed -2-.

102 Rep. gr.40 - Front suspension

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Install outer constant velocity joint of drive shafts:

– Push boot -3- onto drive shaft -1-.
– Renew retaining ring -2-.
– Drive clean outer constant velocity joint -4- onto drive shaft
-1- with a plastic mallet until retaining ring engages -2-.
– Inject 100 grammes of lubricating grease ⇒ Electronic parts
catalogue “ETKA” into outer constant velocity joint through the
ball tracks.
– Fill boot of joint with 135 grammes of lubricating grease ⇒
Electronic parts catalogue “ETKA” .
– Install boot professionally.

Tightening large clip on outer constant velocity joint:

– Apply clamp tensioner - V.A.G 1682- as shown in illustration.
Ensure edges of tool lie in corners of ear -B- on clip.
– Tighten O-type clip by turning spindle -A- with a torque wrench
- V.A.G 1331- .

Tightening small clip on outer joint:

– Apply clamp tensioner - V.A.G 1682- as shown in illustration.
Ensure edges of tool lie in corners of ear -B- on clip.
– Tighten clip by turning spindle -A- with a torque wrench - V.A.G
1331- -C-.

Note

♦ Due to the hard material of the joint boot and, consequently,

to the use of a stainless steel clamp, it is possible to tension
the clamps only with clamp tensioner - V.A.G 1682- .
♦ The clamp tensioner - V.A.G 1682- must not be twisted or
canted as it is tightened.

6. Drive shaft 103

 Transporter 2004 ➤ , Transporter 2010 ➤
Running gear, axles, steering - Edition 12.2018

Removing inner constant velocity joint of drive shafts:

– Remove drive shaft ⇒ page 77 .
– Clamp drive shaft in vice with protective jaw covers.
– Loosen boot clamp and pull boot back onto drive shaft.
– Remove grease with a clean cloth.
– Using retaining ring pliers - VW 161A- , force open retaining
ring -1- as far as possible -2- and hold retaining ring in this
position.
– Remove inner constant velocity joint -4- from drive shaft -3-.
Installing inner constant velocity joint of right drive shaft:
Install in the reverse order of removal, observing the following:
Observe the following when doing this:
Inject 100 grammes of lubricating grease ⇒ Electronic parts cata‐
logue “ETKA” into inner constant velocity joint through the ball
tracks.
Fill boot of joint with 135 grammes of lubricating grease ⇒ Elec‐
tronic parts catalogue “ETKA” .
Specified torques
♦ ⇒ “6.3 Removing and installing drive shaft”, page 77
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159

6.4.3 Repairing outer CV joint of drive shaft

(with triple roller joint AAR 3700i/SX),
vehicles with dual clutch gearbox

Note

Dismantling and assembling triple roller joint AAR 3700i/SX for

drive shaft ⇒ page 106 .

Remove outer constant velocity joint of drive shafts:

– Remove drive shaft ⇒ page 91 .
– Loosen clamp for boot -1- and pull boot back onto drive shaft
-4-.
– Remove remaining grease with a clean cloth.

104 Rep. gr.40 - Front suspension

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– Drive outer constant velocity shaft -3- off drive shaft -4- with a
plastic mallet -2-.

Note

♦ The outer constant velocity joint is secured to the drive shaft

with a retaining ring -2-.
♦ Renew the retaining ring every time it is removed -2-.

Install outer constant velocity joint of drive shafts:

– Push boot -3- onto drive shaft -1-.
– Renew retaining ring -2-.
– Drive clean outer constant velocity joint -4- onto drive shaft
-1- with a plastic mallet until retaining ring engages -2-.
– Inject 100 grammes of lubricating grease ⇒ Electronic parts
catalogue “ETKA” into outer constant velocity joint through the
ball tracks.
– Fill boot of joint with 140 grammes of lubricating grease ⇒
Electronic parts catalogue “ETKA” .
– Install boot professionally.

Tightening large clip on outer constant velocity joint:

– Apply clamp tensioner - V.A.G 1682- as shown in illustration.
Ensure edges of tool lie in corners of ear -B- on clip.
– Tighten O-type clip by turning spindle -A- with a torque wrench
- V.A.G 1331- .

Tightening small clip on outer joint:

– Apply clamp tensioner - V.A.G 1682- as shown in illustration.
Ensure edges of tool lie in corners of ear -B- on clip.
– Tighten clip by turning spindle -A- with a torque wrench - V.A.G
1331- -C-.

Note

♦ Due to the hard material of the joint boot and, consequently,

to the use of a stainless steel clamp, it is possible to tension
the clamps only with clamp tensioner - V.A.G 1682- .
♦ The clamp tensioner - V.A.G 1682- must not be twisted or
canted as it is tightened.

Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159

6. Drive shaft 105

 Transporter 2004 ➤ , Transporter 2010 ➤
Running gear, axles, steering - Edition 12.2018

6.4.4 Dismantling and assembling triple roller

joint AAR 3700i/SX of drive shaft, vehi‐
cles with dual clutch gearbox
Dismantling
– Remove drive shaft ⇒ page 91 .
– Open both clamps on triple roller joint and push joint protective
boot back.
– Pull joint body off drive shaft.
– Remove retaining ring -1-.
1 - Pliers (commercially available)
- or circlip pliers - VW 161 A-
– Insert drive shaft into assembly tool - T10065- .

– Press drive shaft out of triple roller star.

– Pull boot off shaft.
– Clean shaft, joint body and groove for seal.
Installing
– Push small boot clamp onto shaft.
– Push boot onto shaft.
– Push joint body onto shaft.

Installing triple roller star:

Chamfer on triple roller star faces towards shaft and serves as an
assembly aid.
– Fit triple roller star onto shaft and press on to stop.
– Ensure that pressure does not exceed 3.0 t.
– If necessary, coat splines of drive shafts and triple roller star
with lubricating paste - G 052 142 A2- .
– Insert retaining ring, ensuring that it is seated correctly.
– Press 80 gm of lubricating grease ⇒ Electronic Parts Cata‐
logue “ETKA” into triple roller joint.
– Slide joint body over rollers and hold.
– Press 80 gm of lubricating grease ⇒ Electronic Parts Cata‐
logue “ETKA” into rear of triple roller joint.
– Install boot.

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Groove for detecting that joint protective boot has been installed
correctly:
– Position joint protective boot in groove -arrow B-.
Groove -arrow A- must remain visible.
– Install clamps.

– Tension clamps -arrows- with clamp tensioner - V.A.G 1682- .

Tightening large O-type clip on triple roller joint:

– Apply clamp tensioner - V.A.G 1682- as shown in illustration.
Ensure edges of tool lie in corners of ear -B- on clip.
– Tighten O-type clip by turning spindle -A- with a torque wrench
- V.A.G 1331- .

Tightening small O-type clip on triple roller joint:

– Apply clamp tensioner - V.A.G 1682- as shown in illustration.
Ensure edges of tool lie in corners of ear -B- on clip.
– Tighten clip by turning spindle -A- with a torque wrench - V.A.G
1331- -C-.

Note

♦ Due to the hard material of the joint boot and, consequently,

to the use of a stainless steel clamp, it is possible to tension
the clamps only with clamp tensioner - V.A.G 1682- .
♦ The clamp tensioner - V.A.G 1682- must not be twisted or
canted as it is tightened.

Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159

6. Drive shaft 107

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6.4.5 Repairing outer CV joint of drive shaft

(with triple roller joint AAR 3700i + AAR
4100i), vehicles with 6-speed manual
gearbox, automatic gearbox and all-
wheel drive

Note

Dismantling and assembling triple roller joint AAR 3700i for drive
shaft ⇒ page 109 .

Remove outer constant velocity joint of drive shafts:

– Remove drive shaft ⇒ page 77 .
– Loosen clamp for boot -1- and pull boot back onto drive shaft
-4-.
– Remove remaining grease with a clean cloth.

– Drive outer constant velocity shaft -3- off drive shaft -4- with a
plastic mallet -2-.

Note

♦ The outer constant velocity joint is secured to the drive shaft

with a retaining ring -2-.
♦ Renew the retaining ring every time it is removed -2-.

Install outer constant velocity joint of drive shafts:

– Push boot -3- onto drive shaft -1-.
– Renew retaining ring -2-.
– Drive clean outer constant velocity joint -4- onto drive shaft
-1- with a plastic mallet until retaining ring engages -2-.
– Inject 100 grammes of lubricating grease ⇒ Electronic parts
catalogue “ETKA” into outer constant velocity joint through the
ball tracks.
– Fill boot of joint with 135 grammes of lubricating grease ⇒
Electronic parts catalogue “ETKA” .
– Install boot professionally.

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Tightening large clip on outer constant velocity joint:

– Apply clamp tensioner - V.A.G 1682- as shown in illustration.
Ensure edges of tool lie in corners of ear -B- on clip.
– Tighten O-type clip by turning spindle -A- with a torque wrench
- V.A.G 1331- .

Tightening small clip on outer joint:

– Apply clamp tensioner - V.A.G 1682- as shown in illustration.
Ensure edges of tool lie in corners of ear -B- on clip.
– Tighten clip by turning spindle -A- with a torque wrench - V.A.G
1331- -C-.

Note

♦ Due to the hard material of the joint boot and, consequently,

to the use of a stainless steel clamp, it is possible to tension
the clamps only with clamp tensioner - V.A.G 1682- .
♦ The clamp tensioner - V.A.G 1682- must not be twisted or
canted as it is tightened.

Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159

6.4.6 Dismantling and assembling triple roller

joint AAR 3700i + AAR 4100i of drive
shaft, vehicles with 6-speed manual
gearbox, automatic gearbox and all-
wheel drive
Distinguishing features of triple roller joints AAR 3700i + AAR
4100i
– Measure dimension -A- as shown:
♦ Dimension -A- 92.3 mm = triple roller joint AAR 3700i
♦ Dimension -A- 95.5 mm = triple roller joint AAR 4100i

6. Drive shaft 109

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Dismantling
Instruction for repairing the outer joint can be found here
⇒ page 108 .
– Open both clamps on triple roller joint and push joint protective
boot back.
– Pull joint body off drive shaft.
– Remove retaining ring.
1 - Pliers (commercially available)
- or circlip pliers - VW 161 A-

– Insert drive shaft into assembly tool - T10065- .

– Press drive shaft out of triple roller star.
– Pull boot off shaft.
– Clean shaft, joint body and groove for seal.
Installing
– Push small boot clamp onto shaft.
– Push boot onto shaft.
– Push joint body onto shaft.

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Installing triple roller star:

Chamfer on triple roller star faces towards shaft and serves as an
assembly aid.
– Fit triple roller star onto shaft and press on to stop.
– Ensure that pressure does not exceed 3.0 t.
– If necessary, coat splines of drive shafts and triple roller star
with lubricating paste - G 052 142 A2- .
– Insert retaining ring, ensuring that it is seated correctly.
As of 08.2004, a different grease is used in the triple roller joints.
This grease cannot be mixed with the previous one. The triple
roller joint must therefore be cleaned before greasing during re‐
pair work.
Grease triple roller joint:
Triple roller joint AAR 3700i
– Press 80 gm of lubricating grease ⇒ Electronic Parts Cata‐
logue “ETKA” into triple roller joint.
– Slide joint body over rollers and hold.
– Press 80 gm of lubricating grease ⇒ Electronic Parts Cata‐
logue “ETKA” into rear of triple roller joint.
Triple roller joint AAR 4100i
– Inject 100 gm of lubricating grease ⇒ Electronic Parts Cata‐
logue “ETKA” into triple roller joint.
– Slide joint body over rollers and hold.
– Inject 135 gm of lubricating grease ⇒ Electronic Parts Cata‐
logue “ETKA” into rear of triple roller joint.
Continuation for both triple roller joints:
– Install boot.

Groove for detecting that joint protective boot has been installed
correctly:
– Position joint protective boot in groove -arrow B-.
Groove -arrow A- must remain visible.
– Install clamps.

– Tension clamps -arrows- with hose clip pliers - V.A.G 1275- .

6. Drive shaft 111

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6.5 Removing and installing jointed shaft

support bearing
Special tools and workshop equipment required
♦ Thrust plate - VW 402-

♦ Thrust plate - VW 401-

♦ Support - 40 - 103-

♦ Support - VW 441-

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♦ Thrust piece - VW 442-

♦ Splitter KUKKO 17-2 - VAS 251411-

Pressing off support bearing:

– Remove right drive shaft ⇒ page 67 .
– Separate drive shaft at inner joint ⇒ page 67 .
– Pull protective cover -1- from drive shaft -2- in
-direction of arrow-, if present.

6. Drive shaft 113

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– Fit Splitter KUKKO 17-2 - VAS 251411- between inner joint

and support bearing -2-.
– Fit thrust plate - VW 401- -5- and thrust plate - VW 402- -4-
onto press as shown in illustration.
– Fit drive shaft -2- on thrust plates with splitter KUKKO 17-2 -
VAS 251411- -6-.
– Set thrust piece - VW 442- -1- on upper end of drive shaft
-2-.

Note

Hold drive shaft at inner joint from below because this can other‐
wise fall to the ground.

– Press drive shaft -2- downwards out of support bearing -3-.

– Remove drive shaft from below.
Pressing on support bearing:

– Set thrust plate - VW 401- and thrust plate - VW 402- as shown

on the press.
– Push support bearing -2- onto drive shaft.

Note

Observe installation position of support bearing. Push support

bearing onto drive shaft as shown in figure.

– Push support - 40 - 103- onto drive shaft.

– Set drive shaft wit support bearing -2- and support - 40 - 103-
onto press plates.
– Set support - VW 441- on inner joint -1-.
– Press drive shaft downwards onto support bearing -2- to stop.
– Remove drive shaft from press and check that support bearing
moves freely.
– Press protective cover onto drive shaft, if one was removed.
– Assembling drive shaft ⇒ page 67 .
– Install drive shaft ⇒ page 67 .

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42 – Rear suspension
1 Rear axle
⇒ “1.1 Overview - rear axle”, page 115

1.1 Overview - rear axle

I - Assembly overview - sus‐

pension link ⇒ page 128
II - Assembly overview - wheel
bearing ⇒ page 141
III - Assembly overview - anti-
roll bar ⇒ page 123
IV - Assembly overview - rear
final drive carrier, rear final
drive ⇒ page 117

WARNING

♦ It is not permitted to weld or straighten load-bearing or

wheel-guiding components of the suspension.
♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.

1. Rear axle 115

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Caution

Bonded rubber bushes can be twisted only to a limited extent.

Tighten threaded connections on components with bonded
rubber bushes only if the vehicle is standing on its wheels and
is unladen or if the vehicle is raised and is in the unladen po‐
sition (normal position) ⇒ page 4 .

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2 Subframe
⇒ “2.1 Assembly overview - rear final drive carrier”, page 117
⇒ “2.2 Renewing front bonded rubber bushes in rear final drive
carrier”, page 118
⇒ “2.2.1 Renewing rear bonded rubber bush in rear final drive
carrier”, page 121

2.1 Assembly overview - rear final drive carrier

1 - Rear final drive

❑ Removing and installing
⇒ 6-speed manual
gearbox 0A5 four-wheel
drive; Rep. gr. 39 ; Re‐
moving and installing
rear final drive
2 - Cross member
❑ Fits on rear final drive in
one position only
❑ Removing and installing
⇒ 6-speed manual
gearbox 0A5 four-wheel
drive; Rep. gr. 39 ; Re‐
moving and installing
rear final drive
3 - Bolt
❑ Renew after removal
❑ 90 Nm +90°
4 - Washer
5 - Bolt
❑ Renew after removal
❑ M10 × 105
❑ 50 Nm +180°
6 - Bolt
❑ Renew after removal
❑ 90 Nm +180°
7 - Gearbox carrier
❑ Removing and installing
⇒ 6-speed manual
gearbox 0A5 four-wheel
drive; Rep. gr. 39 ; Re‐
moving and installing
rear final drive
❑ Renewing bonded rubber bush for subframe ⇒ page 118
8 - Bolt
❑ Renew after removal
❑ M12 x 1.5 x 100
❑ 90 Nm +180°
9 - Washer

2. Subframe 117
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2.2 Renewing front bonded rubber bushes in rear final drive carrier

Special tools and workshop

equipment required

♦ Crankshaft seal installing tool - VW 204 B-

♦ Thrust plate - VW 401-
♦ Thrust plate - VW 402-
♦ Press tool - VW 407-
♦ Press tool - VW 412-
♦ Tube - 30 - 14-

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♦ Joint tensioner - 40 - 204 A-

♦ Thrust piece - 2007-
♦ Sleeve - 3144-
♦ Thrust piece - 3236-
♦ Assembly tool - 3253-
♦ Removal wedge - 3409-

♦ Splitter - VAS 6180/2- from assembly device - VAS 6180-

2. Subframe 119
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♦ Two-arm puller KUKKO 20/-10 - VAS 251001-

Removing
– Remove rear final drive with rear final drive carrier ⇒ 6-speed
manual gearbox 0A5 four-wheel drive; Rep. gr. 39 ; Installing
and removing rear final drive .
– Remove final drive carrier from final drive.
– Push thrust plate - VW 401- under edge -B- to stop against
rear final drive carrier.
– Press out bonded rubber bush -C- via puller -A- opposite the
direction of pressing in.
Installing
– Before pressing in, coat rubber bead of bonded rubber bush
with lubricant, e.g. soft soap.

– Position bonded rubber bush with flat surfaces -arrows 1- in

installation position. The lugs -arrow 2- face indirection of trav‐
el -arrow-.
The angle -α- should be 5° ± 3°.

– Set tensioner - 40 - 204 A- on bonded rubber bush -A- so the

lugs ⇒ page 120 will not be damaged.
– Press in the bonded rubber bush to stop.

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– Lever rubber bead of bonded rubber bush -A- out after press‐
ing work is completed.
– Attach rear final drive carrier to rear final drive and install in
vehicle ⇒ 6-speed manual gearbox 0A5, four-wheel drive;
Rep. gr. 39 ; Removing and installing rear final drive .
Specified torques
♦ ⇒ “2.1 Assembly overview - rear final drive carrier”,
page 117

2.2.1 Renewing rear bonded rubber bush in

rear final drive carrier
Removing
– Remove rear final drive with rear final drive carrier ⇒ 6-speed
manual gearbox 0A5 four-wheel drive; Rep. gr. 39 ; Installing
and removing rear final drive .
– Remove final drive carrier from final drive.
– Press out rear bonded rubber bush.

Note

The jaws of the separating device - VAS 6180/2- must make con‐
tact between the collar of the bonded rubber bush and the hole
for the bush in the rear final drive carrier.

Installing
– Before pressing in, coat rubber bead of bonded rubber bush
with lubricant, e.g. soft soap.

– Press in bonded rubber bush -A- to stop.

2. Subframe 121
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– Lever rubber bead of bonded rubber bush -A- out after press‐
ing work is completed.
– Attach rear final drive carrier to rear final drive and install in
vehicle ⇒ 6-speed manual gearbox 0A5, four-wheel drive;
Rep. gr. 39 ; Removing and installing rear final drive .
Specified torques
♦ ⇒ “2.1 Assembly overview - rear final drive carrier”,
page 117

122 Rep. gr.42 - Rear suspension

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3 Anti-roll bar
⇒ “3.1 Assembly overview - anti-roll bar”, page 123
⇒ “3.2 Removing and installing anti-roll bar”, page 123
⇒ “3.3 Renewing anti-roll bar bushes”, page 124

3.1 Assembly overview - anti-roll bar

I - “Upper half of illustration”

1 - Body
2 - Mounting bracket
3 - Bolt
❑ 30 Nm
II - “Lower half of illustration”
1 - Suspension link
2 - Mounting bracket
3 - Anti-roll bar
4 - Rubber mounting
❑ Inner for anti-roll bar
❑ Removing and installing
⇒ page 126
5 - Clip
6 - Bolt
❑ 60 Nm
7 - Rubber mounting
❑ Outer for anti-roll bar
❑ Removing and installing
⇒ page 124
8 - Clip
9 - Bolt
❑ 30 Nm

3.2 Removing and installing anti-roll bar

Special tools and workshop equipment required

3. Anti-roll bar 123

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Removing

Caution

Bonded rubber bushes can be twisted only to a limited extent.

Tighten threaded connections on components with bonded
rubber bushes only if the vehicle is standing on its wheels and
is unladen or if the vehicle is raised and is in the unladen po‐
sition (normal position) ⇒ page 4 .

– Raise vehicle.
– Remove rear wheels.
– Unscrew clamps on the left and the right on the outside.
– Unscrew clamps in the middle on the left and right-hand sides,
holding the anti-roll bar while doing so.
– Remove anti-roll bar.
Installing
Install in the reverse order of removal, observing the following:
Specified torques
♦ ⇒ “3.1 Assembly overview - anti-roll bar”, page 123
♦ ⇒ “1.1 Fitting wheels”, page 159

3.3 Renewing anti-roll bar bushes

⇒ “3.3.1 Renewing anti-roll bar bushes, outer”, page 124
⇒ “3.3.2 Renewing anti-roll bar bushes, inner”, page 126

3.3.1 Renewing anti-roll bar bushes, outer

Special tools and workshop equipment required

124 Rep. gr.42 - Rear suspension

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♦ Torque wrench - V.A.G 1331-

Removing
– Raise vehicle ⇒ Maintenance ; Booklet 20.1 ; Description of
work; Raising vehicle with lifting platform and trolley jack .
– Unscrew bolts -arrows- on both sides.
– Remove clamp -1-.
– Turn anti-roll bar downwards.

– Pull off bush -1- in direction of -arrow- from anti-roll bar -2-.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:

– Coat bush -1- on inside with soap solution and push onto anti-
roll bar -2-.
– Push on bush, ensuring that gap -a- is adhered to.
a = 6 ± 2 mm

Note

The flat side of the bush must point towards the suspension link.

3. Anti-roll bar 125

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– Turn anti-roll bar upwards and fit clamp -1-.

– Tighten bolts -arrows- on both sides.
Specified torques
♦ ⇒ “3.1 Assembly overview - anti-roll bar”, page 123

3.3.2 Renewing anti-roll bar bushes, inner

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

Removing
– Raise vehicle ⇒ Maintenance ; Booklet 20.1 ; Description of
work; Raising vehicle with lifting platform and trolley jack .
– Unscrew bolts -arrows- on both sides.
– Remove clamp -1-.

– Open bush -1- in direction of -arrows- and pull off from anti-roll
bar -2-.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:

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– Place bush -1- on anti-roll bar -2-.

– Install bush, ensuring that gap -a- is adhered to.
a = 1050 ± 3 mm

– Fit clamp -1-.

– Tighten bolts -arrows- on both sides.
Specified torques
♦ ⇒ “3.1 Assembly overview - anti-roll bar”, page 123

3. Anti-roll bar 127

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4 Suspension link, track rod

⇒ “4.1 Assembly overview - suspension link”, page 128
⇒ “4.2 Renewing bonded rubber bush for suspension link”,
page 129

4.1 Assembly overview - suspension link

1 - Suspension link
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
2 - Bolt
❑ Renew after removal
3 - Nut
❑ Renew after removal
❑ 120 Nm +180°
4 - Outer bonded rubber bush‐
ing
❑ Pressing out and in
⇒ page 129
5 - Bolt
❑ Renew after removal
6 - Eccentric bolt
❑ Renew after removal
7 - Inner bonded rubber bush
❑ Pressing out and in
⇒ page 129
8 - Eccentric washer
9 - Nut
❑ Renew after removal
❑ 100 Nm +180°
10 - Lower damping ring
11 - Coil spring
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Install coil spring so that
the colour mark on the
coil spring faces down‐
wards
12 - Upper damping ring
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
13 - Bolt
❑ Renew after removal
❑ 80 Nm +90°
14 - Damper
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
15 - Nut
❑ Renew after removal
❑ 120 Nm +180°

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4.2 Renewing bonded rubber bush for sus‐

pension link

Note

♦ The contact surfaces of waxed parts must be cleaned before

the parts are installed. Contact surfaces must be free of wax
and grease.
♦ Load-bearing components and other suspension parts must
not be welded or straightened.
♦ Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing.
♦ Bonded rubber bushes can be twisted only to a limited extent.
♦ Tighten axle components with bonded rubber bushes only if
the vehicle is standing on its wheels and is unladen or if the
vehicle is raised and is in the unladen position ⇒ page 4 .

Special tools and workshop

equipment required

♦ Workshop press - V.A.G 1290/A-

♦ Thrust ring - VW 429-

4. Suspension link, track rod 129

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♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-
♦ Tube - 3110-
♦ Drift sleeve - V.A.G 40-21-

♦ Press tool - VW 407-

♦ Press tool - VW 412-
♦ Thrust piece - VW 459/2-
♦ Tube - 2039-
♦ Removal wedge - 3409-

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Pressing out

Note

♦ The bonded rubber bushes cannot be removed from the suspension link without damage.
♦ Bonded rubber bush -1- is pressed out in -direction of arrow A- and bonded rubber bush -2- in
-direction of arrow B-.
♦ Bonded rubber bushes -1- and -2- are different. The removal of outer bonded rubber bush -2- is described
below. The procedure for the inner bonded rubber bush -1- is identical.

– Remove rear suspension link.

– Using a chisel , bend up metal collar of bonded rubber bush
-3- all around.
– Applying a hack saw -4- in resulting gap, cut off metal collar
-5- flush with suspension link.
– Remove metal shoulder -5- from bonded rubber bush.
This preparatory work is necessary so that the bonded rubber
bush -2- can be pressed out in the -direction of arrow B-.

4. Suspension link, track rod 131

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Note

Do not damage the suspension link when chiselling or sawing.

– Assemble tools as shown in figure.

– Press bonded rubber bush out of suspension link.
Pressing in

Note

The installation of outer bonded rubber bush -2- is described below. The procedure for the inner bonded rubber
bush is identical.

• Before pressing in, coat the lower large rubber bead -4- of
bonded rubber bush -2- with tyre-fitting paste.

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– Assemble tools as shown in figure.

Note

Ensure that the marking -3- of bonded rubber bush -2- aligns exactly with marking -3- of suspension link -1-.

– Using workshop press - V.A.G 1290/A- , apply light pressure

to bonded rubber bush -2- and maintain pressure.
– Press rubber bead -4- into suspension link using removal
wedge - 3409- .

Note

Make sure that rubber bead -4- of bonded rubber bush -2- is correctly pushed into suspension link -1-. This
prevents rubber bead being damaged (shearing off) when pressing in.

– Press bonded rubber bush -2- into suspension link -1- to stop.

4. Suspension link, track rod 133

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Pressing bonded rubber bush further:

Note

Continued pressing is necessary to press the rubber bead -3- out of the suspension link -1-.

– Assemble tools as shown in figure.

– Centre thrust rod - VW 407- -arrow- on bonded rubber bush
-2-.
– Press with light pressure until rubber bead -3- can be »heard«
to pop out of suspension link -1-.

Note

♦ To avoid damage to the bonded rubber bush -2-, stop pressing as soon as the rubber bead -3- has popped
out.
♦ Check that rubber bead -3- is properly seated.

– Fit suspension link.

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Specified torques
♦ ⇒ “4.1 Assembly overview - suspension link”, page 128
♦ ⇒ “1.1 Fitting wheels”, page 159

4. Suspension link, track rod 135

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5 Suspension strut, shock absorber,

spring
⇒ “5.1 Assembly overview - suspension strut, shock absorber,
spring”, page 136
⇒ “5.2 Removing and installing shock absorbers”, page 136
⇒ “5.3 Removing and installing spring”, page 139

5.1 Assembly overview - suspension strut, shock absorber, spring

1 - Buffer stop
2 - Upper damping ring
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
3 - Spring
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Install coil spring so that
the colour mark on the
coil spring faces down‐
wards
❑ Removing and installing
⇒ page 139
4 - Lower damping ring
5 - Suspension link
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
6 - Bolt
❑ Renew after removal
❑ 80 Nm +90°
7 - Shock absorbers
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing
⇒ page 136
8 - Nut
❑ Renew after removal
❑ 120 Nm +180°
9 - Bolt
❑ Renew after removal

5.2 Removing and installing shock absorb‐

ers
Special tools and workshop equipment required

136 Rep. gr.42 - Rear suspension

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♦ Tensioning straps - T10038-

♦ Support - T10149-

♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use

engine and gearbox jack - VAS 6931-

Removing
– Loosen wheel bolts.
– Raise vehicle ⇒ Maintenance ; Booklet 20.1 ; Description of
work; Raising vehicle with lifting platform and trolley jack .
– Remove wheel.
– Secure vehicle to support arms of lifting platform on both sides
using tensioning straps - T10038- .
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- with a wheel bolt.

5. Suspension strut, shock absorber, spring 137

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– Preload suspension link slightly using engine and gearbox

jack - V.A.G 1383 A- or engine and gearbox jack - VAS 6931- .

Vehicles with adaptive chassis control DCC

– Disconnect connector -1- on shock absorber -2-.
– Pull line off shock absorber -2- -arrow-.

Note

If there is moisture in the area of the connector, blow compressed

air on the contacts on the shock absorber and the connector.

Continued for all vehicles

– Unscrew nut -arrow-.

– Pull bolt -1- out of shock absorber -2-.

– Unscrew upper bolt -arrow- of shock absorber.

– Remove shock absorber -1-.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
– Lower suspension link.

138 Rep. gr.42 - Rear suspension

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Vehicles with adaptive chassis control DCC

– Clip line into shock absorber -12- -arrow-.
– Connect electrical connector -1- to shock absorber -2-, and
engage it audibly.
Continued for all vehicles
– Pull out engine and gearbox jack - V.A.G 1383 A- or engine
and gearbox jack - VAS 6931- from underneath the vehicle.
– Remove support - T10149- .
Specified torques
♦ ⇒ “5.1 Assembly overview - suspension strut, shock absorber,
spring”, page 136
♦ ⇒ “1.1 Fitting wheels”, page 159

5.3 Removing and installing spring

Special tools and workshop equipment required
♦ Tensioning straps - T10038-

♦ Support - T10149-

♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use

engine and gearbox jack - VAS 6931-

5. Suspension strut, shock absorber, spring 139

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Removing

Note

Observe TPI service information 2038589/3 if replacing rear axle

springs.

– Loosen wheel bolts.

– Raise vehicle ⇒ Maintenance ; Booklet 20.1 ; Description of
work; Raising vehicle with lifting platform and trolley jack .
– Remove wheel.
– Secure vehicle to support arms of lifting platform on both sides
using tensioning straps - T10038- .
– On vehicle with all-wheel drive, remove respective drive shaft
⇒ page 149 .
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- with a wheel bolt.
– Unscrew outer left clamp and outer right clamp for anti-roll bar
on suspension links.
– Preload suspension link slightly using engine and gearbox
jack - V.A.G 1383 A- or engine and gearbox jack - VAS 6931- .

– Unscrew nut -arrow-.

– Pull bolt -1- out of shock absorber -2-.
– Lower suspension link.
– Remove spring.
Installing
Install in the reverse order of removal, observing the following:

Note

Observe TPI service information 2038589/3 if replacing rear axle

springs.

Specified torques
♦ ⇒ “5.1 Assembly overview - suspension strut, shock absorber,
spring”, page 136
♦ ⇒ “1.1 Fitting wheels”, page 159

140 Rep. gr.42 - Rear suspension

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6 Wheel bearing assembly, trailing arm

⇒ “6.1 Assembly overview - wheel bearing”, page 141
⇒ “6.2 Removing and installing wheel bearing unit”, page 142

6.1 Assembly overview - wheel bearing

1 - Drive shaft
❑ For vehicles with all-
wheel drive
2 - Bolt
❑ 8 Nm
3 - Speed sensor
4 - Suspension link
5 - Cover plate
❑ For vehicles with inte‐
grated drum brakes
6 - Bolt
❑ 20 Nm
❑ For vehicles with inte‐
grated drum brakes
7 - Bolt
❑ 8 Nm
❑ For vehicles with inte‐
grated drum brakes
8 - Cover plate
9 - Bolt
❑ 10 Nm
10 - Wheel bearing
❑ Renew after removal
❑ Removing and installing
⇒ page 142
11 - Brake disc/drum
❑ For vehicles with inte‐
grated drum brakes
12 - Brake disc
13 - Fitted bolt
❑ 15 Nm
14 - Twelve-point nut
❑ Renew after removal
❑ For vehicles with all-wheel drive
❑ Initially tighten to 200 Nm and then slacken off 180°
❑ Final torque setting: 200 Nm
15 - Cap
❑ For vehicles with front-wheel drive
16 - Bolt
❑ Renew after removal
❑ For vehicles with all-wheel drive

6. Wheel bearing assembly, trailing arm 141

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❑ 30 Nm +90°
17 - Support
❑ For vehicles with all-wheel drive

6.2 Removing and installing wheel bearing

unit

Note

The wheel bearings must always be renewed after removal.

Caution

♦ Always ensure proper seating of tools and components

(wheel bearing and hub) throughout the entire procedure.

WARNING

♦ Place engine and gearbox jack - V.A.G 1383 A- or engine

and gearbox jack - VAS 6931- below wheel bearing hous‐
ing throughout the entire process (to prevent accidents
caused by falling parts).

142 Rep. gr.42 - Rear suspension

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Special tools and workshop

equipment required

♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use

engine and gearbox jack - VAS 6931-
♦ Hydraulic cylinder - VAS 6178-
♦ Foot pump - VAS 6179-
♦ Assembly tool - T10205-

♦ Pressure gauge with connection line - VAS 6179/1-

– Remove wheel.

6. Wheel bearing assembly, trailing arm 143

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– Vehicles with front-wheel drive: remove cap

⇒ Item 15 (page 141) .
Vehicles with all-wheel drive
– Remove drive shaft ⇒ page 147 .
Continued for all vehicles:
– Remove brake caliper with brake carrier, and secure it to body
using wire ⇒ Brakes - mechanism; Rep. gr. 46 ; Removing
and installing brake caliper .
– Remove brake disc.
Vehicles with integrated drum brakes
– Remove brake disc ⇒ Brakes - mechanism; Rep. gr. 46 ;
Removing and installing brake shoes .
Continued for all vehicles:
– Remove ABS speed sensor ⇒ Anti-lock brake system; Rep.
gr. 45 ; Sensors; Removing and installing speed sensor on
rear axle .
– Centre gripping pieces - T10205/12- »behind« wheel hub -1-
using wheel bolts-2-.
The wheel bolts -2- must not protrude from backs of gripping
pieces - T10205/12- .

– Fit tools as shown in illustration.

1- Threaded rod M20 - T10205/8-1-
2- Nut M20 - T10205/8-2-
3- Thrust head - T10205/13-
4- Hydraulic cylinder - VAS 6178-
5- Bell - T10205/2-
6- Gripping pieces - T10205/12-
7- Threaded rod M20 - T10205/8-1-
8- Nut M20 - T10205/8-2-
9- Press tool - T10205/3-

144 Rep. gr.42 - Rear suspension

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– Turn bell - T10205/2 - until bridge -1- is in the position shown.

– Turn hub until wheel bolts -arrows- are in the position shown.
– Hold appliance firmly and pull out wheel hub with wheel bear‐
ing.
Installing

Note

♦ The wheel bearings must always be renewed after removal.

♦ The gripping pieces - T10205/11- should prevent the retaining
ring from slipping down the wheel bearing during the pressing
in sequence

– Centre gripping pieces - T10205/11- »behind« wheel hub -1-

using wheel bolts-2-.

Note

♦ Vehicles from model years 2003 - 2006 may be equipped with

integrated drum brakes. ⇒ Electronic parts catalogue “ETKA”
♦ In the case of vehicles with this brake system, the wheel bear‐
ing cannot be fully pressed in with the usual gripping pieces.
♦ If no modified gripping pieces are available, a recess in one of
the gripping pieces must be cut out.

– To do this, clamp the gripping piece -arrow- in a vice.

– Use an angle grinder -1-, e.g. -VAS 5167A- , with a 115-125
disc to cut out the recess -arrow- in the gripping piece.
Width -a- of the recess is 20 mm. Depth -c- is 3 mm.

The radius is 57.5 mm and is achieved if grinding wheels of size

115 or 125 are used.

WARNING

♦ Danger due to workpieces that have not been secured or

clamped.
♦ Danger due to tipping of the cutting and grinding wheel
and surging up of the machine or breakage of the cutting
and grinding wheel.
♦ Danger if machines are put down when still switched on
or if the cutting and grinding wheel is still turning.
♦ Always hold the machine with both hands when grinding/
cutting.
♦ Only carry out grinding work in suitable rooms or use fire-
proof partition walls.
♦ Always wear protective goggles.
♦ Use ear muffs.
♦ Use respiratory equipment if a lot of dust is produced.

6. Wheel bearing assembly, trailing arm 145

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Note

The guide - T10205/16- must always be installed with the recess

facing towards the wheel bearing.

– Fit tools as shown in illustration.

1- Threaded rod M20 - T10205/8-1-
2- Nut M20 - T10205/8-2-
3- Thrust head - T10205/13-
4- Hydraulic cylinder - VAS 6178-
5- Bell - T10205/2-
6- Gripping pieces - T10205/11-
7- Threaded rod M20 - T10205/8-1-
8- Nut M20 - T10205/8-2-
9- Guide - T10205/16-
– Connect pressure gauge with connection line - VAS 6179/1-
between hydraulic press - VAS 6178- and hydraulic line for
foot pump - VAS 6179- .
The pressures described below apply to the hydraulic press -
VAS 6178- only.
When pressing in, the pressure reading taken shortly before the
end of pressing must be between 90 and 140 bar.
The maximum pressure must not exceed 310 bar.
– Press in wheel bearing until circlip engages audibly.
Ensure the wheel bearing does not cant when pressing in.
Install in the reverse order of removal, observing the following:
Specified torques
♦ ⇒ “7.1 Assembly overview - drive shaft”, page 147
♦ ⇒ “1.1 Fitting wheels”, page 159

146 Rep. gr.42 - Rear suspension

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7 Drive shaft
⇒ “7.1 Assembly overview - drive shaft”, page 147
⇒ “7.2 Removing and installing drive shaft”, page 149
⇒ “7.3 Repairing inner constant velocity joint”, page 152
⇒ “7.4 Renewing boot on outer joint”, page 155
⇒ “7.5 Checking inner constant velocity joint”, page 156

7.1 Assembly overview - drive shaft

Assembly overview - drive shaft with constant velocity joint

1 - Drive shaft
❑ Removing and installing
⇒ page 147
2 - Twelve-point nut
❑ Renew after removal
❑ Initially tighten to
200 Nm and then slack‐
en off 180°
❑ Final torque setting:
200 Nm
3 - Outer constant velocity joint
with drive shaft
❑ Renew only as com‐
plete unit
❑ If boot on outer joint has
to be renewed, inner
constant velocity joint
must first be removed
from drive shaft.
4 - Clip
❑ Renew after removal
❑ Tightening ⇒ page 155
❑ 25 Nm
5 - Boot
❑ Check for splits and
chafing, renew if neces‐
sary
❑ Renewing ⇒ page 155
6 - Clip
❑ Renew after removal
❑ Tightening ⇒ page 155
❑ 25 Nm
7 - Cap
❑ Using a drift, carefully drive from inner constant velocity joint.
❑ Renew after removal
❑ Before attaching to constant velocity joint, coat sealing surface with sealant - D 454 300 A2-
⇒ page 152 .
❑ Align cover with bolt holes
8 - Retaining ring
❑ Renew after removal

7. Drive shaft 147

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9 - Inner constant velocity joint

❑ Renew only as complete unit
❑ Checking ⇒ page 156
❑ Pressing off ⇒ page 152
❑ Pressing on ⇒ page 152
❑ Lubricating ⇒ page 148 .
❑ Adhesive surfaces must be free of oil and grease
10 - Cap
❑ Drive off carefully with drift
❑ Renew after removal
❑ Check inner constant velocity joint if boot is damaged ⇒ page 156
❑ Before attaching to constant velocity joint, coat sealing surface with sealant - D 454 300 A2-
⇒ page 152 .
❑ Align with bolt holes.
❑ Adhesive surfaces must be free of oil and grease
11 - Clip
❑ Renew after removal
❑ Tightening ⇒ page 155
❑ 25 Nm
12 - Boot
❑ Check for splits and chafing, renew if necessary
❑ Renewing ⇒ page 152
13 - Clip
❑ Renew after removal
❑ Tightening ⇒ page 155
❑ 25 Nm
14 - Bolt
❑ Renew after removal
Initial tightening torque: 10 Nm

30 Nm +90°

15 - Locking plate

Grease quantities and types

Regrease joint when renewing boot.
Filling joints with high-temperature grease ⇒ Electronic Parts
Catalogue “ETKA” .
Outer side Grease quan‐ of which in:
tity
[mm] [g] [g] [g]
Outer joint Total quantity Joint Boot
97 80 40 40
Inner joint
104 80 40 40

148 Rep. gr.42 - Rear suspension

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7.2 Removing and installing drive shaft

⇒ “7.2.1 Removing and installing left drive shaft”, page 149
⇒ “7.2.2 Removing and installing right drive shaft”, page 150

7.2.1 Removing and installing left drive shaft

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1576-

♦ Torque angle wrench - V.A.G 1756-

Caution

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.

Removing
– Loosen twelve-point nut 90°.

WARNING

When bolt is loosened or tightened, vehicle must be standing

on its wheels.
Danger of accidents.

– Raise vehicle.
– Remove wheel.
– Remove twelve-point nut.
– Unbolt drive shaft from rear final drive.
– Pull drive shaft out of wheel bearing housing.

7. Drive shaft 149

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Installing
Install in the reverse order of removal, observing the following:
Remove any paint residues and/or corrosion on thread and
splines of outer joint.
– Insert drive shaft and push into wheel hub as far as possible.
– Draw in outer joint with new twelve-point nut as far as stop.
– Secure drive shaft to rear final drive.
– Lower vehicle until the wheel touches the ground.
– Tighten new 12-point nut.

WARNING

When bolt is loosened or tightened, vehicle must be standing

on its wheels.
Danger of accidents.

– Mount wheel.
Specified torques
♦ ⇒ “1.1 Fitting wheels”, page 159
♦ ⇒ “7.1 Assembly overview - drive shaft”, page 147

7.2.2 Removing and installing right drive shaft

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1576-

♦ Torque angle wrench - V.A.G 1756-

150 Rep. gr.42 - Rear suspension

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Caution

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.

Removing
– Loosen twelve-point nut 90°.

WARNING

When bolt is loosened or tightened, vehicle must be standing

on its wheels.
Danger of accidents.

– Raise vehicle.
– Remove wheel.
– Screw in all 5 wheel bolts hand-tight again.
– Remove twelve-point nut.
– Unbolt drive shaft from rear final drive.
– Lower rear final drive carrier with rear final drive ⇒ 6-speed
manual gearbox 0A5 four-wheel drive; Rep. gr. 39 ; Installing
and removing rear final drive .
– Push drive shaft, via rear final drive, towards centre.
– Pull drive shaft out down towards rear.
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
Remove any paint residues and/or corrosion on thread and
splines of outer joint.
– Insert drive shaft and push into wheel hub as far as possible.
– Draw in outer joint with new twelve-point nut as far as stop.
– Install rear final drive carrier with rear final drive ⇒ 6-speed
manual gearbox 0A5 four-wheel drive; Rep. gr. 39 ; Installing
and removing rear final drive .
– Secure drive shaft to rear final drive.
– Lower vehicle until the wheel touches the ground.
– Tighten new 12-point nut.

WARNING

When bolt is loosened or tightened, vehicle must be standing

on its wheels.
Danger of accidents.

Specified torques
♦ ⇒ “1.1 Fitting wheels”, page 159
♦ ⇒ “7.1 Assembly overview - drive shaft”, page 147

7. Drive shaft 151

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♦ ⇒ “2.1 Assembly overview - rear final drive carrier”,

page 117

7.3 Repairing inner constant velocity joint

Removing inner constant velocity joint:
– Clamp drive shaft in vice using jaw protectors.
– Drive off sealing cover using a brass or copper drift.
– Use brass or copper drift to drive off cap of boot.

Note

Do not open O-type clip.

– Remove circlip.

– Press off inner constant velocity joint.

– Open small O-type clip on drive shaft and pull boot off drive
shaft.

Note

Always renew cap for boot.

Installing inner constant velocity joint.

152 Rep. gr.42 - Rear suspension

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– Apply sealant ⇒ Electronic Parts Catalogue (ETKA) to

-hatched area- of clean surface of inner side of cap for con‐
stant velocity joint boot. Apply continuous bead of sealant (2
… 3 mm in diameter), passing holes on inner side -arrow-.
– Push boot with new cap and small O-type clip onto drive shaft.
Drive shaft, boot and contact surface of cap must be free from
grease!

– Press joint on to stop.

Chamfer on internal circumference of ball hub (splines) must face
contact shoulder on drive shaft.

– Insert a new retaining ring.

– Check seating of retaining ring.
– Before installing cap, pack boot with 40 grammes of drive shaft
grease.

Note

Take care not to damage sealant bead.

– Align cap and bolts -arrows- with bolt holes.

The alignment must be very accurate, because no further align‐
ment is possible once the part has been hammered on.
– Drive on cap using a plastic head hammer.
– Remove sealant which has been pressed out.
– Apply 40 grammes of drive shaft grease to constant velocity
joint through ball tracks.
– Clean contact surface for sealing cover.

7. Drive shaft 153

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– Apply sealant ⇒ Electronic Parts Catalogue (ETKA) to

-hatched area- of clean surface of inner side of cap for con‐
stant velocity joint boot. Apply continuous bead of sealant (2
… 3 mm in diameter), passing holes on inner side -arrow-.
– Align new sealing cover with bolt holes.
The alignment must be very accurate, because no further align‐
ment is possible once the cover has been pressed on.

– Press on sealing cover -A-.

– Remove sealant which has been pressed out.

– Position joint protective boot in outer groove -arrow 2-. Inner

groove -arrow 1- must remain visible.

154 Rep. gr.42 - Rear suspension

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Fit and tighten clip on inner joint.

– Apply clamp tensioner - V.A.G 1682- as shown in figure. En‐
sure jaws of tensioner lie in corners -arrows B- of ears on O-
type clip.
– Tighten O-type clip by turning spindle -A- with a torque wrench
-C- (do not cant pliers).

Note

♦ Due to the hard material of the protective bellows (compared

to rubber) and the necessity of using a stainless steel clip, it is
only possible to tension the clip with clamp tensioner -
V.A.G 1682- .
♦ Use torque wrench with 5…50 Nm range (e.g. torque wrench
- V.A.G 1331- ).
♦ Ensure that the spindle thread -A- moves smoothly. Lubricate
with MOS2 grease if necessary.
♦ If the thread is tight (e.g. due to dirt), the required clamping
force for the stainless steel clamp will not be attained despite
the specified tightening torque being applied.

Specified torques
♦ ⇒ “1.1 Fitting wheels”, page 159
♦ ⇒ “7.1 Assembly overview - drive shaft”, page 147

7.4 Renewing boot on outer joint

– Remove complete inner joint from drive shaft ⇒ page 152 .
– Open both hose clips and pull off joint boot from outer joint.
– Push new joint boot onto drive shaft.
– Pack 40 grammes of drive shaft grease into joint (boot side).
– Slide boot onto outer joint.
– Make sure boot is properly positioned on outer joint.
– Position joint protective boot on drive shaft in outer groove
-arrow 2-. Inner groove -arrow 1- must remain visible.

7. Drive shaft 155

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Fit clamp and tighten on outer joint.

– Apply clamp tensioner - V.A.G 1682- as shown in figure. En‐
sure jaws of tensioner lie in corners -arrows B- of ears on
stainless steel O-type clip.
– Tighten stainless steel O-type clip by turning spindle -A- with
a torque wrench (do not cant pliers).

Note

♦ Due to the hard material of the protective bellows (compared

to rubber) and the necessity of using a stainless steel clip, it is
only possible to tension the clip with clamp tensioner -
V.A.G 1682- .
♦ Use torque wrench with 5…50 Nm range (e.g. torque wrench
- V.A.G 1331- ).
♦ Ensure that the spindle thread -A- moves smoothly. Lubricate
with MOS2 grease if necessary.
♦ If the thread is tight (e.g. due to dirt), the required clamping
force for the stainless steel clamp will not be attained despite
the specified tightening torque being applied.

Specified torques
♦ ⇒ “1.1 Fitting wheels”, page 159
♦ ⇒ “7.1 Assembly overview - drive shaft”, page 147

7.5 Checking inner constant velocity joint

Joint must be dismantled to renew grease if heavily soiled. Con‐
tact surfaces and balls are to be examined for wear and damage.
Dismantling

Note

Ball hub and joint part are matched and must be marked before
dismantling. Do not interchange race allocation.

– Swing ball hub and ball cage.

– Press out joint body in direction of arrow.
– Press balls out of cage.

156 Rep. gr.42 - Rear suspension

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– Tip ball hub out of ball cage via ball track -arrows-.
– Check joint body, ball hub, ball cage and balls for pitting and
traces of seizing.

Note

Excessive circumferential backlash in the joint is noticeable dur‐

ing load change jolts. In this case the joint must be replaced.
Smoothing and traces of wear of the balls are no reason to renew
the joint.

Installing

– Insert hub into cage via the two chamfers. The hub can be
installed in any position. Press balls into cage.
– Insert hub with cage and balls at a right angle to joint body.

♦ When inserting, ensure that the wide spacing -a- on the joint
body is aligned with the narrow spacing -b- on the hub after it
is swung in.
♦ Chamfer on internal diameter of ball hub (splines) must face
drive shaft.

– Swivel the hub into the joint body; at the same time the hub
must be swivelled out of the cage -arrows- far enough to allow
the balls to fit into the ball tracks.

7. Drive shaft 157

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– Swivel in hub with balls by applying firm pressure to cage

-arrow-.
Checking function of constant velocity joint:
The constant velocity joint is correctly assembled if the ball hub
can be moved by hand backwards and forwards over its entire
range of axial movement.
– Pack required amount of grease into joint body.
Grease quantity and type ⇒ page 148

158 Rep. gr.42 - Rear suspension

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44 – Wheels, tyres, vehicle geometry

1 Wheels, tyres
⇒ “1.1 Fitting wheels”, page 159
⇒ “1.2 Removing tyre from wheel”, page 159
⇒ “1.3 Fitting tyres”, page 160
⇒ “1.4 Tyre sealant”, page 160
⇒ “1.5 Tyre sealant disposal”, page 161
⇒ “1.6 Models with breakdown set”, page 161
⇒ “1.7 Protecting wheel centring seat against corrosion”,
page 163

1.1 Fitting wheels

– Before fitting wheel, protect wheel centring seat against cor‐
rosion ⇒ page 163 .
1- When fitting the wheel, pull in all wheel bolts uniformly by
hand.
2- Tighten bolts diagonally and evenly.
3- Lower vehicle onto the floor and tighten all wheel bolts in
diagonal sequence to specified torque, using torque
wrench.

WARNING

Do not use an impact screwdriver to screw in the bolts.

Observe notes for revised wheel bolts ⇒ Wheels and Tyres Guide
- General information; Rep. gr. 44 ; Useful information about
wheels/tyres (Commercial vehicles); Fitting wheels .
Specified torques
Component Specified torque
Wheel bolt to wheel hub 180 Nm

1.2 Removing tyre from wheel

Tyres which have been filled or sealed using tyre sealant must be
drained before removal.

WARNING

♦ Do not allow tyre sealant to come into contact with eyes

or skin!
♦ It is damaging to health and can cause eye irritation and
allergies.
♦ During assembly work, wear protective gloves and gog‐
gles.

– Place wheel on a flat surface.

– Remove valve core of tyre valve.

1. Wheels, tyres 159

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– Use a suitable drill or mill to carefully drill a hole in shoulder

area of tyre.
– Hold wheel over a suitable container and drain sealant.
– Remove tyre from wheel rim.
– Clean wheel rim with, for example, a moist cloth.

1.3 Fitting tyres

New rims have also been introduced with the launch of the Trans‐
porter.
The tyre fitting unit must be fitted with the tyre fitting head de‐
signed for these rims.

WARNING

Otherwise, there is a risk of damaging the rim.

If the tyre fitting unit has not yet been modified, please contact the
manufacture of the unit.

Note

Ensure that the wheel rim is clean.

– Using valve insertion tool , insert a new tyre valve moistened

with lubricant into rim.
– Remove valve insert using valve screwdriver .
– Fit tyre to rim using tyre fitting machine - VAS 6359- .
– Inflate tyre with compressed air to about 3-4 bar. The bead of
the tyre must slip audibly over the hump of the rim.

WARNING

Danger of accident!
♦ When inflating the tyre, be careful not to reach between
tyre and wheel flange.
♦ Be sure to release excess pressure from tyre before in‐
stalling valve insert.

– Reinstall valve insert using valve screwdriver .

– Inflate tyre to specified tyre pressure.
– Balance wheel.

1.4 Tyre sealant

The tyre sealant in the bottle has a limited shelf life.
The bottle therefore has an expiry date -arrow-.

160 Rep. gr.44 - Wheels, tyres, vehicle geometry

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In this example, the expiry date 05/2003 has expired. The bottle
must be renewed.
If the bottle was opened e.g. at a "flat tyre", it must also be re‐
newed.

1.5 Tyre sealant disposal

If residual tyre sealant or bottles that are still full have exceeded
their shelf life, they must be disposed of.
Old tyre sealant and/or remnants must not be mixed or disposed
of with other fluids. Observe the disposal notes in the ⇒ Service
Organisation Handbook; Environmental protection and disposal
practice .

1.6 Models with breakdown set

These vehicles are equipped with either a spare wheel or a break‐
down set.
Depending on the vehicle model and equipment, the breakdown
set is installed in different locations:
♦ Commercial vehicles ⇒ page 161
♦ Multivan with triple rear seat bench ⇒ page 162
♦ Multivan with individual seats (swivel seats) ⇒ page 162
♦ Commercial vehicle/Multivan with co-pack set ⇒ page 162
Breakdown set in commercial vehicles
Location: In commercial vehicles without a second battery, the
breakdown set is stowed in the driver's seat chassis.

1. Wheels, tyres 161

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Breakdown set in the Multivan with triple rear seat bench

Location: In the Multivan with triple rear seat bench, the break‐
down set is stowed in the left drawer in the triple seat bench.

Breakdown set in the Multivan with individual seats (swivel seats)

Location: In the Multivan with individual seats (swivel seats), the
breakdown set is stowed in the individual seat's (swivel seat's)
drawer.

Breakdown set in the commercial vehicle/Multivan as a parts con‐

signment set
Location: In commercial vehicles with a second battery and in
certain Multivan vehicles, the breakdown set is stored as a parts
consignment set in the passenger door storage compartment.

162 Rep. gr.44 - Wheels, tyres, vehicle geometry

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1.7 Protecting wheel centring seat against

corrosion
Applies to alloy and steel wheels
When changing a wheel, wheel centring seat should be waxed
using wax spray ⇒ Electronic parts catalogue (ETKA) to prevent
corrosion between wheel centring seat and rim.
– Remove wheel.
– Clean wheel centring seat of hub and centring ring of wheel
rim.
– Apply wax to centring ring -arrow- with a brush.

WARNING

Wheel bolts, contact surfaces of wheel hub and wheel, brake

discs and threads of wheel hub must not be waxed. Never treat
wheel securing bolts with lubricant or corrosion protection ma‐
terials!

Observe notes for revised wheel bolts ⇒ Wheels and Tyres Guide
- General information; Rep. gr. 44 ; Useful information about
wheels/tyres (Commercial vehicles); Fitting wheels .
– Install wheel and tighten bolts or nuts ⇒ page 159 .

1. Wheels, tyres 163

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2 Tyre Pressure Monitoring System

⇒ “2.1 General mode of function”, page 164
⇒ “2.2 Perform basic setting”, page 164

2.1 General mode of function

Note

The Tyre Pressure Monitoring System is part of the software in

the ABS control unit - J104- .

General mode of function:

The tyre pressure monitor display serves as a warning device in
the event of a slow puncture. Within certain limits, this system is
able to draw conclusions about changes in tyre pressures based
on changes in the rotation speed ratios (data obtained using ABS
speed sensors). In this way, the tyre pressure monitor display can
in most cases detect a pressure loss on one wheel. Event memory
entries for the Tyre Pressure Loss Indicator are stored in the ABS
control unit - J104- .
A change in a wheel's rolling circumference will be indicated by
the tyre pressure monitor warning lamp - K220- lighting up in the
dash panel insert. A tyre's rolling circumference may change as
a result of:
♦ Insufficient tyre inflation pressure
♦ Structural tyre damage
♦ One-sided loading of vehicle
♦ Increased load on one axle, e.g. due to towing a trailer
♦ Use of snow chains
♦ Temporary spare wheel installed
♦ Wheel renewal

2.2 Perform basic setting

Performing basic setting:
After the following work or modifications, the tyre pressure mon‐
itor display button - E492- must be pressed and held until a
confirmation is sounded.
♦ Change in tyre pressures
♦ Changing one or more wheels
♦ Interchanging wheels, e.g. from front to rear

164 Rep. gr.44 - Wheels, tyres, vehicle geometry

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– Switch on ignition with vehicle stationary.

– After each change to wheels, press Set -arrow- until an au‐
dible signal sounds. The audible signal confirms basic setting
has been performed.

Note

♦ Tyre pressure monitor warning lamp - K220- -arrow- also lights

up if a fault in anti-lock brake system is displayed by ESP and
TCS warning lamp - K155- or traction control system warning
lamp - K86- , although there is no fault stored in tyre pressure
monitoring system.
♦ In this case, the tyre pressure monitoring system cannot be
set to basic setting using tyre pressure monitor display button
- E492- .

Perform basic setting with system error in anti-lock brake system:

– Please perform following steps:
– Carry out basic setting using ⇒ Vehicle diagnostic tester.

2. Tyre Pressure Monitoring System 165

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3 Wheel alignment
⇒ “3.1 Notes for wheel alignment”, page 166
⇒ “3.2 Conditions for testing”, page 166
⇒ “3.3 Models with electronic stabilisation program”, page 167
⇒ “3.4 Specifications for wheel alignment”, page 167
⇒ “3.5 Wheel alignment procedure”, page 169
⇒ “3.6 Necessity of wheel alignment”, page 170
⇒ “3.7 Explanatory notes on production control numbers (PR
no.)”, page 172
⇒ “3.8 Adjusting camber at front wheels”, page 175
⇒ “3.9 Adjusting toe at rear axle”, page 175
⇒ “3.10 Adjusting front axle toe”, page 177

3.1 Notes for wheel alignment

Wheel alignment must be performed only using a VW/AUDI-ap‐
proved wheel alignment unit!
Whenever wheels are aligned, both the front and rear axles must
be measured.
Otherwise, the steering rack may not be centred!
All the information required to perform alignment can be found in
the wheel alignment computer.
Current data »updates« are located in Volkswagen ServiceNet.
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐
ware; Beissbarth
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐
ware; Hunter
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐
ware; Corghi
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐
ware; John Bean

3.2 Conditions for testing

• Check wheel suspension, wheel bearings, steering and steer‐
ing linkage for excessive play and damage.
• Tread depth difference does not exceed 2 mm on one axle.
• Check that tyres are inflated to specification.
• Have vehicle at kerb weight.
• Fuel tank must be full.
• The spare tyre and vehicle tool set must be secured at the
specified locations in the vehicle.
• The washer fluid reservoir must be full.
• When checking wheel alignment, ensure that sliding plates
and turntables are not touching end stop.

166 Rep. gr.44 - Wheels, tyres, vehicle geometry

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Note

♦ To allow running gear to »fully settle«, wheel alignment should

not be checked before the vehicle has completed 1000 to
2000 km.
♦ When making adjustments, try to adhere to the relevant spec‐
ifications precisely.
♦ Refer to the user's manual of the equipment maker for proper
attachment and adjustment of the measuring devices.
♦ Wheel alignment platforms and alignment units and comput‐
ers should be checked and adjusted as necessary during
inspection and maintenance at least once per year!
♦ Precision equipment of this type should be treated carefully
and conscientiously.

3.3 Models with electronic stabilisation pro‐

gram
If steering wheel was realigned, basic setting of steering angle
sender - G85- must be checked ⇒ Vehicle diagnostic tester.

3.4 Specifications for wheel alignment

Note

The ride heights shown in the table refer to dimension -a-.

Specified values for wheel alignment

Front axle

PR num‐ +A8B/A8E/A9K/ +A8B/A8E/ +8AE/K4H/A9W 1/2 payload Full Trans‐ Trans‐

bers A9A+1BA A9K+2MD +1BV/2MD/ load porter porter
and +2MF/1BB/ +A8J/K4H 2MH “MAXI” “Wid‐
Model 1BH/1BJ/2MG +1BA/2MF der”
designa‐ +2MK/2ML/ +K4L+1BA/
tion 2MQ/2MR/2MT 2MF
+2MU/K4H/ +A9W+0E1
K4F/A9W+0E2 +1BA/2MF
+1BA/2MF +A9A+2S3
+1BA/2MF
Toe-in at 5' ± 10' 5' ± 10' 5' ± 10' 5' ± 10' 0' ± 10' 0°05' ± 0°05' ±
wheel 5' 5'
Total toe 10′ ± 20′ 10′ ± 20′ 10′ ± 20′ 10' ± 20' 0' ± 20' 0°10' ± 0°10' ±
(without 10' 10'
load)
Camber -20′ ± 45′ -30′ ± 45′ -40′ ± 45′ -35' ± 45' -1° ± 0°15' ± 0°15' ±
(in 45' 30' 30'
straight-
ahead
position)

3. Wheel alignment 167

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PR num‐ +A8B/A8E/A9K/ +A8B/A8E/ +8AE/K4H/A9W 1/2 payload Full Trans‐ Trans‐

bers A9A+1BA A9K+2MD +1BV/2MD/ load porter porter
and +2MF/1BB/ +A8J/K4H 2MH “MAXI” “Wid‐
Model 1BH/1BJ/2MG +1BA/2MF der”
designa‐ +2MK/2ML/ +K4L+1BA/
tion 2MQ/2MR/2MT 2MF
+2MU/K4H/ +A9W+0E1
K4F/A9W+0E2 +1BA/2MF
+1BA/2MF +A9A+2S3
+1BA/2MF
Maxi‐ Max. 1° Max. 1° Max. 1° - - ± 1° ± 1°
mum
permis‐
sible dif‐
ference
between
sides
Caster 4° 10′ ± 40′ 4° 20′ ± 40′ 4° 30′ ± 40′ 4° 40' ± 40' 5° ± 40' 3° 50' ± 3° 50' ±
30' 30'
Maxi‐ Max. 1° Max. 1° Max. 1° Max. 1° Max. 1° - -
mum
permis‐
sible dif‐
ference
between
sides

Checking dimensions for ride height, front axle

Damping 1BA/2MF 1BA/2MF 1BJ/1BB/ 2MD/2MH/ 2MD (low‐ 1BH 1BX
(standard) (standard) 2MG 1BV (Sport) ered) (3.2 t
2MK/2ML/ )
2MQ
2MR/2MT/
2MU
PR numbers +A8B/A8E/ +K4H/K4L/ All vehicles +K4H/A8E/ +A8B/A9K All Tran Tran
and Model A9K/A9A A8E/A8J A9W+0E1 vehi‐ sport sport
designation +3R0 +A9W+0E1 cles er er
+K4H/K4F/ +A9A+2S3 “MA “Wid‐
A9W+0E2 XI” der”
Ride height 471 ± 10 mm 455 ± 10 mm 471 ± 10 mm 437 ± 10 mm 455 ± 10 mm 471 490 502
± ± ±
15 m 10 m 10 m
m m m

Rear axle
PR +A8B/A8E/ +A8B/A8E/ +K4H/A8E/ +K4L+1BA/ 1/2 payload Full Trans‐ Trans‐
num‐ A9K+1BA/2MF A9K+2MD A9W 2MF load1) porter porter
bers +1BB/1BH/ +K4H/A8J +1BV/2MD/ +A9A+2S3 “MAX “Wid‐
and 1BJ/2MG/2ML +1BA/2MF 2MH +1BA/2MF I” der”
Model +2MK/2MQ/ +A9W+0E1
desig‐ 2MR/2MT/ +1BA/2MF
nation 2MU
+K4H/K4F/
A9W+0E2
+1BA/2MF
+A9A+3R0
Toe-in 5' ± 10' 5' ± 10' 5' ± 10' 5' ± 10' 15' ± 10' 25' 0° 05' 0° 05'
at ± 10' ± 5’ ± 5’
wheel

168 Rep. gr.44 - Wheels, tyres, vehicle geometry

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PR +A8B/A8E/ +A8B/A8E/ +K4H/A8E/ +K4L+1BA/ 1/2 payload Full Trans‐ Trans‐

num‐ A9K+1BA/2MF A9K+2MD A9W 2MF load1) porter porter
bers +1BB/1BH/ +K4H/A8J +1BV/2MD/ +A9A+2S3 “MAX “Wid‐
and 1BJ/2MG/2ML +1BA/2MF 2MH +1BA/2MF I” der”
Model +2MK/2MQ/ +A9W+0E1
desig‐ 2MR/2MT/ +1BA/2MF
nation 2MU
+K4H/K4F/
A9W+0E2
+1BA/2MF
+A9A+3R0
Total 10′ ± 20′ 10′ ± 20′ 10′ ± 20′ 10′ ± 20′ 30' ± 20' 50' 0° 10' 0° 10'
toe ± 20' ± 10’ ± 10’
(with‐
out
load)
Cam‐ -50′ ± 45′ -1′ ± 20′ -1° 10′ ± 45′ -1° 15′ ± 45′ -1° 25' ± 45' -2° ± -0° 00' -0° 00'
ber (in 45' ± 30' ± 30'
straight
-ahead
posi‐
tion)
Maxi‐ Max. 1° Max. 1° Max. 1° Max. 1° Max. 1° Max. Max. Max.
mum 1° 1° 1°
permis‐
sible
differ‐
ence
be‐
tween
sides
1) Vehicles which permanently travel with gross axle weight rating must be set to these values.

Checking dimensions for ride height, rear axle

Damping 1BA/2MF 1BA/2MF 1BJ/1BB/ 2MD/ 2MD 1BA/2MF 1BX
(standard) (standard) 1BH/2MG 2MH/1BV (lowered) (stand‐
2MK/2ML/ (Sport) ard)
2MQ
2MR/2MT/
2MU
PR num‐ +A8B/ +K4H/ All vehicles +K4H/ +A8B/ +K4L/ Trans‐ Trans‐
bers A8E/A9K/ A8E/A8J/ A8E/A9W A9K A9A+2S3 porter porter
and Model A9A+3R0 A9W+0E1 +0E1 “MAXI” “Widder”
designa‐ +K4H/
tion K4F/A9W
+0E2
Ride 479 ± 459 ± 479 ± 15 mm 439 ± 459 ± 429 ± 525 ± 525 ±
height 15 mm 10 mm 10 mm 10 mm 10 mm 15 mm 15 mm

3.5 Wheel alignment procedure

Note

Always adhere to the following procedure!

Also observe instructions for your wheel alignment device.

Alignment procedure

3. Wheel alignment 169

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Start → Carry out wheel runout com‐ → Bounce springs.

pensation.
↓
Turn steering wheel to ← Measure vehicle height. ← Fit brake pedal depressor - V.A.G
straight-ahead position 1869/2-
and lock in place 1)
↓
Check front axle camber → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Inspect axle components and
body ⇒ page 175
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle camber → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Inspect axle components and
body
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle toe → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Adjusting ⇒ page 175
↓ ↓
↓ ← ← ← ← ←
↓
Check front axle caster → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Inspect axle components and
body
↓ ↓
↓ ← ← ← ← ←
↓
Check front axle toe → Is actual value within toler‐ → no
ance?
↓ ↓
End ← yes Adjusting ⇒ page 177
↑ ↓
↑ ← ← ← ← ←
1)If steering wheel is not centred, it must be straightened after
wheel alignment is finished. Then carry out basic setting for steer‐
ing angle sender - G85- using ⇒ Vehicle diagnostic tester.

3.6 Necessity of wheel alignment

♦ The vehicle does not handle properly.

170 Rep. gr.44 - Wheels, tyres, vehicle geometry

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♦ Vehicle has been involved in an accident and components

have been renewed.
♦ Axle components have been removed and reinstalled.
♦ Tyres are worn more on one side.
Front axle component was Alignment neces‐ Rear axle component re‐ Alignment necessary
renewed. sary newed
yes no yes no
Suspension link X Suspension link X
Bonded rubber bush in sus‐ X Bonded rubber bush in sus‐ X
pension link pension link
Wheel bearing housing X Wheel bearing X
Wheel bearing X Coil spring X
Track rod/track rod ball joint X Shock absorbers X
Steering rack X Anti-roll bar X
Subframe X
Suspension strut X
Anti-roll bar X
Swivel joint X
Bonded rubber bush in sub‐ X
frame

Front axle component re‐ Alignment neces‐ Rear axle component re‐ Alignment necessary
moved and reinstalled sary moved and reinstalled
yes no yes no
Subframe X 1) Suspension link X
Suspension link X Coil spring X
Wheel bearing housing X Shock absorbers X
Suspension strut X Anti-roll bar X
Swivel joint X
Anti-roll bar X
Steering rack removed X 2)
from subframe, raised and
secured
1 Misalignment of steering wheel following removal and installa‐
tion of subframe is permitted within a tolerance of ± 1.5° without
requiring wheel alignment.
2) Misalignment of steering wheel following removal and installa‐
tion of steering rack on subframe is permitted within a tolerance
of ± 1.5° without requiring wheel alignment.

3. Wheel alignment 171

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3.7 Explanatory notes on production control

numbers (PR no.)

Note

♦ Various types of running gear are installed depending on en‐

gine and equipment level. These are identified by production
control numbers.
♦ Production control numbers are relevant for the wheel align‐
ment specifications.
♦ The appropriate production control numbers on vehicle data
sticker or in "Vehicle-specific notes" indicate which running
gear is fitted to a vehicle ⇒ Vehicle-specific notes; Vehicle
data; PR numbers .
♦ The vehicle data sticker is located in the area of the front seats
on the left, on the footwell trim.
♦ From production date March 2007, the vehicle data sticker
-1- is located on the frame of the driver seat.

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Example of PR number allocation:

In this example, the vehicle is a Multivan (K4H) with the running
gear -arrow- 1BA, standard springs and dampers. The vehicle
should be adjusted according to the specifications table for Mul‐
tivan (K4H), column 1BA/2MF, Standard without basic or shuttle
equipment ⇒ page 167 .
Some important “PR numbers” are listed in the table below.

3. Wheel alignment 173

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PR number table:
PR Definition PR Definition
number number

1BA Standard suspen‐ K4H Multivan

sion
1BB Heavy duty suspen‐ K4L Camper
sion
1BH Standard 2 (Maxi)
suspension
1BJ Reinforced suspen‐ 2S3 Pop-up roof
sion
1BV Sport suspension 3R0 Flat roof
1BX Suspension/damp‐
ing slave
2MD Lowered suspen‐
sion
2MF Reinforced anti-roll
bar at front and rear
2MG Reinforced springs,
dampers and anti-
roll bar at front and
rear
2MH Lowered springs/
dampers + rein‐
forced anti-roll bar at
front and rear
2MK Reinforced rear A8B Basic Equipment
springs
2ML Reinforced damp‐ A8J Multivan Startline
ers front and rear
2MQ/ Springs and damp‐ A9A Multivan Beach
2MT ers with increased
front axle load
2MR/ Springs and damp‐ A9K Caravelle Trendline
2MU ers with increased
front axle load + re‐
inforced anti-roll
bars front and rear
A9W Caravelle Comfortline
2E3 16-inch running
gear
2E4 17 inch running gear OWL Gross vehicle weight
rating 2.6 t
OE1 Short wheelbase OWM Gross vehicle weight
rating 2.8 t
OE2 Long wheelbase OWN Gross vehicle weight
rating 2.85 t
OWP Gross vehicle weight
rating 2.9 t
1AT ESP OWQ Gross vehicle weight
rating 3.0 t
1AJ ABS/TCS/EDL OWR Gross vehicle weight
rating 3.2 t
0WS Gross vehicle weight
rating 3.08 t

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3.8 Adjusting camber at front wheels

Note

♦ It is not possible to adjust camber of front wheels!

♦ If the measured values are outside the allowed tolerance,
camber can only be corrected by renewing the affected axle
components.

3.9 Adjusting toe at rear axle

Required special tools, testers, measuring instruments and aux‐
iliary items
♦ Torque wrench - V.A.G 1332/-

Note

♦ Note that loosened bolts and nuts must be renewed.

♦ Tighten bolted connection to coupling rod only if the vehicle is standing on its wheels and is unladen or if
the vehicle is raised and is in the unladen position (normal position) .
♦

3. Wheel alignment 175

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– Remove nut -1-.

– Remove eccentric bolt and replace it with an new eccentric
bolt ⇒ Electronic Parts Catalogue "ETKA" .
– But do not tighten eccentric bolt.
– Turn eccentric bolt -2- until specification is attained.
– Tighten nut -1-.
Specified torques
♦ ⇒ “4.1 Assembly overview - suspension link”, page 128
♦
♦

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3.10 Adjusting front axle toe

Required special tools, testers, measuring instruments and aux‐
iliary items

♦ Torque wrench - V.A.G 1332/-

♦ Insert - V.A.G 1332/11-

Note

♦ Before beginning adjustment work, bring steering into centre

position according to wheel alignment computer.
♦ Procedure for adjusting toe on front axle is explained for left
track rod. Setting must be performed on right side as well if
necessary.

– Loosen lock nut -1- while counterholding on track rod head

-4-.

3. Wheel alignment 177

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– Loosen clamp -2- using hose clip pliers - V.A.G 1921- and
push clamp off boot.
– Turn track rod on hexagon flats -3- until the specified value is
attained.

Note

♦ After completing the adjustment, ensure that the boot is not

twisted.
♦ Twisted boots have a shorter service life.

– Tighten lock nut -1- with tool insert - V.A.G 1332/11- while
counterholding on track rod head -4-.
– Check toe adjustment again.

Note

♦ It is possible that the value will change slightly when lock nut
is tightened.
♦ If the measured toe value lies within the tolerance, the adjust‐
ment is correct.

– Install clamp -2- properly.

Specified torques
Component Specified torque
Lock nut 60 Nm

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48 – Steering
1 Steering column
⇒ “1.1 Assembly overview - steering column”, page 179
⇒ “1.2 Removing and installing steering column”, page 182
⇒ “1.3 Removing and installing intermediate steering shaft”, page
188
⇒ “1.4 Removing and installing protective sleeve for intermediate
steering shaft”, page 191

1.1 Assembly overview - steering column

⇒ “1.1.1 Assembly overview - steering column”, page 179
⇒ “1.1.2 Assembly overview - steering column, model year 2010
►”, page 181

1.1.1 Assembly overview - steering column

WARNING

♦ It is not permitted to weld or straighten load-bearing or

wheel-guiding components of the suspension.
♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.

1. Steering column 179

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1 - Steering column
❑ Removing and installing
⇒ page 182
2 - Bolt
❑ 20 Nm
3 - Nut
❑ Renew after removal
❑ 20 Nm +90°
4 - Protective cover
❑ Ensure it is properly
seated
❑ Part of steering column.
5 - Clip
❑ Renew after removal
6 - Protective cover
❑ For intermediate steer‐
ing shaft.
❑ Ensure it is properly
seated
❑ Removing and installing
⇒ page 191
7 - Steering rack
8 - Eccentric bolt
9 - Intermediate steering shaft
❑ Removing and installing
⇒ page 188
10 - Bolt
❑ 25 Nm

180 Rep. gr.48 - Steering

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1.1.2 Assembly overview - steering column, model year 2010 ►

WARNING

♦ It is not permitted to weld or straighten load-bearing or

wheel-guiding components of the suspension.
♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.

1 - Steering column
❑ There is no provision for
repairing the steering
column
❑ Supplied as complete
component
❑ Removing and installing
⇒ page 182
2 - Bolt
❑ 20 Nm +90°
3 - Bolt
❑ 20 Nm +90°
4 - Bolt
❑ 20 Nm
5 - Nut
❑ 20 Nm +90°
6 - Protective cover
❑ Ensure it is properly
seated
❑ Part of steering column.
7 - Clip
❑ Renew after removal
8 - Protective cover
❑ For intermediate steer‐
ing shaft.
❑ Ensure it is properly
seated
❑ Removing and installing
⇒ page 191
9 - Power steering rack
10 - Eccentric bolt
❑ Observe installation instructions ⇒ page 188
11 - Intermediate steering shaft
❑ Removing and installing ⇒ page 188
12 - Bolt
❑ 25 Nm

1. Steering column 181

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1.2 Removing and installing steering col‐

umn
⇒ “1.2.1 Removing and installing steering column”, page 182
⇒ “1.2.2 Removing and installing steering column, model year
2010 ►”, page 184

1.2.1 Removing and installing steering col‐

umn
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Removing
Only the complete steering column is supplied as a replacement
part. Repair is not possible.
The steering lock housing can be transferred ⇒ Rep. gr. 94 ;
Ignition switch and lock cylinder .

WARNING

The following conditions must be met before starting work on

the electrical system and removing the steering wheel:
♦ Earth strap disconnected from battery ⇒ Rep. gr. 27 ;
Battery; Disconnecting and reconnecting battery .
♦ The wheels must be in straight-ahead position.
Failure to comply with these precautions may lead to subse‐
quent failure of the airbag system!

– Turn wheels to straight-ahead position.

– Pull down lever beneath steering column.
– Swing steering column down as far as possible and pull out.
– Remove steering wheel ⇒ Rep. gr. 69 ; Steering wheel .
– Remove lower dash panel trim on left and right ⇒ Rep. gr.
70 ; Removing and installing dash pane trim .
– Remove steering column trim ⇒ Rep. gr. 70 ; Removing and
installing steering column trim .
– Steering column switch module; Remove switch module ⇒
Rep. gr. 94 ; Steering column switch module .

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– Fold protective sleeve -1- upwards.

– Remove nut -3-, counter holding on eccentric bolt -2-.
– Pull universal joint off intermediate steering shaft.

– Remove lower securing bolts -arrows- near brake pedal -B-.

– Remove cap nut -2- for earth cable.

– Remove connector -A- from steering column.
– Pull connector -B- and clips -arrows- off steering column.
Vehicles with an automatic gearbox
– Unhook ignition key removal lock cable from steering lock
housing ⇒ Rep. gr. 94 .

Continuation for all vehicles

– Remove bolts -1- and pull out steering column upwards.
Installing
Install in the reverse order of removal, observing the following:
– Insert steering column.

Note

The sleeve on the steering column must seat in hole in body.

– Bolt on steering column.

– Attach universal joint to intermediate steering shaft.
– Fit nut and eccentric bolt.

1. Steering column 183

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– Turn eccentric bolt -2- left »to stop« -arrow- and hold.
– Tighten nut -3- to prescribed torque.
– Fold protective sleeve -1- downwards.
– Steering column switch module; Install switch module ⇒ Rep.
gr. 94 ; Steering column switch module .
– Install steering wheel and airbag ⇒ Rep. gr. 69 ; Steering
wheel .
After installation, position of steering wheel must be checked dur‐
ing road test.
– Carry out basic setting for steering angle sender - G85- using
⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ “1.1 Assembly overview - steering column”, page 179
♦ Removing and installing steering wheel ⇒ Rep. gr. 69 ; Steer‐
ing wheel
♦ Dash panel; Removing and installing steering column trim ⇒
Rep. gr. 70 ; Dash panel

1.2.2 Removing and installing steering col‐

umn, model year 2010 ►
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Removing

Note

♦ Only the complete steering column is supplied as a replace‐

ment part. Repair is not possible.
♦ The steering lock housing can be transferred ⇒ Rep. gr. 94 ;
Ignition switch and lock cylinder .

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WARNING

The following conditions must be met before starting work on

the electrical system and removing the steering wheel:
♦ Disconnect earth strap from battery ⇒ Rep. gr. 27 ; Bat‐
tery; Disconnecting and reconnecting battery .
♦ The wheels must be in straight-ahead position.
Failure to comply with these precautions may lead to subse‐
quent failure of the airbag system!

– Move wheels to straight-ahead position.

– Unlock lever under steering column downwards. Pull it down
as far as possible and out as far as possible.
– Remove steering wheel ⇒ Rep. gr. 69 .
– Remove lower dash panel trim on left and right ⇒ Rep. gr.
70 ; Removing and installing dash pane trim .
– Remove steering column trim ⇒ Rep. gr. 70 ; Removing and
installing steering column trim .
– Steering column switch module; Remove switch module ⇒
Rep. gr. 94 ; Steering column switch module .
– Pull back protective sleeve -1-.
– Unscrew nut -3- while counterholding eccentric bolt -2-.
– Turn eccentric bolt -2- in -direction of arrow- out of its clamped
connection and remove eccentric bolt from universal joint.

– Pull universal joint off intermediate steering shaft.

– Unscrew bolt -1- and remove earth cable from steering col‐
umn.
– Disconnect connector of immobiliser -2- on read coil.

1. Steering column 185

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– Disconnect connector of ignition/starter switch -3- on steering

lock housing.
– Separate complete wiring harness -3- with cable guide -2-
from steering column.
Vehicles with automatic gearbox:
– Unhook ignition key removal lock cable from steering lock
housing ⇒ Rep. gr. 94 .

Continuation for all vehicles:

– Unscrew and remove bolts -4-, -5- and -1- of steering column
one after another.

– Unscrew and remove bolts -3-, -2- and -1- of steering column
one after another.
– Remove complete steering column -3- in -direction of arrow-
out of assembly guide -2- of assembly carrier -1-.

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Installing
Installation is carried out in the reverse order of removal. Observe
the following when doing this:
– Hook complete steering column -4- in -direction of arrow- into
subframe -1-. Guide centring pin -3- into assembly hole -2-
when doing this.

– Position all securing bolts of steering column on left and right.

– First tighten left and right bolts -1-.
– Then tighten left and right bolts -2- and -3- one after another.
– Mount universal joint on intermediate steering shaft.

1. Steering column 187

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– Insert eccentric bolt into universal joint.

– Turn eccentric bolt -2- left “to stop” -arrow-.
– Hold eccentric bolt firmly in this position. Install nut -3- in this
position and tighten.
– Pull protective sleeve -1- down.
– Steering column switch module; Install switch module ⇒ Rep.
gr. 94 ; Steering column switch module .
– Install lower dash panel trim on left and right ⇒ Rep. gr. 70 ;
Removing and installing dash pane trim .
– Install steering column trim ⇒ Rep. gr. 70 ; Removing and
installing steering column trim .
– Install steering wheel with driver airbag ⇒ Rep. gr. 69 ; Steer‐
ing wheel .
After complete installation, position of steering wheel must be
checked during road test.
– Carry out basic setting for steering angle sender - G85- using
⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ “1.1 Assembly overview - steering column”, page 179
♦ Removing and installing steering wheel ⇒ Rep. gr. 69 ; Steer‐
ing wheel
♦ Dash panel; Removing and installing steering column trim ⇒
Rep. gr. 70 ; Dash panel

1.3 Removing and installing intermediate

steering shaft
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Locking pliers for Phaeton steering rack - VAS 6199-

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Removing
– Move wheels to straight-ahead position.
– Pull back protective sleeve -1-.
– Unscrew nut -3- while counterholding eccentric bolt -2- in
-direction of arrow-.
– Remove eccentric bolt -2- from universal joint.
– Tip universal joint back from intermediate steering shaft.
– Pull up carpet from beneath pedal cluster back to driver seat.
This provides access to the 3 securing bolts
⇒ Item 10 (page 180) .
– Remove the 3 bolts.
– Raise vehicle.
– Remove front left wheel.

– If cover -1- was installed near wheel housing liner, remove it.

– Remove clip from protective sleeve -1-

– Push protective sleeve -1- upwards and secure it against slip‐
ping with, e.g. a 6 mm hexagon socket wrench -A-.
– Unscrew nut -3- while counterholding eccentric bolt -2- in
-direction of arrow-.
– Remove eccentric bolt -2- from universal joint.
– Tip universal joint back from intermediate steering shaft.
– Remove intermediate steering shaft downwards.

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Installing
Install in the reverse order of removal, observing the following:
– Re-fit intermediate steering shaft.
– Fit universal joint of intermediate steering shaft to steering
pinion.
– Fit eccentric bolt -2- with nut -3- hand-tight.
– Tighten rear securing bolt ⇒ Item 12 (page 181) .

Note

Ensure that the guides of the cover plate for the intermediate
steering shaft sit exactly in the holes in the body.

– Tighten bolts of universal joint.

– To do this, turn eccentric bolt -2- left »to stop« -arrow- and hold
eccentric bolt in this position.
– Tighten nut -3-.

– Push protective sleeve -1- with clip -2- onto steering rack -3-
to stop.
Ensure that mark -arrow A- on protective sleeve and mark
-arrow B- on steering rack align.
In left-hand drive vehicles, the mark "LHD" on protective sleeve
-arrow A- and mark on steering rack -arrow B- must align.
In right-hand drive vehicles, the mark "RHD" on protective sleeve
-arrow A- and mark on steering rack -arrow B- must align.
– Secure clip -2- of protective sleeve -1- to steering rack -3-.

– If cover -1- was installed near wheel housing liner, fit it.
– Install front left wheel.

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– Fit universal joint on steering column to intermediate steering

shaft.
– To do this, turn eccentric bolt -2- left »to stop« -arrow- and hold
eccentric bolt in this position.
– Tighten nut -3-.
– Refit protective sleeve -1- properly.
– Refit floor covering.

Note

After fitting intermediate steering shaft, make a test drive to en‐

sure that the centre position of the steering wheel is correct.

– Carry out basic setting for steering angle sender - G85- using
⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ “1.1 Assembly overview - steering column”, page 179
♦ ⇒ “1.1 Fitting wheels”, page 159

1.4 Removing and installing protective

sleeve for intermediate steering shaft
Special tools and workshop equipment required
♦ Locking pliers for Phaeton steering rack - VAS 6199-

Removing
– Move wheels to straight-ahead position.
– Remove front left wheel.
– If cover -1- was installed near wheel housing liner, remove it.
– Remove both clamps from protective sleeve

1. Steering column 191

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– Push protective sleeve -1- upwards and secure it against slip‐

ping with, e.g. a 6 mm hexagon socket wrench -A-.
– Unscrew nut -3- while counterholding eccentric bolt -2- in
-direction of arrow-.
– Remove eccentric bolt -2- from universal joint.
– Tip universal joint back from intermediate steering shaft.
– Pull protective sleeve -1- down off intermediate steering shaft.

Installing
Install in the reverse order of removal, observing the following:
– Align recesses in protective sleeve -arrows A- with detents on
intermediate steering shaft -arrows B-.
– Carefully push protective sleeve -3- with upper clip -2- onto
intermediate steering shaft -1- to stop.

Note

Ensure that lugs -arrows B- on intermediate steering shaft -1- en‐

gage correctly in recesses in protective sleeve -arrows A-.

– Secure protective sleeve -3- with clip -2- to intermediate steer‐

ing shaft -1-.

– Push universal joint onto steering pinion and tighten.

– To do this, turn eccentric bolt -2- left »to stop« -arrow- and hold
eccentric bolt in this position.
– Tighten nut -3-.

– Push protective sleeve -1- with clip -2- onto steering rack -3-
to stop.
Ensure that mark -arrow A- on protective sleeve and mark
-arrow B- on steering rack align.
In left-hand drive vehicles, the mark "LHD" on protective sleeve
-arrow A- and mark on steering rack -arrow B- must align.
In right-hand drive vehicles, the mark "RHD" on protective sleeve
-arrow A- and mark on steering rack -arrow B- must align.
– Secure protective sleeve -1- with clip -2- to steering rack -3-.

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– If cover -1- was installed near wheel housing liner, fit it.
– Install front left wheel.
Specified torques
♦ ⇒ “1.1 Assembly overview - steering column”, page 179
♦ ⇒ “1.1 Fitting wheels”, page 159

1. Steering column 193

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2 Steering rack
⇒ “2.1 Assembly overview - steering rack”, page 194
⇒ “2.2 Removing and installing steering rack”, page 199
⇒ “2.3 Removing and installing track rod”, page 202
⇒ “2.4 Repairing steering rack”, page 204
⇒ “2.5 Checking rack seals”, page 206

2.1 Assembly overview - steering rack

⇒ “2.1.1 Assembly overview - steering rack”, page 194
⇒ “2.1.2 Assembly overview - steering rack, model year 2010 ►”,
page 196

2.1.1 Assembly overview - steering rack

WARNING

♦ It is not permitted to weld or straighten load-bearing or

wheel-guiding components of the suspension.
♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.

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1 - Steering rack
❑ Removing and installing
⇒ page 199
❑ Repairing ⇒ page 204
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
2 - Wheel bearing housing
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
3 - Nut
❑ Renew after removal
❑ Specified torque
⇒ Item 11 (page 55)
4 - Clip
5 - Bolt
❑ 8 Nm
6 - Return line
❑ 32 Nm
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
7 - Seal
❑ Renew after removal
8 - Pressure line
❑ 32 Nm
9 - Seal
❑ Renew after removal
10 - Subframe
11 - Nut
❑ Renew after removal
❑ 33 Nm +90°
12 - Nut
❑ Renew after removal
❑ 20 Nm +180°
13 - Console
14 - Bolt
❑ Renew after removal
15 - Bolt
❑ 8 Nm
16 - Pressure line
❑ 32 Nm
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
17 - Bolt
❑ Renew after removal
18 - Eccentric bolt
❑ Observe installation instructions ⇒ page 188
19 - Protective cover
❑ For intermediate steering shaft.

2. Steering rack 195

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❑ Removing and installing ⇒ page 191
20 - Universal joint
21 - Nut
❑ Renew after removal
❑ 20 Nm +90°
22 - Clip
❑ Renew after removal

2.1.2 Assembly overview - steering rack, model year 2010 ►

WARNING

♦ It is not permitted to weld or straighten load-bearing or

wheel-guiding components of the suspension.
♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.

1 - Bolt
❑ 6 Nm
2 - Reservoir
❑ Hook reservoir into lock
carrier, clip in and se‐
cure with bolt
⇒ Item 1 (page 196)
3 - Connection hose
❑ Clip connecting hose in‐
to reservoir (only 4-cyl.
diesel engines)
❑ Fit connection on cool‐
ing pipe with clip in 9
o'clock position
❑ Fit connection on reser‐
voir, with clip on colour
identification flush with
push-on limit
4 - Spring-type clips
❑ Pay attention to installa‐
tion notes/colour identi‐
fications on hoses for
installation
5 - Coolant pipe
❑ Cools power steering oil
in return to reservoir
6 - Bracket
❑ Fit bracket for cooling
pipe on radiator on left in
driving direction
7 - Return line
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Fit return line to cooling pipe, connection on cooling pipe with clip in 9 o'clock position

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❑ For installation notes/installation position, see ⇒ page 198
❑ 32 Nm
8 - Bracket
❑ Retainer of return line on longitudinal member
9 - Protective cover
❑ For intermediate steering shaft.
❑ Removing and installing ⇒ page 191
10 - Eccentric bolt
❑ Observe installation instructions ⇒ page 188
11 - Universal joint
12 - Nut
❑ Renew after removal
❑ 20 Nm +90°
13 - Clip
❑ Renew after removal
14 - Seal
❑ Renew after removal
15 - Bolt
❑ Securing bolt for pressure line on power steering box
❑ 9 Nm
16 - Pressure line
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ For installation notes/installation position, see ⇒ page 198
❑ 32 Nm
17 - Bolt
❑ Renew after removal
18 - Servotronic solenoid valve - N119-
❑ Mode of operation: Force of power-assisted steering declines as vehicle speed increases.
❑ Cannot be renewed individually
19 - Nut
❑ Self-locking, always renew after removing
❑ 60 Nm +90°
20 - Nut
❑ Self-locking, always renew after removing
❑ 33 Nm +90°
21 - Power steering rack
❑ Removing and installing ⇒ page 199
❑ Repairing ⇒ page 204
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
22 - Vane pump
❑ Altered version ⇒ Varioserv version from model year 2010 ►
❑ Vane pump adapts displacement to actual requirement for delivery volume, used with all 4-cyl. diesel
engines only
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ Removing and installing ⇒ page 220
23 - Bracket
❑ Retainer of suction hose on longitudinal member

2. Steering rack 197

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24 - Suction hose
❑ From reservoir to vane pump
25 - Bracket
❑ Bracket for cooling pipe mounted on radiator on right in driving direction

Installation note/installation position of pressure line:

Note

During installation/tightening of pressure line, make sure that lo‐

cating mechanism of pressure line -2- is in contact with housing
-1-.

Installation note/installation position of return line:

Note

During installation/tightening of return line, make sure that locat‐

ing mechanism of return line -2- is in contact with housing -1-.

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2.2 Removing and installing steering rack

Special tools and workshop

equipment required

♦ Hose clamps to 25 mm - 3094-

♦ Torque wrench - V.A.G 1331-
♦ Torque wrench - V.A.G 1332-
♦ Locking pliers for Phaeton steering rack - VAS 6199-
♦ Ball joint puller - T10187-

2. Steering rack 199

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Removing
– Turn steering to straight-ahead position and engage steering
lock.
– Remove front left wheel.
– Clamp off suction hose at reservoir.
– Press off track rods using ball joint puller - T10187- .
– Raise vehicle.
– Open clip on protective sleeve -1-.
– Push protective sleeve -1- upwards and secure it against slip‐
ping with, e.g. a 6 mm hexagon socket wrench -A-.
– Unbolt universal joint from steering pinion.
– Unbolt anti-roll bar from coupling rods.
– Unbolt ant-roll bar from subframe.
– Depending on engine version, unbolt the respective pressure
line from steering rack.
– Catch escaping hydraulic fluid.

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For vehicles with Servotronic

– Disconnect electrical connector -2- from Servotronic solenoid
valve - N119- -1-.
Vehicles with all-wheel drive
– Remove assembly carrier ⇒ page 13 .
– Unbolt steering rack from subframe.
Vehicles with front-wheel drive
– Unbolt steering rack from subframe.

Note

♦ For vehicles with particulate filters, the filter must be pushed

up a little further in order to remove the bracket under the en‐
gine carrier to the side.
♦ To do this, remove the securing nut for the particulate filter on
the engine carrier.

– Separate threaded connection between particulate filter and

engine carrier.
– Remove bracket bolts ⇒ Item 13 (page 195) .
– Remove bolt for bracket to engine carrier and remove bracket.
– Remove anti-roll bar to left.
– Push steering rack to left, turning it at the same time until
steering pinion faces downwards.
– Remove steering rack to left.
Installing
Install in the reverse order of removal, observing the following:
– Insert steering rack from left and lay on subframe.
– Insert anti-roll bar from left and lay on subframe.
– Install bracket and tighten.
– Attach steering rack to subframe and tighten nuts.
– Attach anti-roll bar to subframe and tighten bolts.
– Fit nut and eccentric bolt.

– To tighten universal joint on steering pinion, turn eccentric bolt

-2- left »to stop« -arrow- and hold.
– Tighten nut -3-.

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– Pull protective sleeve -1- down to stop.

Ensure that mark -arrow A- on protective sleeve and mark
-arrow B- on steering rack align.
In left-hand drive vehicles, the mark "LHD" on protective sleeve
-arrow A- and mark on steering rack -arrow B- must align.
In right-hand drive vehicles, the mark "RHD" on protective sleeve
-arrow A- and mark on steering rack -arrow B- must align.
– Secure protective sleeve -1- with new O-type clip -2- on steer‐
ing rack -3-. To do this, use locking pliers for Phaeton steering
rack - VAS 6199- .
– Attach coupling rods to anti-roll bar and tighten nuts
⇒ Item 17 (page 12) .
– Tighten return line on power steering box. When doing this,
pay attention to installation note/installation position of return
line ⇒ page 198 .
– Tighten pressure line on power steering box. When doing this,
pay attention to installation note/installation position of pres‐
sure line ⇒ page 198 .
– Fill up with hydraulic fluid and bleed steering system
⇒ page 217 .
– Checking power steering fluid level ⇒ page 216
– Install tracks rods ⇒ page 202 and check track setting; adjust
if necessary ⇒ page 166 .
– Carry out basic setting for steering angle sender - G85- using
⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ “2.1 Assembly overview - steering rack”, page 194
♦ ⇒ “3.1 Assembly overview - vane pump”, page 207
♦ ⇒ “2.1 Assembly overview - subframe”, page 10
♦ ⇒ “1.1 Fitting wheels”, page 159

2.3 Removing and installing track rod

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Special tools and workshop

equipment required

♦ Hose clip pliers - V.A.G 1275 A-

♦ Torque wrench - V.A.G 1332-
♦ Insert tool - V.A.G 1332/9-
♦ Open-end spanner attachment - V.A.G 1923-
♦ Locking pliers for Phaeton steering rack - VAS 6199-
♦ Ball joint puller - T10187-
Removing
– Turn steering to straight-ahead position and engage steering
lock.
– Clean steering rack in area of boot.

2. Steering rack 203

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– Use ball joint puller - T10187- to press track rod ball joint -1-
off wheel bearing housing steering arm.
– Loosen clamp -3- and pull boot -4- off steering rack -5-.
– Using open-end spanner attachment - V.A.G 1923- (38 mm),
unscrew track rod -2- from rack of steering gear. Counterhold‐
ing at steering rack is not necessary.

Note

If the steering rack shows signs of corrosion, damage or wear,

renew the complete steering rack.

Installing
Install in the reverse order of removal, observing the following:
The steering rack steering rack must be greased before installing
the track rod.
Grease designation ⇒ Electronic Parts Catalogue “ETKA” .
Under no circumstances may a different grease be used!
– To grease, turn steering to full lock at both sides in succession.
– Grease steering rack on toothed and thrust piece side.
– Turn steering to straight-ahead position.

– Screw track rod -2- into steering rack of steering rack -5-.
– Tighten track rod -2- with open-end spanner attachment -
V.A.G 1923- (38 mm). Counterholding at steering rack is not
necessary.
– Secure boot -4- to steering rack -5- to stop using new clamp
-3-.
– To do this, use locking pliers for Phaeton steering rack - VAS
6199- or hose clip pliers - V.A.G 1275 A- .
– Make sure that the boot is not twisted.
– Bolt track rod ball joint -1- to wheel bearing housing steering
arm using a new nut.
– Carry out wheel alignment ⇒ page 166 .
Specified torques
♦ ⇒ “2.4 Repairing steering rack”, page 204

2.4 Repairing steering rack

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1 - Right track rod ball joint

❑ Check that dust caps
are undamaged and
correctly seated.
❑ If a track rod ball joint
was renewed, or re‐
moved and installed,
wheels must be aligned
⇒ page 166 .
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
2 - Nut
❑ When loosening and
tightening nut, a 24 mm
spanner must be used
to counterhold on track
rod ball joint contact sur‐
face.
❑ 60 Nm
3 - Track rod
❑ Removing and installing
⇒ page 202
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ As a spare part, is sup‐
plied only with track rod
ball joint
⇒ Item 1 (page 205) or
⇒ Item 11 (page 205)
and nut
⇒ Item 2 (page 205) .
❑ 100 Nm
4 - Spring-type clip
5 - Boot
❑ Check for damage
❑ Must not be twisted after toe setting has been adjusted.
6 - Clip
❑ Renew after removal
❑ Install new O-type clip with locking pliers for Phaeton steering rack - VAS 6199- or with hose clip pliers
- V.A.G 1275- .
7 - O-ring
❑ Renew after removal
8 - Servotronic solenoid valve - N119-
❑ Mode of operation: Force of power-assisted steering declines as vehicle speed increases.
❑ Cannot be renewed individually
9 - Rubber mounting
❑ Check for damage
10 - Steering rack
❑ Removing and installing ⇒ page 199
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
11 - Left track rod ball joint
❑ Check that dust caps are undamaged and correctly seated.
❑ If a track rod ball joint was renewed, or removed and installed, wheels must be aligned ⇒ page 166 .

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❑ Allocation ⇒ Electronic parts catalogue “ETKA”

2.5 Checking rack seals

– Open clip on bellows.
– Push boot back.

Note

If hydraulic fluid is visible in steering rack housing or in boot,

steering rack must be replaced.

206 Rep. gr.48 - Steering

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3 Hydraulic power steering

⇒ “3.1 Assembly overview - vane pump”, page 207
⇒ “3.2 Checking hydraulic fluid level of power steering”,
page 216
⇒ “3.3 Bleeding steering system after repairs”, page 217
⇒ “3.4 Check steering for leaks”, page 217
⇒ “3.5 Checking delivery pressure of vane pump”, page 217
⇒ “3.6 Removing and installing vane pump”, page 220

3.1 Assembly overview - vane pump

⇒ “3.1.1 Assembly overview - vane pump, 4-cylinder and 6-cylin‐
der petrol engines”, page 207
⇒ “3.1.2 Assembly overview - vane pump, 4-cylinder diesel en‐
gine”, page 208
⇒ “3.1.3 Assembly overview - vane pump, 5-cylinder diesel en‐
gine”, page 210
⇒ “3.1.4 Assembly overview - vane pump, 4-cylinder diesel en‐
gine, model year 2010 ►”, page 212
⇒ “3.1.5 Assembly overview - vane pump, 4-cylinder petrol en‐
gine, model year 2010 ►”, page 214

3.1.1 Assembly overview - vane pump, 4-cyl‐

inder and 6-cylinder petrol engines

Note

♦ Always check steering system for leaks if fluid level in reservoir

is low.
♦ If leakage occurs near pipe connections, first check lines and
connections for leaks and, if necessary, tighten connections
and wipe dry.
♦ Pumps taken from parts stock contain no fluid. Therefore it is
essential to fill pump with hydraulic fluid and to rotate pump by
hand prior to installation. Otherwise pump may be damaged
or be noisy during operation.
♦ Type of oil: hydraulic fluid, allocation ⇒ Parts catalogue
♦ Fluid capacity in system: 0.7 … 0.9 l.

There is no provision for repairing the vane pump. If problems are

reported, determine the cause by means of a pressure test and a
leakage test ⇒ page 217 . If a fault is found, the vane pump unit
must be renewed.

3. Hydraulic power steering 207

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1 - Banjo bolt
❑ 35 Nm
2 - Seal
❑ Renew after removal
3 - Pressure line
4 - Suction hose
5 - Clip
6 - Vane pump
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
7 - Pulley
8 - Bolt
❑ 25 Nm
9 - Bolt
❑ 25 Nm
10 - Bracket

3.1.2 Assembly overview - vane pump, 4-cyl‐

inder diesel engine

Note

♦ Always check steering system for leaks when the fluid level in
reservoir is low.
♦ When checking for leaks, start with the lines and their con‐
nections. If necessary, tighten line connections and wipe them
dry.
♦ Never reuse hydraulic fluid which has runout, but dispose of it
in an ecologically responsible manner.
♦ Vane pumps from the parts stock are supplied dry (without
fluid). Before installing the vane pump, fill it with hydraulic fluid
and turn pump by hand. Otherwise, the pump may be noisy or
even be damaged during operation.
♦ Use only the specified sort of fluid: hydraulic fluid, allocation
⇒ Electronic spare parts catalogue
♦ The quantity of fluid in the system is 0.7-0.9 litres.

208 Rep. gr.48 - Steering

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There is no provision for repairing the vane pump. If problems are

reported, determine the cause by means of a pressure test and a
leakage test. If no fault is found, the vane pump unit must be re‐
newed.

1 - Banjo bolt
❑ 35 Nm
2 - Seal
❑ Renew after removal
3 - Pressure line
4 - Suction hose
5 - Clip
6 - Vane pump
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
7 - Pulley
8 - Bolt
❑ 25 Nm
9 - Bolt
❑ 25 Nm
10 - Console

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3.1.3 Assembly overview - vane pump, 5-cyl‐

inder diesel engine

Note

♦ Always check steering system for leaks when the fluid level in
reservoir is low.
♦ When checking for leaks, start with the lines and their con‐
nections. If necessary, tighten line connections and wipe them
dry.
♦ Never reuse hydraulic fluid which has runout, but dispose of it
in an ecologically responsible manner.
♦ Vane pumps from the parts stock are supplied dry (without
fluid). Before installing the vane pump, fill it with hydraulic fluid
and turn pump by hand. Otherwise, the pump may be noisy or
even be damaged during operation.
♦ Use only the specified sort of fluid: hydraulic fluid, allocation
⇒ Electronic spare parts catalogue
♦ The quantity of fluid in the system is 0.7-0.9 litres.

There is no provision for repairing the vane pump. If problems are

reported, determine the cause by means of a pressure test and a
leakage test ⇒ page 217 . If no fault is found, the vane pump unit
must be renewed.

210 Rep. gr.48 - Steering

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1 - Cylinder block
2 - Seal
❑ Renew after removal
❑ Lubricate before as‐
sembling
3 - Vane pump
❑ For vehicles with an air
conditioning system
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing
⇒ page 220
4 - Vane pump
❑ For vehicles without air
conditioning.
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
❑ Removing and installing
⇒ page 220
5 - Bolt
❑ Renew after removal
❑ Tighten to 40 Nm and
turn further in 2 steps of
45° each (due to restric‐
ted space)
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
6 - Elastic drive coupling
❑ For vehicles with an air
conditioning system
7 - Clip
8 - Suction hose
9 - Seal
❑ Renew after removal
10 - Pressure line

Note

♦ Vehicles from vehicle identifica‐

tion number
WV2ZZZ7HZ8H157811 and
WV1ZZZ7JZ8X021717 have a
new pressure line installed. The
distinguishing features of the dif‐
ferent pressure lines can be
found in ⇒ page 212 .
♦ Allocation ⇒ Electronic parts
catalogue “ETKA”

11 - Banjo bolt

Note

♦ Specified torque for the banjo

bolt ⇒ page 212 .

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♦ Allocation ⇒ Electronic parts

catalogue “ETKA”

Distinguishing features of the different pressure lines in the vehi‐

cles:

Note

During series production, new vehicles from vehicle identification

number WV2ZZZ7HZ8H157811 and WV1ZZZ7JZ8X021717 had
a new pressure line installed.

The distinguishing features are:

♦ -A-: new pressure line with flexible ferrule and modified speci‐
fied torque for banjo bolt, 15 Nm and turn 90° further.
♦ -B-: old pressure line with specified torque for banjo bolt,
35 Nm

3.1.4 Assembly overview - vane pump, 4-cyl‐

inder diesel engine, model year 2010 ►

Note

♦ Never reuse hydraulic that has escaped; always dispose of it

in an ecologically responsible manner.
♦ Vane pumps from the parts stock are supplied dry (without
fluid). Before installing the vane pump, fill it with hydraulic fluid
and turn pump by hand. Otherwise, the pump may be noisy or
even be damaged during operation.
♦ Use only the specified sort of fluid: hydraulic fluid, allocation
⇒ Electronic spare parts catalogue
♦ The quantity of fluid in the system is 0.7-0.9 litres.

There is no provision for repairing the vane pump. If problems are

reported, determine the cause by means of a pressure test and a
leakage test. If no fault is found, the vane pump unit must be re‐
newed.

212 Rep. gr.48 - Steering

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1 - Console
❑ Removing and installing
⇒ Rep. gr. 13 ; Cylinder
block, pulley end; Re‐
moving and installing
ancillary bracket
2 - Spacer
❑ Press back before in‐
stalling vane pump
3 - Bolt
❑ Securing bolt of vane
pump on bracket
❑ 25 Nm
4 - Suction hose
❑ From reservoir to vane
pump
❑ Pay attention of installa‐
tion position on vane
pump, see
⇒ Item 6 (page 213) or
⇒ Item 7 (page 213)
5 - Spring-type clip
❑ Fit spring-type clip on
colour identification us‐
ing hose clip pliers -
V.A.G 1921-
6 - Suction hose marking
❑ Suction hose marking
must line up with mark‐
ing on vane pump pipe
⇒ Item 7 (page 213)
when installed
7 - Marking on vane pump pipe
❑ Marking on vane pump
pipe must line up with suction hose marking ⇒ Item 6 (page 213) when installed
8 - Vane pump
❑ Altered version ⇒ Varioserv version from model year 2010 ►
❑ Vane pump adapts displacement to actual requirement; used with all 4-cyl. diesel engines only
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ Removing and installing ⇒ page 220
9 - Pulley
❑ For removal/installation, use 2-hole pin wrench - 3212- as counterhold
10 - Bolts
❑ Securing bolts of pulley on vane pump
❑ 25 Nm
11 - Seal
❑ Renew after removal
12 - Bolts
❑ Securing bolts for block connection of pressure line
❑ 9 Nm

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13 - Pressure line

Caution
Insert pressure line com‐
pletely when installing.

14 - Bolt
❑ Securing bolt of vane pump on bracket
❑ 25 Nm

3.1.5 Assembly overview - vane pump, 4-cyl‐

inder petrol engine, model year 2010 ►

Note

♦ Never reuse hydraulic that has escaped; always dispose of it

in an ecologically responsible manner.
♦ Vane pumps from the parts stock are supplied dry (without
fluid). Before installing the vane pump, fill it with hydraulic fluid
and turn pump by hand. Otherwise, the pump may be noisy or
even be damaged during operation.
♦ Use only the specified sort of fluid: hydraulic fluid, allocation
⇒ Electronic spare parts catalogue
♦ The volume of fluid in the system is 0.7-0.9 litres.

214 Rep. gr.48 - Steering

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1 - Console
2 - Spacer
❑ Press back before in‐
stalling vane pump
3 - Bolt
❑ Securing bolt of vane
pump on bracket
❑ 25 Nm
4 - Suction hose
❑ From reservoir to vane
pump
❑ Observe installation po‐
sition on vane pump,
see
⇒ Item 6 (page 215)
5 - Spring-type clip
❑ Fit spring-type clip on
colour identification us‐
ing hose clip pliers -
V.A.G 1921-
6 - Suction hose marking
❑ Suction hose marking
must line up with mark‐
ing on vane pump pipe
⇒ Item 7 (page 215)
when installed
7 - Marking on vane pump pipe
❑ Marking on vane pump
pipe must line up with
suction hose marking
⇒ Item 6 (page 215)
when installed
8 - Vane pump
❑ Removing and installing ⇒ page 220
9 - Pulley
❑ Use counter-hold tool - T10172- to install/remove.
10 - Bolts
❑ Securing bolts of pulley on vane pump
❑ 25 Nm
11 - Seal
❑ Renew after removal
12 - Bolts
❑ Securing bolts for block connection of pressure line
❑ 9 Nm
13 - Pressure line

Caution
Insert pressure line com‐
pletely when installing.

14 - Bolt
❑ Securing bolt of vane pump on bracket

3. Hydraulic power steering 215

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❑ 25 Nm

3.2 Checking hydraulic fluid level of power

steering
⇒ “3.2.1 Checking fluid level when cold”, page 216
⇒ “3.2.2 Checking fluid level at operating temperature (from ap‐
prox. 50°C)”, page 216

3.2.1 Checking fluid level when cold

• Engine switched off
• Front wheels in straight-ahead position
– Unscrew reservoir cap with fitted dipstick.
– Wipe dipstick with a clean cloth.
– Screw filler cap on hand-tight and unscrew again.

Note

The cap must be fully screwed on in order to obtain an accurate

fluid level reading.

– Check fluid level. The fluid level must be near the min. marking
(up to 2 mm above or below mark).

Note

♦ If fluid level is above specified range, fluid must be extracted.

♦ If fluid level is below specified area, hydraulic system must be
checked for leaks (repair measure). It is not sufficient just to
top up with fluid.
♦ If hydraulic system is free of leaks, top up fluid ⇒ Electronic
Parts Catalogue .

– Screw cap on hand-tight.

3.2.2 Checking fluid level at operating tem‐

perature (from approx. 50°C)
Carry out following procedure:
– With the engine switched off, turn wheels to straight-ahead
position.
– Unscrew sealing cover with built-in dipstick from tank.
– Wipe dipstick with a clean cloth.
– Screw filler cap on hand-tight and unscrew again.

Note

The cap must be fully screwed on in order to obtain an accurate

fluid level reading.

– Check fluid level: The fluid level should be between the min.
and max. markings.

216 Rep. gr.48 - Steering

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Note

♦ If fluid level is above the max. marking, fluid must be extracted.

♦ If fluid level is below the min. marking, the hydraulic system
must be checked for leaks (repair measure). It is not sufficient
just to top up with fluid. If hydraulic system is free of leaks, top
up hydraulic fluid ⇒ Electronic Parts Catalogue .

– Screw cap on hand-tight.

3.3 Bleeding steering system after repairs

– Check hydraulic fluid level and top up if necessary.
– Raise vehicle until front wheels are free.
– With engine switched off, turn steering wheel 10 times from
lock to lock.
– Check hydraulic fluid level and top up if necessary.
– Lower vehicle.
– Start engine.
– Turn steering wheel 10 times from lock to lock.
– Check hydraulic fluid level and top up if necessary
⇒ page 216 .
Any air remaining in steering system will dissipate by itself over
the next 10 … 20 km driven.

3.4 Check steering for leaks

Note

If hydraulic fluid level in reservoir is low after repairs are comple‐

ted, steering system must be checked for leaks.

– Start engine.
– Turn steering wheel left and right to lock and hold briefly.
This develops the maximum possible pressure.
In this position, the following components must be checked for
leaks:
♦ Pinion seal on steering rack valve housing
♦ All pipe connections
♦ Rack seals ⇒ page 206

3.5 Checking delivery pressure of vane

pump
Special tools and workshop equipment required

3. Hydraulic power steering 217

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♦ Power steering tester - V.A.G 1402-

♦ Adapter set - V.A.G 1402/6-

♦ Hose clamp to 25 mm - 3094-

♦ Adapter set - V.A.G 1402/19–1+2-

Procedure
– Clamp off suction and return hoses at reservoir using hose
clamp, up to 25 mm - 3094- .
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Noise insulation .
– Position suitable drip tray underneath to collect hydraulic fluid.

218 Rep. gr.48 - Steering

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– Unscrew pressure line -2- from steering rack -1-.

– Fit special tools as shown in illustration.

1 - Power steering tester - V.A.G 1402-
2 - Hose from adapter set - V.A.G 1402/6-
3 - Adapter - V.A.G 1402/19–1-
4 - Seal
5 - Connection of pressure line
6 - Pressure line vane pump/steering rack
7 - Adapter - V.A.G 1402/19-2-
8 - Seal
– Remove hose clamp, up to 25 mm - 3094- from return suction
hose.

Lever on power steering tester - V.A.G 1402- must be in position

-2-.
– Start engine.
– Turn steering wheel approx. 10 times from lock to lock.
– Switch off engine and check hydraulic fluid level, if necessary
replenishing it ⇒ page 216 .
– Check delivery pressure
Prerequisites for testing:
• System must be free of leaks
• Hoses and lines are not kinked or restricted.
• Poly V-belt tension OK.

Caution

Ensure that the shut-off valve is not closed in position -1- for
more than 5 seconds to avoid damage to the vane pump.
Take pump pressure reading immediately after shut-off valve
closes. Employ the aid of a second mechanic if necessary.

– Start engine. Set shut-off valve to closing position -1- with en‐
gine idling.

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– Read pressure from power steering tester - V.A.G 1402- .

Specification for delivery pressure:
110 to 120 bar
If the specification is not attained, renew the vane pump.
– Switch off engine.
– Clamp off suction and return hoses at reservoir using hose
clamp, up to 25 mm - 3094- .
– Remove pressure gauge and adapter.

– Install pressure line leading to steering rack.

Note

When tightening pressure line, ensure that locating mechanism

of pressure line -2- is in contact with housing -1-.

– Remove hose clamp, up to 25 mm - 3094- from return suction

hose.
– Bleed steering system ⇒ page 217 .
– Check hydraulic fluid level and replenish if necessary
⇒ page 216 .
– Check steering system for leaks ⇒ page 217 .
– Install noise insulation (if previously fitted) ⇒ General body
repairs, exterior; Rep. gr. 50 ; Noise insulation .

3.6 Removing and installing vane pump

⇒ “3.6.1 Removing and installing vane pump, 4-cylinder and 6-
cylinder petrol engines”, page 220
⇒ “3.6.2 Removing and installing vane pump, 4-cylinder diesel
engine”, page 222
⇒ “3.6.3 Removing and installing vane pump, 5-cylinder diesel
engine”, page 225
⇒ “3.6.4 Removing and installing vane pump, 4-cylinder diesel
engine, 2010 ►”, page 227
⇒ “3.6.5 Removing and installing vane pump, 4-cylinder petrol
engine, 2010 ►”, page 233

3.6.1 Removing and installing vane pump, 4-

cylinder and 6-cylinder petrol engines
Special tools and workshop equipment required

220 Rep. gr.48 - Steering

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♦ Hose clamps to 25 mm - 3094-

♦ Torque wrench - V.A.G 1331-

Removing
– Clamp off suction hose at reservoir using hose clamp, up to
25 mm - 3094- .
– Release tension on poly V-belt ⇒ Rep. gr. 27 ; Alternator C;
Removing and installing alternator C .
– Clamp off suction hose on vane pump with hose clamps up to
25 mm diameter - 3094- .
– Remove suction hose.
– Unbolt pressure line.
– Catch escaping hydraulic fluid.
– Unbolt power steering pump from bracket
⇒ Item 9 (page 208) and remove pump.
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Install vane pump in bracket and tighten bolts.
– Attach pressure line with new seals and tighten
⇒ Item 2 (page 208) .
– Attach suction hose.
– Remove hose clip.
– Lay poly V-belt over pulleys and tension belt ⇒ Rep. gr. 27 ;
Alternator C; Removing and installing alternator C .
– Fill with hydraulic fluid.
– Bleed steering system and check for leaks ⇒ page 217 .
– Checking power steering fluid level ⇒ page 216

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Specified torques
♦ ⇒ “3.1 Assembly overview - vane pump”, page 207

3.6.2 Removing and installing vane pump, 4-

cylinder diesel engine
Special tools and workshop equipment required
♦ Hose clamps to 25 mm - 3094-

♦ Torque wrench - V.A.G 1331-

Removing

222 Rep. gr.48 - Steering

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– Relieve tension on poly V-belt ⇒ Rep. gr. 27 ; Alternator C;

Removing and installing alternator C .
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Noise insulation .
– Remove poly V-belt pulley.
– Clamp off suction hose -2- for vane pump using hose clamps,
up to 25 mm - 3094- .
– Loosen clip with hose clip pliers - V.A.G 1921- -4- and pull
suction hose -2- off connection.
– Catch hydraulic fluid which runs out in an oil drain tub .
– Unscrew banjo bolt for pressure line -6- from vane pump -5-.
– Unscrew securing bolts -1- and -3- for vane pump -5-.
– Remove vane pump -5- from bracket.
Installing
Install in the reverse order of removal, observing the following:

3. Hydraulic power steering 223

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– Locate power steering pump in bracket -5-.

– Bolt on vane pump -5-.
– Attach pressure line with new seals ⇒ Item 2 (page 209) .
– Attach suction hose -2- and hose clip -4- with hose clip pliers
- V.A.G 1921- .
– Top up hydraulic fluid if necessary. Allocation ⇒ Electronic
Parts Catalogue .
– Bleed steering system and check for leaks ⇒ page 217 .
– Check fluid level of steering system ⇒ page 216 .
– Install noise insulation (if previously fitted) ⇒ General body
repairs, exterior; Rep. gr. 50 ; Noise insulation .
Specified torques
♦ ⇒ “3.1 Assembly overview - vane pump”, page 207
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.
gr. 50 ; Assembly overview - noise insulation

224 Rep. gr.48 - Steering

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3.6.3 Removing and installing vane pump, 5-

cylinder diesel engine
Special tools and workshop equipment required
♦ Hose clamps to 25 mm - 3094-

♦ Torque wrench - V.A.G 1331-

Removing
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Noise insulation .
– Remove support mounting and front torque reaction support
⇒ 5-cylinder diesel engine; Rep. gr. 10 ; Removing and in‐
stalling front torque reaction support .
Vehicles with air conditioner:
– Remove air conditioning compressor and secure compressor
to body ⇒ Heating, air conditioning; Rep. gr. 87 ; Repairs to
refrigerant circuit which may be performed only in appropriate
workshops with trained mechanics .

Caution

Refrigerant lines must not be strained!

– Remove elastic drive coupling ⇒ Item 6 (page 211) .

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Continuation for all vehicles:

– Clamp off suction hose for vane pump using hose clamps, up
to 25 mm - 3094- .
– Separate clamp -2- from suction hose using hose clip pliers -
V.A.G 1921- and pull off suction hose.
– Catch hydraulic fluid which runs out in an oil drain tub .
– Unscrew banjo bolt for pressure line -1- from vane pump -4-.
– Loosen bolts -3- for vane pump and then pull vane pump -4-
out of cylinder block.

226 Rep. gr.48 - Steering

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Installing
Install in the reverse order of removal, observing the following:
– Lubricate seal -1- before inserting it in vane pump
⇒ Item 2 (page 211) .
– Bolt vane pump to cylinder block ⇒ Item 5 (page 211) .
– Attach suction hose and hose clip with hose clip pliers - V.A.G
1921- .

Note

♦ Vehicles from vehicle identification number

WV2ZZZ7HZ8H157811 and WV1ZZZ7JZ8X021717 have a
new pressure line installed. Note modified torque on vane
pump connection ⇒ page 212 .
♦ Allocation ⇒ Electronic parts catalogue “ETKA”

– Attach pressure line with new seals.

Vehicles with air conditioner:
– Install elastic drive coupling.
– Fit air conditioning compressor ⇒ Rep. gr. 13 ; Dismantling
and assembling engine, Part III .
Continuation for all vehicles:
– Install support mounting and front torque reaction support ⇒
5-cylinder diesel engine; Rep. gr. 10 ; Removing and installing
front torque reaction support .
– Remove hose clamps up to 25 mm - 3094- .
– Top up hydraulic fluid if necessary. Allocation ⇒ Electronic
Parts Catalogue
– Bleed steering system and check for leaks ⇒ page 217 .
– Check fluid level in power steering ⇒ page 216 .
– Install noise insulation (if previously fitted) ⇒ General body
repairs, exterior; Rep. gr. 50 ; Noise insulation .
Specified torques
♦ ⇒ “3.1 Assembly overview - vane pump”, page 207
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.
gr. 50 ; Assembly overview - noise insulation
♦ Air conditioning compressor, Removing and installing air con‐
ditioning compressor ⇒ Rep. gr. 87 ; Air conditioning com‐
pressor

3.6.4 Removing and installing vane pump, 4-cylinder diesel engine, 2010 ►

3. Hydraulic power steering 227

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Special tools and workshop

equipment required

♦ Drip tray for workshop hoist - VAS 6208-

♦ Hose clip pliers - V.A.G 1921-
♦ Counterhold - T10172-
♦ Engine bung set - VAS 6122-
♦ Torque wrench - V.A.G 1331-
♦ Hose clamps to 25 mm - 3094-
Procedure
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Noise insulation .
– Remove poly V-belt ⇒ Engine/gearbox assembly; Rep. gr.
13 ; Removing and installing poly V-belt

Note

Before removing poly V-belt, mark running direction. A used belt

can break if it runs in the opposite direction. When installing belt,
ensure that it is correctly seated in pulleys.

228 Rep. gr.48 - Steering

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Vehicles with air conditioning system

– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Air conditioner compressor; Removing and
installing air conditioner compressor .
Continued for all vehicles
– Remove poly V-belt pulley -1-. When loosening bolts -2- brace
with counter-hold - T10172- .
– Position drip tray for workshop hoist - VAS 6208- underneath
vane pump.
– Clamp off suction hose -1- at vane pump with hose clamps,
up to 25 mm - 3094- -2-.

– Loosen clip -3- using hose clip pliers - V.A.G 1921- . Detach
hose -1- from nozzle -4-.
– Seal suction hose with a suitable plug from engine plug set -
VAS 6122- .
– Unscrew bolts of pressure line -1- and remove pressure line
from vane pump -2-.
– Seal pressure line with a suitable plug from engine plug set -
VAS 6122- .

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– Unscrew bolt -3-.

– Unscrew bolts -1- of vane pump -2-.

– Remove vane pump -2- from bracket -3-.

– Unscrew bolt of bumper cover -3-.
– Remove coolant hose -1- from plastic bracket -2- and pull
coolant hose away to side.

– Swing vane pump -4- out forwards over cross-member. Pull

bumper cover -5- forwards slightly as you do so.

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– To prepare for installation, press spacer -1- back until flush

with bracket -2-.
Installing
Install in the reverse order of removal, observing the following:

Note

♦ Always remove seals and oil seals.

♦ Before installing a new vane pump, fill with hydraulic oil on suction side. Turn vane pump by hand until
hydraulic oil exits from pressure side.

– Swing vane pump in from below over front cross-member.

– Insert vane pump -7- into bracket -1-. Fit bolts by hand.
Pay attention to tightening sequence of securing bolts:
– First tighten vane pump bolts -8-.
– Then tighten vane pump bolts -3-.
– Fit pressure line -2- with new seal ⇒ Item 11 (page 213) .

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Note

Make sure that pressure line -2- is pressed fully into block connection of vane pump.

– Fit suction hose -5- to connection of vane pump -6-. When

installing, make sure that markings -arrow- align.
– Fit spring-type clip ⇒ Item 5 (page 213) using hose clip pliers
- V.A.G 1921- in marked area.
– Loosen hose clamps, up to 25 mm - 3094- on suction hose
-5-.

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– Install poly V-belt pulley -1- and tighten bolts -2-. When doing
this, brace using counter-hold - T10172- .
– Install poly V-belt for vane pump ⇒ Rep. gr. 13 .
– Top up hydraulic fluid if necessary. Allocation ⇒ Electronic
parts catalogue
– Bleed steering system and check for leaks ⇒ page 217 .
– Check oil level in steering system and top up, if necessary
⇒ page 216 .
Specified torques
♦ ⇒ “3.1 Assembly overview - vane pump”, page 207
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.
gr. 50 ; Assembly overview - noise insulation
♦ Air conditioner compressor; Assembly overview - drive unit for
air conditioner compressor ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air conditioner compressor; Assembly overview - drive
unit for air conditioner compressor

3.6.5 Removing and installing vane pump, 4-cylinder petrol engine, 2010 ►

Special tools and workshop

equipment required

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♦ Drip tray for workshop hoist - VAS 6208-

♦ Hose clip pliers - V.A.G 1921-
♦ Counterhold - T10172-
♦ Engine bung set - VAS 6122-
♦ Torque wrench - V.A.G 1331-
♦ Hose clamps to 25 mm - 3094-
Procedure
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Noise insulation .
– Remove poly V-belt ⇒ Engine/gearbox assembly; Rep. gr.
13 ; Removing and installing poly V-belt

Note

Before removing poly V-belt, mark running direction. A used belt

can break if it runs in the opposite direction. When installing belt,
ensure that it is correctly seated in pulleys.

Vehicles with air conditioning system

– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Air conditioner compressor; Removing and
installing air conditioner compressor .
Continued for all vehicles
– Remove poly V-belt pulley -1-. When loosening bolts -2- brace
with counter-hold - T10172- .
– Position drip tray for workshop hoist - VAS 6208- underneath
vane pump.
– Clamp off suction hose -1- at vane pump with hose clamps,
up to 25 mm - 3094- -2-.

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– Loosen clip -3- using hose clip pliers - V.A.G 1921- . Detach
hose -1- from nozzle -4-.
– Seal suction hose with a suitable plug from engine plug set -
VAS 6122- .
– Unscrew bolts of pressure line -1- and remove pressure line
from vane pump -2-.
– Seal pressure line with a suitable plug from engine plug set -
VAS 6122- .

– Unscrew bolt -3-.

– Unscrew bolts -1- of vane pump -2-.

– Remove vane pump -2- from bracket -3-.

– Remove vane pump between subframe and engine.

3. Hydraulic power steering 235

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– To prepare for installation, press spacer -1- back until flush

with bracket -2-.
Installing
Install in the reverse order of removal, observing the following:

Note

♦ Always remove seals and oil seals.

♦ Before installing a new vane pump, fill with hydraulic oil on suction side. Turn vane pump by hand until
hydraulic oil exits from pressure side.

– Insert vane pump -7- into bracket -1-. Fit bolts by hand.
Pay attention to tightening sequence of securing bolts:
– First tighten vane pump bolts -8-.
– Then tighten vane pump bolts -3-.
– Fit pressure line -2- with new seal ⇒ Item 11 (page 215) .

236 Rep. gr.48 - Steering

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Note

Make sure that pressure line -2- is pressed fully into block connection of vane pump.

– Fit suction hose -5- to connection of vane pump -6-. When

installing, make sure that markings -arrow- align.
– Fit spring-type clip ⇒ Item 5 (page 215) using hose clip pliers
- V.A.G 1921- in marked area.
– Loosen hose clamps, up to 25 mm - 3094- on suction hose
-5-.

3. Hydraulic power steering 237

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– Install poly V-belt pulley -1- and tighten bolts -2-. When doing
this, brace using counter-hold - T10172- .
– Install poly V-belt for vane pump ⇒ Rep. gr. 13 .
– Top up hydraulic fluid if necessary. Allocation ⇒ Electronic
parts catalogue
– Bleed steering system and check for leaks ⇒ page 217 .
– Check oil level in steering system and top up, if necessary
⇒ page 216 .
Specified torques
♦ ⇒ “3.1 Assembly overview - vane pump”, page 207
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.
gr. 50 ; Assembly overview - noise insulation
♦ Air conditioner compressor; Assembly overview - drive unit for
air conditioner compressor ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air conditioner compressor; Assembly overview - drive
unit for air conditioner compressor

238 Rep. gr.48 - Steering