Volkswagen Phaeton - Volkswagen Technical Site

Rear axle (front and all wheel drive), servicing

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Volkswagen Phaeton 42 - 2

Rear axle (front and all wheel drive), servicing Note :

If components with bonded rubber bushings were replaced or bolts/nuts on these components were loosened, corresponding wheel suspension must be lifted into curb weight position 40-2, Wheel bearing, lifting to curb weight position .

Always replace self-locking nuts.

Always replaced corroded nuts and bolts.

I - Subframe, assembly overview 423, I - Subframe, assembly overview II - Link, tie rod, air spring strut, assembly overview 42-4, II - Link, tie

Rear axle (front and all wheel drive), servicing

rod, air spring strut, assembly overview III - Wheel bearing, assembly overview 42-5, III - Wheel bearing, assembly overview IV - Driveshaft, assembly overview 42-6, IV - Drive axle, assembly overview

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I - Subframe, assembly overview

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42 - 3


On vehicles with front wheel drive, only subframe and mounting components are installed.

Final drive

Removing and installing

Repair Manual, Automatic Transmission, Repair Group 39, Rear final drive, removing and installing

Hex bolt

Washer


Hex nut

40 Nm

Self-locking

Always replace

Hex bolt

130 Nm plus an additional 90 ( 1 / 4 turn)

Always replace

Washer

Washer

Subframe

Steel version

This version is replaced in 2004 with the aluminum version

Application Electronic Parts Catalog "ETKA"

Subframe

Aluminum version


Hex socket head bolt

55 Nm

Washer

Hex nut

40 Nm

Self-locking

Always replace

Cross member

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Hex bolt

Final drive support

For vehicles with V6 and W12 drivetrain


Final drive support

For vehicles with V8 and V10 drivetrain


Hex bolt


Always replace

Multi-point socket head bolt

20 Nm

Brace

Between rear final drive and final drive support

For vehicles with V8 and V10 drivetrain


Subframe, removing and installing

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Special tools, testers and auxiliary items required

Engine/transmission jack V.A.G 1383 A

Tightening strap T10038

Torque wrench V.A.G 1332

Removing

- Brake pedal loading device V.A.G 1869/2 . - Remove rear wheels. - Remove rear cover on rear bumper

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Repair Manual, Body Exterior, Repair Group 63, Bumper cover, removing and installing . - Disconnect all electrical wires from body to rear axle. Note:

Secure vehicle to hoist to continue procedure.

- Remove plugs (2 per vehicle side).

- Secure vehicle to hoist lifting arm with Tensioning Strap T10038 . - Remove rear section of exhaust system

Repair Manual, Engine Mechanical, Fuel Injection Ignition, Repair Group 26, Exhaust system parts, removing and installing - Disconnect brake lines. - Remove brake cable from rear axle

Repair Manual, Brake System, Repair Group 46, Rear brake cable, removing and installing .

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- Remove heat shield - 1 - from spare wheel well - arrows . - Remove drive shaft from rear final drive and tie up to body

Repair Manual, Automatic Transmission, Repair Group 39, Drive shaft, removing and installing . - Place engine/transmission jack V.A.G 1383 A with Support 1359/2 below final drive.

- Remove nut - 1 - , remove bolt - 2 - and press air spring strut - 3 - to center of vehicle. - Remove subframe from body. - Slowly lower rear axle. Installing

Installation is in reverse order of removal, note the following: - Tighten subframe with bolts originally installed. Replace these with new bolts after vehicle alignment. - Tighten bolts originally installed to specified torque

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without additional tightening. - Tighten drive shaft to rear final drive

Repair Manual, Automatic Transmission, Repair Group 39, Drive shaft, removing and installing . - Attach brake caliper to brake carrier

Repair Manual, Brake System, Repair Group 46, Rear brakes, servicing; Disc brakes . - Adjust parking brake

Repair Manual, Brake System, Repair Group 46, Rear brakes, servicing; Disc brakes; Parking brake, adjusting . - Bleed brake system

Repair Manual, Brake System, Repair Group 47, Brake system, bleeding . - Install wheels and tighten - Perform vehicle alignment

44-2, Wheel mounting . 44-3, Wheel alignment .

Tightening torque Bumper to body Repair Manual, Body Exterior, Repair Group 63, Bumper cover, removing and installing Exhaust system to body Repair Manual, Engine Mechanical, Fuel Injection Ignition, Repair Group 26, Exhaust system components, removing and installing Drive shaft to body and final drive


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Repair Manual, Automatic Transmission, Repair Group 39, Drive shaft, removing and installing Air spring damper to lower link

80 Nm plus an additional 1 / 4 turn (90

1) 2)

Subframe to body 1)


1) Always

use new nuts and bolts

2) Tighten

bolts and nuts in curb weight position

)

II - Link, tie rod, air spring strut, assembly overview

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42 - 4

II - Link, tie rod, air spring strut, assembly overview Note :

If components with bonded rubber bushings were replaced or bolts/nuts on these components were loosened, corresponding wheel suspension must be lifted into curb weight position 40-2, Wheel bearing, lifting to curb weight position .

Welding and straightening work on supporting or wheel carrying components of the suspension is not permitted.

Always replace self-locking nuts.

Always replaced corroded bolts and nuts.


Wheel bearing housing

Removing and installing 42-5, Wheel bearing housing, removing and installing

Wheel bearing unit, removing and installing 42-5, Wheel bearing unit, removing and installing

Eccentric washer

Hex nut

95 Nm

Self-locking

Always replace

Coupling rod

For tie rod to lower link

Removing and installing 42-4, Tie rod to lower link connecting links, removing and installing

Washer

Hex nut

95 Nm

Self-locking

Always replace

Hex nut


)

Self-locking

Always replace

Hex nut

80 Nm plus an additional 1 / 4

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turn (90

Self-locking

Always replace

Hex head bolt

Lift the wheel bearing housing before fastening

Always replace

Lower link

Removing and installing 42-4, Lower link, removing and installing

Bracket

Hex nut


)

)

Self-locking

Always replace

Lift wheel bearing housing before fastening

Hex nut

Self-locking

Always replace

Hex head bolt


Always replace


Hex head bolt

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Always replace


Bracket

Hex bolt

Hex bolt


replace after every removal

Hex bolt

Self-locking

Always replace

Connecting link for vehicle level sensor Do not pull connecting link from ball joint!

Hex bolt

Always replace

Hex nut

10 Nm

10 Nm

Coupling rod

For stabilizer bar to lower link

Removing and installing 42-4, Stabilizer bar to lower link connecting links, removing and installing

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25 Nm

Stabilizer bar clamp

Stabilizer bar

Removing and installing 42-4, Stabilizer bar, removing and installing

Hex bolt


Always replace

Cable channel

Hex bolt


)

Always replace

Upper link

)

Removing and installing 42-4, Upper link, removing and installing

Hex nut

Self-locking

Always replace

Eccentric bolt

For toe adjustment

Bolt

Bolt

Tie rod

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Removing and installing 42-4, Tie rod, removing and installing

Eccentric washer

Hex nut

95 Nm

Self-locking

Always replace


Air spring strut

The air spring damper protective boot must not sustain any indentations!

Removing and installing 42-4, Air spring strut, removing and installing

Hex bolt


Always replace

Hex nut

Self-locking

Always replace

Eccentric bolt

For camber adjustment

Air spring strut, removing and installing


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Removing

During assembly work, make sure that no indentations form on boot of air spring strut!

- Remove level control system sensor bolt - 2 - from lower link.

- Remove nut - 1 - , remove bolt - 2 - and press air spring strut - 3 - to center of vehicle. - Remove wheel housing liner

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Repair Manual, Body Exterior, Repair Group 66, Wheel housing liner, removing and installing; Rear wheel housing liner . Left rear - Remove air line (yellow) from reservoir. Seal off both air connections after air is released.

- Remove reservoir - A - by removing air line - 1 - and hex nuts - arrows - . - Disconnect damper adjustment switching valve electrical connector. Right rear

- Remove hex screw - 1 - and move tank - B - as far down as possible. - Disconnect damper adjustment switching valve electrical connector. - Remove air line from air spring strut and seal off both connectors. Continued for all vehicles The wheel bearing housing must be pulled down slightly so

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that the strut can be removed. If air spring strut is to be replaced, first read the following 42-4, Air spring strut, filling . Installing

Installation is in reverse order of removal, note the following: During assembly work, make sure that no indentations form on boot of air spring shock absorber! - Insert air spring strut and tighten. - Attach air spring strut to link. - Raise wheel bearing housing to tighten. - Check basic setting of level control system Vehicle Diagnosis, Testing and Information System VAS 5051 . Tightening torque Connecting link from vehicle level sensor to lower link

10 Nm 80 Nm plus an additional 1 / 4 turn (90

Air spring strut to lower link 1)

)

2)

Wheelhouse liner to body Repair Manual, Body Exterior, Repair Group 66, Wheelhouse liner, removing and installing; Rear wheelhouse liner Air line to air spring strut

5 Nm

Reservoir to body

9 Nm

Air spring strut to body

30 Nm

1) Always


2) Tighten


Air spring strut, filling



Adapter T10157

Air suspension strut charger VAS 6231 , not illustrated

Steel gas cylinder filled with Argon or Corgon, not depicted

Note:

Air spring struts are supplied as replacement parts with a minimum pressure. By sitting in storage for extended periods this minimum pressure can diminish (just like a tire). Before the air spring strut is removed from its packaging, this minimum pressure must be controlled and restored by "refilling" . Without this necessary refilling, folds can form in the underfilled air spring boot. These folds cause damage which can lead to premature failure.

- Remove cover from packaging.

- Remove union bolt - arrow - from residual pressure retaining valve. Illustration shows front air spring strut. - Close steel gas bottle pressure valve.

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Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

- Become familiar with relevant rules for prevention of accidents for pressurized containers and technical gases.

- Connect air spring filler unit VAS 6231 and adapter T10157 as shown in illustration.

Air spring strut in packaging Steel gas bottle for argon, corgon with gauges Air spring filler unit VAS 6231 Adapter T10157

- Set flow rate limiter gauge to 2.0 L/min - arrow - . - Fill gas into air spring strut using several individual pressure bursts.


The display only shows a correct gas pressure if the "oscillatory pressure" of the residual pressure retaining valve is overcome. The "oscillatory pressure" is at approx. 3.5 bar. When the display reaches 3.5 to 4.5 bar, air spring damper is sufficiently filled with gas. - Make sure gas pressure does not exceed 4.5 bar when filling. - Disconnect air spring filler unit VAS 6231 from adapter T10157 . This dissipates the gas above an internal pressure of 3.5 bar. Minimum pressure is reproduced, air spring strut can be removed from packaging. - After installation, first drive the vehicle at high ride height and then at normal ride height. Repeat this sequence once more. By moving the ride height settings twice, the majority of the gas is exchanged with filtered air from the air supply motor. - Install air spring strut

42-4, Installing .

Stabilizer bar, removing and installing



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Removing

- Remove wheels.

- Remove heat shield - 1 - from spare wheel well - arrows .

- Remove stabilizer bar - 1 - from left and right connecting links - arrow - . - Remove tie rod

42-4, Removing .

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- Remove nut - 1 - , remove bolt - 2 - and press air spring strut - 3 - to center of vehicle.

- Remove bolts - arrows - evenly on both sides. - Turn stabilizer bar so that clamps - 1 - can be guided out of notches on subframe. - Remove clamps - 1 - from stabilizer bar brackets. - Turn stabilizer bar so that connecting link mounts face downward. - Guide stabilizer bar out toward left. Installing

- Guide in stabilizer bar from left over exhaust system. - Place clamps on stabilizer bar bracket. Make sure longer clamp tab faces opposite to direction of travel.

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- Turn stabilizer bar in subframe so that clamps - 1 - project into subframe notches. - Install bolts - arrows - hand-tight evenly on both sides and tighten to specified torque.

- Move air spring strut - 3 - outward on link bracket and upward. - Insert bolt - 2 - and tighten nut - 1 - to specified torque. - Install tie rod

42-4, Installing .

- Tighten stabilizer bar - 1 - at left and right connecting links - arrow - .

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- Attach heat shield - 1 - to spare wheel well - arrows - . - Install wheels and tighten - Perform vehicle alignment


Tightening torque Air spring strut to upper link 1)


)


)

2)

Connecting link to stabilizer bar 1) 2)

Stabilizer bar to body 1) Always


2) Tighten


Upper link, removing and installing



Removing

25 Nm


- Remove wheel. - Remove brake caliper with brake carrier and brake disc

Repair Manual, Brake System, Repair Group 46, Brake caliper, removing and installing .

- Remove bolts - 1 - and remove cover plate - 2 - from wheel bearing housing.


- Remove cable channel - 1 - from upper link - 2 - .

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- Mark position of eccentric washer - 3 - to wheel bearing housing, e.g. using a felt tip pen. - Remove nut - 4 - and remove bolt - 5 - from wheel bearing housing.

- Remove nut from bolt - 1 - for securing upper link - 2 - to subframe. - Remove bolt - 1 - until it comes in contact with fuel tank 4 - - arrow - . - Lightly press bolt - 1 - in direction of - arrow - downward toward subframe while moving it slightly toward upper link. - Remove bolt - 1 - . - Move upper link toward wheel bearing housing until it comes out of subframe. - Remove upper link behind lower link. Installing

- Insert upper link in subframe.

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- Insert bolt - 1 - at a slight angle in upper link and then push in direction of - arrow - toward fuel tank - 4 - . - Insert bolt - 1 - straight into upper link and secure with a new nut.

- Install bolt - 5 - together with an eccentric washer - 3 - and nut - 4 - . - Install cable channel - 1 - to upper link - 2 - . - Install eccentric washer - 3 - to marking applied to wheel bearing housing and tighten nut - 4 - to specified torque.

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- Move air spring strut - 3 - outward on link bracket and upward. - Install bolt - 2 - and tighten nut - 1 - to specified torque. - Tighten upper link and subframe bolted connection to specified torque.

- Place cover plate - 2 - on wheel bearing housing and secure with screws - 1 - . - Install brake disc and brake caliper with brake carrier

Repair Manual, Brake System, Repair Group 46, Brake caliper, removing and installing . - Install wheel and tighten - Perform vehicle alignment


Tightening torque Upper link to subframe 1)


2)

Upper link to wheel bearing housing

95 Nm

)


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1) 2)

Air spring strut to upper link 1)


2)

Cover plate to wheel bearing housing 1) Always


2) Tighten


Tie rod, removing and installing



Removing

- Remove wheel.

- Mark location of eccentric washer to subframe, e.g. with a felt-tip pen. - Remove nut - 2 - , remove eccentric washer and eccentric bolt. - Pivot tie rod - 3 - down.

10 Nm

)


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- Remove nut - 1 - from tie rod. - Lightly press brake caliper upward and at the same time, remove tie rod from connecting link/wheel bearing housing mount. Installing

- Lightly press brake caliper upward and place tie rod in connecting link/wheel bearing housing mount.

- Pivot tie rod - 3 - upward in subframe. - Insert eccentric bolt and eccentric washer. - Turn eccentric bolt to marking applied to subframe and tighten nut - 2 - to specified torque. - Install nut - 1 - to tie rod and tighten to specified torque, counter holding at tie rod hex head, if necessary. - Install wheel and tighten

44-2, Wheel mounting .

- Perform vehicle alignment

44-3, Wheel alignment .

Tightening torque Tie rod to subframe 1)

95 Nm

2)

Tie rod to wheel bearing housing

1) 2)

1) Use

new nut

2) Tighten


Stabilizer bar to lower link connecting links, removing and installing


95 Nm



Removing

- Remove wheel.

- Remove bolt - 1 - . - Disconnect connecting link/lower link bolted connection 2-. - To remove bolt from connecting link, push wheel bearing housing downward. - Remove connecting link - 3 - . Installing

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- Attach connecting link - 3 - to lower link. - Insert a new bolt - 2 - for this and at the same time, attach brake line bracket - 4 - . - Hand-tighten new nut. - Screw connecting link to stabilizer bar with a new bolt - 1 . - Tighten connecting link/stabilizer bar bolt - 1 - to specified torque. - Tighten connecting link/lower link nut to specified torque. - Install wheel and tighten


Tightening torque Coupling rod to stabilizer 1)


)


)

2)

Connecting link to lower link 2) 3) 1) Use

new bolt

3) Use

new bolt and nut

2) Tighten

bolts in curb weight position

Tie rod to lower link connecting links, removing and installing



Removing


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- Remove wheel. 42-4, Removing .

- Remove tie rod

- Remove nut - 1 - . - Remove bolt - 2 - from lower link/connecting link. - Remove connecting link - 3 - from lower link. Installing

- Insert connecting link - 3 - in lower link. - Insert bolt - 2 - and hand-tighten nut - 3 - . - Install tie rod

42-4, Installing .

- Tighten bolt - 2 - to specified torque. - Install wheel and tighten


Tightening torque Connecting link to lower link 1) 2) 1) Use

new bolt and nut

2) Tighten



)


Lower link, removing and installing




Removing

- Remove wheel.

- Disconnect connecting link/lower link bolted connection 1-. - To remove bolt from connecting link, push wheel bearing housing downward.

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- Remove bolt from - 2 - level control system sensor.

- Remove nut - 1 - , remove bolt - 2 - and press air spring strut - 3 - to center of vehicle. - Remove brake line bracket bolt - 4 - . - Remove brake caliper with brake carrier and brake disc



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- Remove bolted connection nuts - 1 to 4 - from lower link 6-. - Remove screw - 5 - . - First remove bolt - 3 - and then bolt - 4 - . - Remove lower link from notches on subframe and swing downward.

- Remove bolt - 1 - and disengage lower link - 2 - from connecting link - 3 - . Installing

- Engage lower link - 2 - in wheel bearing housing and control link - 3 - . - Insert bolt - 1 - and secure with a new nut. - Pivot lower link - 2 - upward and press into notches in subframe.

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- First insert bolt - 3 - and then bolt - 4 - . Note:

To insert bolt, holes in bracket must be aligned with subframe.

- Move tie rod downward and place bolt - 5 - in lower link and connecting link. Note:

To insert bolt, trapezoidal link holes must be aligned with connecting link.

- Move air spring strut - 3 - outward on link bracket and upward. - Insert bolt - 2 - and tighten nut - 1 - to specified torque. - Install brake line bracket bolt - 4 - .

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- Tighten bolted connection nuts - 1 to 4 - .

- Place cover plate - 2 - on wheel bearing housing and secure with bolts - 1 - . - Install brake disc and brake caliper with brake carrier


- Connect connecting link/lower link bolted connection - 1 and tighten to specified torque. - Install bolt in - 2 - level control system sensor.

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- Install wheel and tighten - Perform vehicle alignment

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Tightening torque Lower link to subframe 1)

80 Nm plus an additional 1 / 4 turn (90 )

2)

Lower link to wheel bearing housing 1)


2)

Level control system sensor connecting link to lower link Air spring strut to lower link 1)

10 Nm 80 Nm plus an additional 1 / 4 turn (90 )

2)

Stabilizer bar connecting link to lower link 1)


2)

Tie rod connecting link to lower link 1)


2)

Cover plate to wheel bearing housing 1) Use

new bolt and nut

2) Tighten


10 Nm

III - Wheel bearing, assembly overview

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42 - 5


Wheel bearing housing

Removing and installing 42-5, Wheel bearing housing, removing and installing

Servicing 42-5, Wheel bearing housing bonded rubber bushings, replacing

Wheel bearing

Replacing 42-5, Wheel bearing, replacing

Slide washer

Always replaced together with


wheel bearing Item - 2 - or wheel hub Item - 4

Wheel hub

Replacing 42-5, Slide washer, prying out

Replacing 42-5, Wheel bearing, replacing

Wheel bearing unit

Consists of wheel bearing Item - 2 - , slide washer Item - 3 - and wheel hub Item - 4 -

Removing and installing 42-5, Wheel bearing unit, removing and installing

Shield plate

Bolt, 10 Nm

Hex socket head collar bolt


Always replace


Bolt, 23 Nm

Cover

Drive axle

Removing and installing 42-6, Drive axle, removing and installing

Servicing servicing


Bolt, 70 Nm

42-6, Drive axle,

Стр. 2 из 16


First pre-tighten to 10 Nm then tighten diagonally to specified torque

Backing plate

Stub axle

Bonded rubber bushing

Bearing with large contact surface

Replace with bonded rubber bushing Item - 16 -

Installing 42-5, Wheel bearing housing bonded rubber bushings, replacing

Bonded rubber bushing

Bearing with small contact surface

Replace with bonded rubber bushing Item - 15 -

Installing 42-5, Wheel bearing housing bonded rubber bushings, replacing

Cap bolts

Follow tightening sequence:

80 Nm plus an additional 135 turn

Rotate bolt back 360


Always replace

Wheel bearing housing, removing and installing


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Removing

- Remove hex socket head collar bolt from drive axle 6, Drive axle, removing and installing .

42-

- Remove bolt - 1 - from speed sensor - 2 - . - Pull speed sensor out from wheel bearing housing. - Remove brake caliper with brake carrier and brake disc





- Remove tie rod - 2 -

42-4, Removing .

- Mark location of bolted connection eccentric bolt - 1 - to wheel bearing housing - 4 - , e.g. with a felt-tip pen. - Remove bolt - 1 - from upper link.

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- Remove bolt - 3 - from lower link. - Remove wheel bearing housing - 4 - from drive axle and out of suspension.

- If wheel bearing unit should be removed, then clamp wheel bearing housing in vise with protective covers. - To remove wheel bearing unit, remove bolts - arrows - . Installing

- Place wheel bearing housing - 4 - on drive axle. - Insert wheel bearing housing - 4 - on upper link and in lower link. - Install new bolts - 1 - and - 3 - and secure with new nuts - Install tie rod - 2 -

42-4, Installing .

- Turn bolted connection eccentric washer - 1 - to mark placed on wheel bearing housing and tighten nut to specified torque. Note:

Do not turn eccentric bolt more than 90 left or right (that is smallest to largest possible adjustment).

Стр. 6 из 16


- Tighten bolt - 3 - to specified torque.

- Place cover plate - 2 - on wheel bearing housing and secure with bolts - 1 - .

- Move air spring strut - 3 - outward on link bracket and upward. - Insert bolt - 2 - and tighten nut - 1 - to specified torque. - Install brake disc and brake caliper with brake carrier


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- Insert speed sensor - 2 - in wheel bearing housing and tighten bolt - 1 - . - Tighten drive axle hex socket head collar bolt 6. - Install wheel and tighten - Perform vehicle alignment

Topic 42-


Tightening torque Lower link to wheel bearing housing

80 Nm plus an additional 90

1)

( 1 / 4 turn)

2)

Upper link to wheel bearing housing

95 Nm

1) 2)

Air spring strut to lower link

80 Nm plus an additional 90

1) 2)

Cover plate to wheel bearing housing 1) Use

10 Nm

new bolt and nut

2) Tighten


Wheel bearing unit, removing and installing



Removing

- Remove axle pins or drive axle removing and installing .

42-6, Drive axle,

- Remove brake caliper with brake carrier and brake disc

( 1 / 4 turn)


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- Remove bolts - 1 - . - Remove wheel bearing unit from wheel bearing housing. Installing

- Insert wheel bearing unit in wheel bearing housing and tighten bolts - 1 - . - Install brake disc and brake caliper with brake carrier

Repair Manual, Brake System, Repair Group 46, Brake caliper, removing and installing . - Install axle pins or drive shaft

Topic 42-6 .

Tightening torque Wheel bearing unit to wheel bearing housing 1)

Follow tightening sequence: 1st, 80 Nm plus an additional 135


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2nd, turn bolt back 360 3rd, 80 Nm plus an additional 90 1) Use

new botls

Wheel bearing, replacing


Thrust plate VW 401

Thrust plate VW 402

Punch VW 407

Punch VW 412

Thrust pad VW 511

( 1 / 4 turn)


Press tube 30-100



KUKKO separating tool 17/2 Abbildung 3

Assembly tool T40089/2

Pressing out hub

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- Press out wheel hub.

- Insert separating tool in bearing inner race ring groove arrow - and pretension threaded spindle. Note:

Use a commercially-available separating tool , for example Kukko 17/2 .

This deforms slide washer and it must be replaced. - Press bearing inner race of wheel hub.

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Pressing off bearing inner ring

Slide washer, prying out

- Carefully pry out old slide washer - 1 - with a screwdriver. Wheel hub, pressing in

- Position new slide washer on wheel hub.

Стр. 13 из 16


- Install special tools as shown in illustration.

Press piece VW 473 Assembly tool T40089/2 Slide washer Wheel hub Thrust plate VW 401

Note:

Slide washer must be pressed on up to wheel bearing hub radius.

- Press wheel hub into wheel bearing to stop. Wheel bearing housing bonded rubber bushings, replacing


Стр. 14 из 16


Assembly tool 3292

Press piece 3292/3

Observe installation position: Bonded rubber bushing - 1 - with larger contact surface faces toward wheel bearing housing side - arrow - . Bonded rubber bushing - 2 - with smaller contact surface faces away from wheel bearing housing. - Insert new bearing into wheel bearing housing with thrust pieces 3292/3 and threaded spindle 3292 . Note:

Стр. 15 из 16


Do not use lubricant!

Carefully insert bearing so that it does not tilt.

- Screw thrust pieces together to stop. Outer sleeve collar on both bearings must contact wheel bearing housing.

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IV - Drive axle, assembly overview

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42 - 6


Hex socket head collar bolt


Vehicle must be standing on the ground when loosening/tightening

Always replace

Outer constant velocity joint

Replace only as a unit

Checking 42-6, Outer constant velocity (CV) joint, checking


Driving off 42-6, Outer constant velocity joint, servicing

Installing: Drive onto shaft using plastic hammer until compressed circlip seats.

Circlip must lie in joint chamfer when guiding in, guide with pliers if necessary.

Clamp

Always replace

Tensioning 42-6, Clamp large clamping sleeve to outer joint

Outer constant velocity protective joint boot

Check for tears and chafing, replace if necessary

Circlip

Always replace

Insert in shaft groove

Axle shaft

Clamp

Always replace

Tensioning 42-6, Clamp small clamping sleeve to inner joint

Protective boot for inner constant velocity joint

Check for tears and chafing, replace if necessary

Axle shaft must be cleaned before new protective joint boot is installed

Lightly lubricate axle shaft

Стр. 2 из 24


profile before installing protective joint boot

Clamp

Always replace

Tensioning 42-6, Clamp large clamping sleeve to outer joint

Cover

Carefully drive off using drift

Before installing on constant velocity joint, coat sealing surface with D-3

Adhesive surface must be free of oil and grease


Pre-tighten to 10 Nm in diagonal sequence

Tighten to 70 Nm

Always replace

Backing plate

Inner constant velocity joint

Replace only as a unit

Checking 42-6, Inner constant velocity (CV) joint, checking

Pressing off 42-6, Inner CV joint, servicing

Pressing on

Circlip

Topic 42-6

Always replace

Gasket

Replacing. Pull off protective

Стр. 3 из 24


foil and stick into joint.

Cover

Pry out with screwdriver 42-6, Inner CV joint, servicing

Always replace

Replace seal before attaching to CV joint Item - 15 -

Pressing on

Topic 42-6

Drive axle, removing and installing


engine/transmission jack V.A.G 1383 A


Removing

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- Only loosen hex socket head bolt - arrow - 90 otherwise wheel bearing is damaged.

Стр. 5 из 24

,

Warning! When loosening collar bolt, vehicle must stand on wheels -risk of accident-. - Remove wheel. - Install all 4 wheel bolts hand-tight. - Activate parking brake. - Remove collar bolt. If collar bolt is loose or removed, wheel bearings must not be loaded. If bearings are loaded by the vehicles own weight the wheel bearing will be damaged. The wheel bearings will be stressed and the life expectancy reduced. If a vehicle that has a drive axle removed is to be moved, an outer CV joint must be installed in place of the drive axle and be tightened to 200 Nm. Otherwise, wheel bearing will be damaged.


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Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

- Remove bolts - 2 - and cover. - Remove bolts - 1 - . - Loosen parking brake.

- Disconnect connecting link/lower link bolted connection 1-. - To remove bolt from connecting link, push wheel bearing housing downward. - Remove bolt from - 2 - level control system sensor.


- Remove nut - 1 - , remove bolt - 2 - and press air spring strut - 3 - to center of vehicle. - Remove brake line bracket bolt - 4 - .

- Loosen bolted connection nuts - 1 and 2 - from lower link -6-. - Remove bolted connection bolts - 3 and 4 - . - Remove lower link from notches on subframe and swing downward. - Loosen double clamp and retainers on exhaust system center muffler and lower this as much as possible

Repair Manual, Engine Mechanical, Fuel Injection Ignition, Repair Group 26, Exhaust system parts, removing and installing . - Push wheel bearing housing towards outside in order to remove drive axle from flange on transmission rear axle. - Move drive axle inward until it can be removed from wheel hub. - Remove drive axle from vehicle behind lowered lower link.

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Installing

- Insert drive axle in vehicle behind lowered link. - Insert drive axle in wheel hub to stop. - Push wheel bearing housing towards outside in order to insert drive axle in flange on transmission rear axle.

- Pivot lower link upward into notches on subframe and secure with new bolts and nuts - 1 and 2 - . - Attach brackets on exhaust system center muffler to vehicle underbody and fasten double clamp to designated position

Repair Manual, Engine Mechanical, Fuel Injection Ignition, Repair Group 26, Exhaust system parts, removing and installing .

- Align drive axle holes and flange shaft/transmission to

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each other. - Install bolts - 1 - and tighten to specified torque. - Insert cover and combi-bolts - 2 - and tighten to specified torque.

- Move air spring strut - 3 - outward on link bracket and upward. - Insert bolt - 2 - and tighten nut - 1 - to specified torque. - Install brake line bracket bolt - 4 - .

- Tighten bolted connection nuts - 1 to 4 - to specified torque.

- Connect connecting link/lower link bolted connection - 1 -

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tighten to specified torque without additional tightening. - Install bolt - 2 - in level control system sensor. - Activate parking brake. - Tighten drive axle collar bolt to 200 Nm. - Install wheel and tighten


- Tighten collar bolt to specified additional torque angle of 180 . Warning! When tightening collar bolt to additional torque angle, vehicle must be standing on wheels -risk of accident-. Drive axle, servicing


Thrust plate VW 401

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Thrust plate VW 402

Punch V 409

Punch VW 412

Support sleeve VW 522

Clamp 40-204 A

Assembly tool T10065 can also be used instead of clamp 40-204 A .


Bracket 2036/1

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Sleeve 3144

CV joint boot clamp tool V.A.G 1275


CV joint boot clamp tool V.A.G 1682

Assembly tool T10065

Sealant D 454 300 A2

Circlip pliers (commerciallyavailable)

Inner CV joint, servicing

Inner CV joint, removing - Secure drive axle with protective covers in vise.

- Pry off cap, e.g. with a screwdriver.

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- Remove sealing ring - arrow - .

- Drive protective joint boot cap under with a brass or copper drift. Note:

Clamping sleeves must not be loosened.

- Remove circlip.

- Press inner CV joint off of drive axle with special tool shown in illustration. - Open small clamping sleeve on drive axle and remove protective joint boot from drive axle. Inner CV joint, installing

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- Apply sealant - hatched surface - to clean surface on inner side of protective joint boot cover. Sealant bead: unbroken, diameter 2 to 3 mm, skirting area around inner holes - arrow - . - Use sealant D 454 300 A2 for this. - Slide protective joint boot with small clamping sleeve on drive axle. Shaft, protective joint boot and cap contact surfaces must be free of grease.

- Press on joint until stop. Chamfer on inner diameter of ball hub (splines) must face contact shoulder of drive axle. Use special tool shown in illustration. You can also use assembly tool T10065 instead of clamp 40-204 A . Clamp 40-204 A or assembly tool T10065 and clamping surfaces on drive axle must be free of grease. Circlip must be replaced.

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- Install circlip. - Check circlip for correct seating. - Before installing cover, apply 60 grams of drive axle grease in CV joint through ball paths. Make sure you do not damage sealant bead.

- Align cover with bolts - arrows - to bolt holes. It must be aligned exactly because it cannot be aligned after driving on. - Drive cover on with a plastic hammer. - Wipe away any sealant leaking out. - Apply 60 grams of joint grease to CV joint through ball paths. - Lubricate contact surfaces for sealing ring.

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- Remove adhesive foil from seal and adhere to CV joint.

- Align new cover - A - to bolt holes. It must be aligned exactly because it cannot be aligned after pressing on. - Press cover - A - on with special tool shown in illustration. Flat steel in an appropriate size can be used instead of bracket 2036/1 .

- Position protective joint boot in outer groove - arrow 2 - . Inner groove - arrow 1 - must remain visible "identifying groove" (for correct installation of protective joint boot).

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Clamp large clamping sleeve to outer joint

- Use CV joint boot clamp tool V.A.G 1682 as shown in illustration. Make sure that the jaws of the tension clamp seat in the corners - arrows B - of hose clip. - Tighten hose tie by turning spindle using a torque wrench (do not bend tensioning clamp). Note:

A stainless steel clamp must be used due to the hardness of the CV boot material (compared to rubber). This clamp can only be tensioned using the CV joint boot clamp tool V.A.G 1682 .

Torque specification: 25 Nm

Use torque wrench - C - with a range of 5 to 50 Nm (e.g. V.A.G 1331 ).

Be sure thread of spindle - A - of clamp tool moves freely. Grease with grease MOS 2 if necessary.

If does not move freely, e.g. due to dirt in thread, required clamp tension will not be achieved at specified torque.

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Clamp small clamping sleeve to inner joint

Inner constant velocity (CV) joint, checking

In order to replace grease in case of strong soiling, joint must be disassembled and if journal surfaces and balls must be checked for wear and damage. Disassembling Note:

Ball hub and joint are paired and should be identified before removal. Do not interchange cage allocation.

- Pivot ball hub and ball cage. - Press out ball joint housing in direction of - arrow - . - Press balls out of cage.

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- Flip out ball hub from ball cage via running path of ball arrows - . - Check joint housing, ball hub, ball cage and balls for indentations (pitting) and signs of seizure. Note:

Excessive circumferential backlash in joint makes itself noticed via tip-in shock. In such cases the joint must be replaced. Flattening and running marks of balls are no reason to replace joint.

Assembling

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

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When inserting make sure that the wide space - a on joint housing is aligned with the narrow space - b on hub after swiveling in.

Chamfer on inner diameter of wheel hub (splines) must face toward drive axle.

- Install ball hub, whereby the hub must be swiveled out of cage - arrows - far enough to allow balls to fit into ball tracks.

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- Press cage firmly - arrow - until hub swings fully in position. Constant velocity joint, checking for function Constant velocity joint is properly assembled, if ball hub can be slid back and forth by hand over whole compensation length. - Press grease into joint body. Outer constant velocity joint, servicing

Outer CV joint, removing - Secure axle shaft with protective covers in vise clamp. - Open both clamping sleeves and remove protective joint boot from outer joint.

- Strike a copper or brass drift - A - on CV joint inner race with a hammer. - Remove joint and protective joint boot. Outer CV joint, installing - Slide joint protective boot onto drive axle.

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Joints and protective joint boots must be free of grease. 1 - Circlip (snap ring), must be replaced. - Position protective joint boot between - arrows - . - Apply 40 grams of joint grease to inside of joint.

- Screw old drive shaft bolt into joint as shown in illustration. - Drive joint onto shaft with plastic hammer until circlip engages. - Apply 50 grams of joint grease in boot side of joint. Install clamping sleeve on outer joint and clamp

- Install clamping sleeve on outer joint.

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- Bleed protective joint boot. - Tension clamp using pliers V.A.G 1275 . Outer constant velocity (CV) joint, checking

In order to replace grease in case of strong soiling, joint must be disassembled or if journal surface of balls must be checked for wear and damage. Disassembling

- Before disassembling mark ball hub position in relation to ball cage and housing using an electric scriber or oil stone. - Swivel ball hub and ball cage. - Remove balls one after another.

- Turn cage, until two rectangular windows - arrow contact joint body. - Lift out cage together with hub.

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- Swing hub segment with smaller pins into rectangular window on cage. - Tilt hub out of cage. Checking 6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small indentations (pitting) and signs of seizure. Excessive circumferential backlash in joint makes itself noticed via tip-in shock, in such cases joint should be replaced. Flattening and running marks of balls are no reason to replace joint. Assembling - Install cage with hub in the joint housing. Note:

Cage must be installed laterally correct.

- Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body must be re-established. - Press grease into joint body.

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