SKODA Rapid 2011 Workshop Manual

Service

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Workshop Manual

Rapid 2011 ➤

Axles, steering

Edition 12.2018

Service Department. Technical Information

List of Workshop Manual Repair Groups

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Re pa ir G ro up

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

Service

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.

Rapid 2011 ➤

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Axles, steering - Edition 12.2018

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Accident vehicle assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Checklist for assessing the chassis of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Seals and sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.4 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 Front axle - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Front axle - Overview of the repair chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Raise the wheel-bearing housing in the rebound state (unladen weight position) . . . . . . . . 5

2 Repairing front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 Summary of components of assembly carrier, track control arm, anti-roll bar, coupling rod,

support and pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.2 Lower the assembly carrier in the service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3 Inspecting the suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.4 Removing and installing the suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.5 Removing and installing the track control arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.6 Replacing the rubber-metal bearing for track control arm . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.7 Removing and installing the anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.8 Removing and installing the rubber bearing for the anti-roll bar . . . . . . . . . . . . . . . . . . . . . . 29

2.9 Removing and installing assembly carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3 Repairing front suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.1 Installation general view of the suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.2 Removing and installing the suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.3 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.4 Inspect shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.5 Disposing of the shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 Repairing wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.1 Summary of components of the wheel bearing, suspension strut, drive shaft and brake C54

. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 45

4.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.3 Removing and installing the wheel hub with wheel bearing with the wheel-bearing housing

fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5 Drive shafts with inner CV joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.1 Summary of components of drive shaft with inner CV joint . . . . . . . . . . . . . . . . . . . . . . . . 58

5.2 Removing and installing fixing nut of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5.3 Removing and installing outer joint of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.4 Removing and installing drive shaft with CV joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.5 Push the cardan shaft out of the wheel hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

5.6 Repairing drive shaft with CV joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

5.7 Inspecting the CV joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

6 Drive shafts with inner tripod joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

6.1 Summary of components of drive shaft with inner tripod joint . . . . . . . . . . . . . . . . . . . . . . 76

6.2 Removing and installing inner drive shaft with tripod joint . . . . . . . . . . . . . . . . . . . . . . . . . . 78

6.3 Repairing drive shaft with inner tripod joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

6.4 Check outer joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

6.5 Repairing outer CV joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

1 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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1.1 Raise the wheel-bearing of the rear axle in the rebound state (unladen weight position) . . 85

1.2 Summary of components of rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

1.3 Fitting location of the shock absorber on the rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1.4 Removing and installing rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

2 Repairing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.1 Summary of components of shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.2 Inspect shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

2.3 Disposing of the shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

2.4 Removing and installing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

2.5 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

2.6 Replacing the rubber-metal bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3 Repairing wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

3.1 Summary of components of the wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

3.2 Removing and installing the wheel hub with wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . 119

3.3 Removing and installing axle studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

1 Chassis - Specified values of steering geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

1.1 Nominal values front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

1.2 Nominal values rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

2 Axle alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

2.1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

2.2 Axle alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

2.3 Test conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

2.4 Measurement preliminaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

2.5 Check transversal inclination of the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

2.6 Checking the camber on the front axle, if necessary take the mean . . . . . . . . . . . . . . . . . . 132

2.7 Checking the camber on the rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

2.8 Check misalignment of the rear axle, if necessary take the mean . . . . . . . . . . . . . . . . . . . . 134

2.9 Checking the track on the front axle, adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . . . 136

2.10 Check position of steering wheel, align if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

2.11 Calculation of the misalignment on the rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

2.12 Checking the left and right steering angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

1 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

1.1 Steering wheel - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

1.2 Removing and installing the steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

2 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

2.1 Summary of components - steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

3 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

3.1 Measures for handling and transportation of the steering column . . . . . . . . . . . . . . . . . . . . 147

3.2 Removing the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

3.3 Installing the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

3.4 Removing and installing steering column electronics control unit J500 . . . . . . . . . . . . . . 152

4 Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

4.1 Removing and installing steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

5 Electro/mechanical power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

5.1 Assembly overview of the power-assisted steering drive . . . . . . . . . . . . . . . . . . . . . . . . . . 157

5.2 Disassembling and assembling the power-assisted steering gear . . . . . . . . . . . . . . . . . . . . 158

5.3 Removing and installing steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

5.4 Removing and installing track rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

5.5 Inspecting boots, play and correct attachment of track rod ends . . . . . . . . . . . . . . . . . . . . 166

5.6 Removing and installing track rod ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

5.7 Check and adjust the length of the tie rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

ii Contents

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5.8 Check the centre position of the gear rack of the power-steering gear, if necessary adjust

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

5.9 Adjusting the power-steering gear (adjusting the pressure plate clearance) . . . . . . . . . . . . 170

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Axles, steering - Edition 12.2018

iv Contents

00 – Technical data

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1 Accident vehicle assessment

(SRL001334; Edition 12.2018)

⇒ “1.1 Checklist for assessing the chassis of accident vehicles”, page 1

1.1 Checklist for assessing the chassis of accident vehicles

Concealed chassis damage may remain after load-bearing and wheel-bearing parts have been repaired on accident vehicles. Under certain circumstances, this hidden damage could lead to serious consequential damage during later vehicle operation. On accident vehicles it is therefore necessary to check the specified parts in the manner described and in the order specified, irre‐ spective of the axle alignment being carried out. If you cannot find any deviations from the nominal values during axle alignment, this means the suspension does not have any deformations.

Visual inspection and check functional reliability of the steering system

♦ Visual inspection of deformations and cracks ♦ Check the play of the link rod and steering gear ♦ Check the state of the track rods ♦ Visual inspection: fault-free bellows and collars, greased ♦ Check electrical and hydraulic lines and hoses for abrasions,

cuts or bends

♦ Make sure hydraulic lines, thread connections and steering

gear are leak tight ♦ Make sure the steering gear and lines are securely fastened ♦ Check the faultless functioning of the steering over the entire

steering range by turning the steering from one extreme angle

to the other; when applying constant pressure, the steering

wheel should turn without juddering Visual inspection and check functional reliability of the chassis Adhere to the sequence of the following inspection steps! ♦ Check all of the parts listed in the summary of components to

make sure they are not deformed, cracked or otherwise dam‐

aged ♦ Replace damaged component parts ♦ Align the vehicle on a Škoda-approved alignment gauge Visual inspection and check functional reliability of the wheels,

tyres ♦ Check for evenness and balance ♦ Make sure the profile or side wall has not cracked or been

damaged as a result of the impact ♦ Check tyre pressure; compare pressure with the specification

on the tank flap The tyre must be replaced if the rim and/or tyre is/are damaged.

The same applies if non-recognizable damages are assumed to have occurred, given the type of accident and ensuing damage to the vehicle.

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1. Accident vehicle assessment 1

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If in doubt, the following always applies: Whenever a safety risk cannot be excluded, the tyre(s) must be

renewed. Whole vehicle Check other vehicle systems, such as: ♦ Brake system including ABS ♦ Exhaust gas system, occupant protection system: visual in‐

spection and check functional reliability

For check values, settings and notes, refer to the appropriate re‐ pair manual/the ELSA system.

The examination of accident vehicles described in this document only relates to the chassis and does not constitute a complex ex‐ amination of the entire vehicle.

Electronic vehicle systems For basic safety systems, such as: anti-block system; airbag;

electronically-controlled suspension systems; electro-mechani‐ cal and electro-hydraulic steering systems; on other driver assis‐ tance systems, the saved error messages may need to be retrieved from the ⇒ Vehicle diagnostic tester system where nec‐ essary. If the indicated system faults are saved in the event memories, they must be correct according to the instructions in the repair manual/ELSA system. After a successful repair, the systems concerned must be re-examined to make sure no entries are in the event memory in order to make sure proper operation has been restored.

2 Rep. gr.00 - Technical data

2 General Instructions

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⇒ “2.1 Steering gear”, page 3 ⇒ “2.2 Seals and sealing rings”, page 3 ⇒ “2.3 Nuts and bolts”, page 3 ⇒ “2.4 Electrical components”, page 3

2.1 Steering gear

♦ Thoroughly clean all unions and the adjacent areas before

disconnecting. ♦ When installing the steering gear, ensure the dowel sleeves

are correctly located between the console and steering gear. ♦ Place removed parts on a clean supporting plate and cover,

in order to avoid contamination. Only use lint-free cloths. ♦ Only install clean parts: Remove spare parts from their wrap‐

ping immediately before installing. ♦ Use only the grease and sealants with specified part numbers. ♦ Carefully cover or close opened components if the repair is not

completed immediately.

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2.2 Seals and sealing rings

♦ Replace all gaskets and seals every time they are removed. ♦ After removing gaskets, examine the contact surfaces in the

housing or on shafts for sharp edges or damage, and correct

if necessary. ♦ Completely remove all liquid sealants from the sealing sur‐

faces, making sure that no residual sealant gets into the

steering box housing.

2.3 Nuts and bolts

♦ Slacken and tighten securing bolts and nuts of covers and

housings diagonally. ♦ Avoid canting particularly sensitive parts such as servo motor

with control unit. Loosen and tighten them diagonally in

stages. ♦ Tightening torques are for unlubricated nuts, bolts and screws. ♦ Always replace the self-locking screws and nuts.

2.4 Electrical components

♦ Touch an earthed object - e.g. water pipe, heating, metal sup‐

port or lift platform - before working on the electrical compo‐

nents. Please do not touch the connector contacts.

2. General Instructions 3

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40 – Front suspension

1 Front axle - Overview

⇒ “1.1 Front axle - Overview of the repair chapter”, page 4 ⇒ “1.2 Raise the wheel-bearing housing in the rebound state (un‐

laden weight position)”, page 5

1.1 Front axle - Overview of the repair chapter

Note

♦

Welding and straightening work is not allowed on the bearing and wheel control components of the wheel suspension.

♦

Always replace the self-locking screws and nuts.

♦

Always replace corroded self-locking nuts and screws.

♦

All screws must always be tightened firmly in the unladen condition (unladen weight position) to the chassis parts with rubber-metal bearings - do not load the vehicle ⇒ “1.2 Raise the wheel-bearing housing in the

rebound state (unladen weight position)”, page 5 .

I - ⇒ “2 Repairing front axle”,

page 7

II - ⇒ “4 Repairing wheel bear‐

ing”, page 45

III - ⇒ “3 Repairing front sus‐

pension strut”, page 34

4 Rep. gr.40 - Front suspension

1.2 Raise the wheel-bearing housing in the

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rebound state (unladen weight position)

Special tools and workshop equipment required ♦ Engine and gearbox jack e.g. -V.A.G 1383/A- or -VAS6931♦ Tensioning strap - T10038♦ Mounting bracket - T10149-

Note

The screws must always be tightened firmly in the unladen con‐ dition (unladen weight position) to the chassis parts with rubbermetal bearings - do not load the vehicle!

Unladen weight: Vehicle weight with a full fuel tank and washer fluid/headlight

cleaning system reservoir, spare wheel and jack (if it is fitted at the factory), tool kit and without driver. The spare wheel, tool kit and jack must be located in the position prescribed by the vehicle manufacturer.

Rubber-metal bearings can be twisted only to a limited extent. Therefore the axle components with rubber-metal bearings must

be put in a position before tightening, which corresponds to the position while driving.

Otherwise the rubber-metal bearing will be under tension and as a result, will have a lower life.

This position can be simulated on the lift platform by raising the corresponding wheel bearing housing with the engine/gearbox jack e. g. -V.A.G 1383/A- or -VAS6931- and the uptake - T10149- .

– Before commencing work, measure e.g with a measuring

tape, the dimension -a- from wheel centre to lower edge of the

wheelhouse. Measuring must be performed when the vehicle is on the ground

and in the unladen condition (unladen weight position) - do not load the vehicle.

– Note the measured value. It is required when tightening the

screws to the chassis parts with rubber-metal bearings. Before the corresponding wheel-bearing housing is lifted, the ve‐

hicle must be lashed securely at the supporting arms of the lift platform with the tensioning straps - T10038- .

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DANGER!

If the vehicle is not lashed, there is a risk of the vehicle toppling off the lift platform.

– Remove wheel. – Rotate the wheel hub until one of the holes for the wheel bolts

is located at the top. – Install support - T10149- with wheel bolt at the wheel hub.

1. Front axle - Overview 5

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The tightening of the corresponding screw must only be per‐ formed, if the measured dimension -a- between the wheel hub centre and the lower edge of the wheel house is achieved before commencing work.

– Raise up the wheel-bearing housing using the engine and

gearbox jack e. g. -V.A.G 1383/A- or -VAS6931- with mount T10149- until dimension -a- is achieved.

Caution

♦ Do not raise or lower the vehicle, if the engine/gearbox

jack is positioned under the vehicle.

♦ Do not leave the engine/gearbox jack e. g. -V.A.G 1383/

A- or -VAS6931- positioned under the vehicle for longer than necessary.

– Tighten up the corresponding screws fully to the specified

tightening torque. – Lower the wheel bearing housing. – Remove the engine/gearbox jack e.g. -V.A.G 1383/A- or -

VAS6931- from underneath the vehicle. – Remove support - T10149- . – Remove tensioning strap - T10038- .

6 Rep. gr.40 - Front suspension

2 Repairing front axle

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⇒ “2.1 Summary of components of assembly carrier, track control arm, anti-roll bar, coupling rod, support and pendulum support”, page 7

⇒ “2.2 Lower the assembly carrier in the service position”, page 9

⇒ “2.3 Inspecting the suspension link”, page 15 ⇒ “2.4 Removing and installing the suspension link”, page

15 ⇒ “2.5 Removing and installing the track control arm”, page

19 ⇒ “2.6 Replacing the rubber-metal bearing for track control arm”,

page 22 ⇒ “2.7 Removing and installing the anti-roll bar”, page 23 ⇒ “2.8 Removing and installing the rubber bearing for the anti-roll

bar”, page 29 ⇒ “2.9 Removing and installing assembly carrier”, page 30

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Axles, steering - Edition 12.2018

2.1 Summary of components of assembly carrier, track control arm, anti-roll bar, coupling rod, support and pendulum support

Note

♦

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

♦

Welding and straightening work is not allowed on the bearing and wheel control components of the wheel suspension.

♦

Always replace the self-locking screws and nuts.

♦

Always replace corroded self-locking nuts and screws.

♦

rebound state (unladen weight position)”, page 5 .

2. Repairing front axle 7

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Axles, steering - Edition 12.2018

1 - Assembly carrier

❑ Removing and installing

⇒ “2.9 Removing and in‐ stalling assembly carri‐ er”, page 30

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

2 - Screw

❑ Screws for anti-roll bar

clamps

❑ replace after each re‐

moval

❑ 20 Nm + 90°.

3 - Self-locking nut

❑ replace after each re‐

moval

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

❑ 40 Nm

4 - Anti-roll bar

❑ to remove and install

lower assembly carrier

❑ Removing and installing

⇒ “2.7 Removing and in‐ stalling the anti-roll bar”, page 23

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

5 - Rubber bearing

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

6 - Spring clip

❑ Assignment ⇒ Electronic Catalogue of Original Parts

7 - Self-locking nut

❑ replace after each removal ❑ Assignment ⇒ Electronic Catalogue of Original Parts ❑ 40 Nm

8 - Coupling rod

❑ Assignment ⇒ Electronic Catalogue of Original Parts 9 - Countersupport 10 - Nut

❑ replace after each removal 11 - Rubber-metal bearing

❑ Rear rubber-metal bearing for track control arm

❑ Replace ⇒ “2.6 Replacing the rubber-metal bearing for track control arm”, page 22 12 - Screw

❑ replace after each removal

❑ 20 Nm + 90°.

8 Rep. gr.40 - Front suspension

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Axles, steering - Edition 12.2018

13 - Screw

❑ replace after each removal ❑ 70 Nm + 90°.

14 - Self-locking nut

❑ replace after each removal ❑ 20 Nm + 90°.

15 - Steering joint

❑ Check ⇒ “2.3 Inspecting the suspension link”, page 15 ❑ Removing and installing ⇒ “2.4 Removing and installing the suspension link”, page 15

16 - Nut

❑ replace after each removal ❑ 100 Nm

17 - Screw

❑ replace after each removal ❑ 70 Nm + 90°.

18 - Suspension link

❑ Removing and installing ⇒ “2.5 Removing and installing the track control arm”, page 19

19 - Screw

❑ replace after each removal ❑ 70 Nm + 90°.

20 - Rubber-metal bearing

❑ Front rubber-metal bearing for track control arm ❑ Replace ⇒ “2.6 Replacing the rubber-metal bearing for track control arm”, page 22

21 - Screw

❑ replace after each removal ❑ 70 Nm + 90°.

22 - Dowel screws

❑ replace after each removal ❑ 40 Nm + 90°.

23 - Screw

❑ replace after each removal ❑ Position the screws in the elongated holes of the pendulum support in such a way that there is maximum

distance between the gearbox and the assembly carrier

❑ 30 Nm + 90°.

24 - Pendulum support

❑ do not disassemble ❑ Position the screws in the elongated holes of the pendulum support in such a way that there is maximum

distance between the gearbox and the assembly carrier

❑ Assignment ⇒ Electronic Catalogue of Original Parts

2.2 Lower the assembly carrier in the ser‐ vice position

Special tools and workshop equipment required ♦ Engine and gearbox jack e.g. -V.A.G 1383/A- or -VAS6931♦ Fixing device - T10486/1♦ Fixing device - T10096-

2. Repairing front axle 9

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Axles, steering - Edition 12.2018

Release the assembly carrier - remove:

Caution

Bring the steering wheel to its central position (with the wheels straight ahead) and make sure that it does not turn during re‐ pairs as this could damage the restoring ring with slip ring of the airbag unit.

– Secure the steering wheel with the wheels in straight ahead

position with adhesive tape -arrow- against unintended turn‐ ing.

– Unscrew plastic nuts -arrows- and remove trim panel -1-.

– Release screw -1-. – Remove the universal joint (in the direction of the arrow) from

the input shaft of the power-steering gear. Vehicles with the exhaust system below the assembly carrier – Remove pre-exhaust pipe ⇒ Engine; Rep. gr. 26 . Continued for all vehicles

10 Rep. gr.40 - Front suspension

– Unscrew the screws -1- and -2- of the pendulum support.

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– Screw out the left and right nuts -1-. – Pull out left and right coupling rod -3- from stabilizer -2-. – Swivel the anti-roll bar upwards.

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Axles, steering - Edition 12.2018

– Insert wooden insert -1- in the adapter , e. g. -V.A.G 1359/2- . – Support the assembly carrier with engine/gearbox jack with

adapter.

Note

♦

Note the following work steps and absolutely ensure that you follow the sequence.

♦

The fixing bolts out from -T10096- and -T10486/1- must only be tightened to maximum 20 Nm as otherwise the fixing bolt thread becomes damaged.

– Unscrew left screw -1- for assembly carrier -4-, screw in fixing

bolt of -T10096- and tighten to 20 Nm.

– Unscrew right screw -1- for assembly carrier (not shown in

figure), screw in a fixing bolt from -T10096- and tighten to 20

Nm. – Unscrew bolts -3- on both sides. – Unscrew the left screw -2- and remove support -5-. – Screw in fixing bolt -T10486/1- and tighten to 20 Nm. – Unscrew the right screw -2- and remove support -5-. – Screw in fixing bolt -T10486/1- and tighten to 20 Nm. The alignment of the assembly carrier is completed once all 4

screws (Pos. -1- and -2- on both vehicle sides) are consecutively replaced with the fixing bolts.

If it is not possible to insert the fixing devices - T10096- or T10486/1- into the corresponding openings of the assembly car‐ rier, the following measures must be carried out:

2. Repairing front axle 11

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Axles, steering - Edition 12.2018

– Prepare the inlet openings in the lower area of the assembly

carrier e.g. with a file so that the fixing devices - T10096- or T10486/1- can be inserted into the openings.

– Treat prepared openings to protect against corrosion, e.g. with

zinc spray - D 007 500 04- . For vehicles with exhaust pipe inserted on the assembly carrier – Remove spring washer for exhaust system to assembly carrier

⇒ Engine; Rep. gr. 26 . Continued for all vehicles – Lower assembly carrier approx. 4 cm and through this slacken

from the fixing bolts.

Note

When lowering the assembly carrier make sure there is sufficient clearance between the drive shafts and the stabilizer.

– Slowly lower the assembly carrier with engine/gearbox jack

and with adapter. Tighten assembly carrier - install: – Raise assembly carrier onto the fixing bolts until the consoles

touch both sides of the body.

Note

♦

Note the following work steps and absolutely ensure that you

follow the sequence.

♦

Unscrew the fixing bolts from -T10096- and -T10486/1- one at

a time. It should be subsequently replaced by a new bolt tight‐

ened to the recommended torque.

– Unscrew left fixing bolt -1- from -T10096- , screw in new screw

and tighten to the recommended tightening torque. – Unscrew right fixing bolt -1- from -T10096- (not shown in fig‐

ure), screw in new screw and tighten to the recommended

tightening torque. – Unscrew left fixing bolt -2- from -T10486/1- . – Install left support. – Screw in new bolts for the left support and tighten at the rear

by hand. – Screw in new bolt for assembly carrier and left support and

tighten to the recommended tightening torque. – Tighten the rear left support bolts to the recommended tight‐

ening torque. – Unscrew right fixing bolt -2- from -T10486/1- (not shown in

figure). – Install right support. – Screw in new bolts for the right support and tighten at the rear

by hand. – Screw in new bolt for assembly carrier and right support and

tighten to the recommended tightening torque.

12 Rep. gr.40 - Front suspension

– Tighten up the rear right support bolts to the recommended

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tightening torque.

– Remove engine/gearbox jack with adapter .

– Mount pendulum support on the gearbox and tighten new

screws -1- and -2-.

Note

Position the screws -1- in the elongated holes of the pendulum support in such a way that there is maximum distance between the gearbox and the assembly carrier.

Vehicles with the exhaust system below the assembly carrier – Install the pre-exhaust pipe ⇒ Engine; Rep. gr. 26 . For vehicles with exhaust pipe inserted on the assembly carrier – Install spring washer for exhaust system to assembly carrier

⇒ Engine; Rep. gr. 26 . Continued for all vehicles – Install the noise insulation ⇒ Body Work; Rep. gr. 50 .

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Axles, steering - Edition 12.2018

– Slide the universal joint of the steering column in the

-direction of the arrow- onto the input shaft of the power steer‐

ing and tighten with a new screw -1-.

– Position cover -1- and screw on plastic nuts -arrows-. – Remove the securing mechanism which prevents the steering

wheel from turning (adhesive tape). – Perform a test drive. – Check the steering wheel position during the test drive.

Note

If after the test drive and with the front wheels pointing straight ahead the steering wheel is off straight, perform an axle alignment

⇒ “2.2 Axle alignment”, page 129 .

2. Repairing front axle 13

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Tightening torques - summaries of components

Note

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

Assembly carrier to body ♦ Use new screws!

Support to body ♦ Use new screws!

Hinged support to gearbox ♦ Use new screws!

Universal joint of the steering column to power-steering gear ♦ Use new screw!

70 Nm + 90°.

20 Nm + 90°.

30 Nm + 90°.

20 Nm + 90°.

2.3 Inspecting the suspension link

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Note

♦

For these two tests no “play” may be felt or be visible.

♦

Observe the suspension link during the tests.

♦

Take into account possible wheel bearing play or “play” in top

suspension strut bearing.

♦

Inspect rubber bellows for damage, if necessary replace.

Inspecting axial play – Forcefully push the track control arm down and up again.

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Axles, steering - Edition 12.2018

Inspecting radial play – Forcefully push the wheel towards the inside and the outside.

2.4 Removing and installing the suspension

link

Special tools and workshop equipment required ♦ Ball joint extractor - 3287ARemoving: – Remove wheel. – Release fixing nuts -arrows-. – Release track control arm from the screws of the steering joint.

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– Position the ball joint extractor as shown in the figure.

Note

♦

To protect the thread, screw the nut a couple of thread turns onto the steering joint.

♦

While pressing out the axle joint, be aware of the injury risk: the ball joint puller may fall out when the pivot pin is loosened.

– Push out the steering joint with the ball joint extractor. Installing:

Note

♦

Observe fitting position of the steering joints according to the marking.

♦

The castor changes if the fitting position of the steering joint is incorrect.

♦

Always fit new nuts for the drive shafts.

Fitting position according to the identification on the steering joint: R - means right L - means left 3 - means for vehicles with mechanical steering (is not available) 4 - means for vehicles with power steering “arrow” - shows in the direction of travel on vehicles with power

steering

Left steering joint Designation “L4” and “arrow” designates the left steering joint in

the direction of travel for vehicle with power steering R3 - marks the right steering joint for vehicle with mechanical

steering (is not available)

Right steering joint Designation “R4” and “arrow” designates the right steering joint

in the direction of travel for vehicle with power steering. L3 - marks the left steering joint for vehicle with mechanical steer‐

ing (is not available) – Insert the steering joint into the wheel-bearing housing (to do

so, pull the track control arm towards the bottom under the steering joint to be inserted).

Note

♦

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Observe fitting position of the steering joints according to the

marking.

♦

The castor changes if the fitting position of the steering joint is

incorrect.

– Screw new nut onto the steering joint and tighten.

While doing this secure steering joint against spinning, so that

the steering joint boot is not damaged.

– Position the track control arm onto the steering joint and tight‐

en nuts -arrows-. – Install and tighten the front wheel. – Perform a test drive. – Check the steering wheel position during the test drive.

Note

If after the test drive and with the front wheels pointing straight ahead the steering wheel is off straight, perform an axle alignment

⇒ “2.2 Axle alignment”, page 129 .

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Axles, steering - Edition 12.2018

Tightening torques - summaries of components

Note

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

Steering joint to wheel-bearing housing ♦ Use new nut!

Steering joint to track control arm ♦ Use new nuts!

Wheel bolts 120 Nm

20 Nm + 90°.

100 Nm

2.5 Removing and installing the track con‐

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trol arm

Removing:

Note

Before commencing work, determine the measurement -a- ⇒

“1.2 Raise the wheel-bearing housing in the rebound state (un‐ laden weight position)”, page 5 .

– Remove front wheel. – Release fixing nuts -arrows-.

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Axles, steering - Edition 12.2018

– Unscrew screw -arrow 1- and screw with nut -arrow 2-. – Release track control arm from the screws of the steering joint. – Take the track control arm out of the assembly carrier. Installing: – Insert the track control arm into the assembly carrier.

– Insert screw -arrow 1- and screw with nut -arrow 2- and do not

tighten yet. – Position the track control arm onto the steering joint and tight‐

en.

Note

The tightening of the screw for steering joint and assembly carrier can be performed, if the dimension -a- is maintained (vehicle in unladen condition - unladen weight position) ⇒ “1.2 Raise the

wheel-bearing housing in the rebound state (unladen weight po‐ sition)”, page 5 .

– Tighten screw -arrow 1- and screw with nut -arrow 2-. – Installing and tightening the wheel. – Perform a test drive. – Check the steering wheel position during the test drive.

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Note

If after the test drive and with the front wheels pointing straight ahead the steering wheel is off straight, perform an axle alignment

⇒ “2.2 Axle alignment”, page 129 .

Tightening torques - summaries of components

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Note

Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

Rapid 2011 ➤

Axles, steering - Edition 12.2018

Track control arm to assembly carrier ♦ Use new screws and nuts!

♦ Tighten in unladen weight position ⇒ “1.2 Raise the wheel-bearing housing in the rebound state (unladen weight position)”, page 5

Steering joint to track control arm ♦ Use new nuts!

Wheel bolts 120 Nm

70 Nm + 90°.

100 Nm

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2.6 Replacing the rubber-metal bearing for track control arm

Special tools and workshop equipment required ♦ Pressure plate - MP3-406 (VW 401)♦ Pressure plate - MP3-407 (VW 402)♦ Pipe - MP3-414 (VW 516)♦ Pipe - MP3-429 (2010)♦ Thrust washer - MP3-456 (VW 447 I)♦ Assembly tool - MP5-402 (3301)♦ Assembly tool - MP6-401 (3288)♦ Base - MP6-407 (40-103)♦ Pipe - MP6-408 (30-14)♦ Workshop press , e.g. -VAS 6654Press off front bearing for track control arm: Press out rubber-metal bearing as shown.

Press in front bearing for track control arm: – Insert front bearing in - pipe section - MP3-414 (VW 516)- . In order not to damage the rubber-metal bearing when inserting

it, it must be positioned at an angle. During the press-in proce‐ dure, insert the rubber-metal bearing in the straightahead posi‐ tion.

– Apply assembly sliding oil - G 294 421 A1- to the outside of

the rubber-metal bearing.

– Press the rubber-metal bearing into the hole of the track con‐

trol arm.

The dimensions -a- and -b- must be identical after pressing in. If the dimensions -a- and -b- are not identical: – Slightly press out the bearing from the track control arm so that

the values -a- and -b- are identical.

Fitting position of rear bearing for track control arm

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– The marking -2- of the rubber-metal bearing must be posi‐

tioned to one axle with the marking -1- on the track control arm.

– The kidney-shaped recess -3- of the rubber-metal bearing

must always point towards the longitudinal vehicle axis.

Pressing out and in the rear bearing for the track control arm Pay attention to the correct installation position of the rubber-

metal bearing during the press-in procedure (see Fig. S40-0389).

Rapid 2011 ➤

Axles, steering - Edition 12.2018

Note

♦

Use the assembly sliding oil (acid-free). E.g. 294 421 A1 to press in the bearings.

♦

Do not use another grease!

2.7 Removing and installing the anti-roll bar

Special tools and workshop equipment required ♦ Engine and gearbox jack e.g. -V.A.G 1383/A- or -VAS6931♦ Fixing device - T10486/1♦ Fixing device - T10096Removing: Vehicles with the exhaust system below the assembly carrier – Remove pre-exhaust pipe ⇒ Engine; Rep. gr. 26 . For vehicles with exhaust pipe inserted on the assembly carrier – Remove spring washer for exhaust system to assembly carrier

⇒ Engine; Rep. gr. 26 .

Continued for all vehicles

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– Unscrew the screws -1- and -2- of the pendulum support.

– Unscrew the clamps of the anti-roll bar from the assembly car‐

rier -arrows-.

Note

♦

The anti-roll bar clamp is located behind the assembly carrier and is not visible in the figure shown.

♦

The bottom screw of the right clamp can only be removed once the assembly carrier has been lowered.

– Screw out the left and right nuts -1-. – Pull out left and right coupling rod -3- from stabilizer -2-.

– Unscrew the screws -arrows- and tie up the power-steering

gear e.g with wire (attach), so that it maintains its position.

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