Volkswagen Rear axle User Manual
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Стр. 1 из 2Rear axle (front and all wheel drive), servicin
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Volkswagen Phaeton
Rear axle (front and all wheel drive), servicin
:
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.
42 - 2
I - Subframe, assembly overview 42-
3, I - Subframe, assembly overview
II - Link, tie rod, air spring strut,
assembly overview 42-4, II - Link, tie
rod, air spring strut, assembly
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overview
III - Wheel bearing, assembly overview
42-5, III - Wheel bearing, assembly
overview
IV - Driveshaft, assembly overview
42-6, IV - Drive axle, assembly
overview
Стр. 2 из 2Rear axle (front and all wheel drive), servicin
Стр. 1 из 8I - Subframe, assembly overview
42 - 3
I - Subframe, assembly overview
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
Always replace
Washer
( 1 / 4 turn)
Стр. 2 из 8I - Subframe, assembly overview
Washer
Subframe
Steel version
This version is replaced in 2004
with the aluminum version
Application Electronic Parts
Catalog "ETKA"
Subframe
Aluminum version
Application Electronic Parts
Catalog "ETKA"
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
Application Electronic Parts
Catalog "ETKA"
Final drive support
For vehicles with V8 and V10
drivetrain
Стр. 3 из 8I - Subframe, assembly overview
Application Electronic Parts
Catalog "ETKA"
Hex bolt
40 Nm plus an additional 90
( 1 / 4 turn)
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
Application Electronic Parts
Catalog "ETKA"
Subframe, removing and installin
Стр. 4 из 8I - Subframe, assembly overview
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
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.
Стр. 5 из 8I - Subframe, assembly overview
- 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
.
Стр. 6 из 8I - Subframe, assembly overview
- Remove heat shield
from spare wheel well
- 1 -
- 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
strut
to center of vehicle.
- 3 -
- Remove subframe from body.
- Slowly lower rear axle.
Installing
, remove bolt
- 1 -
and press air spring
- 2 -
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
Стр. 7 из 8I - Subframe, assembly overview
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 44-2, Wheel mounting .
- Perform vehicle alignment 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
Repair Manual, Automatic Transmission, Repair Group 39, Drive
shaft, removing and installing
Стр. 8 из 8I - Subframe, assembly overview
Air spring damper to
80 Nm plus an additional 1 / 4 turn (90 )
lower link
1)
2)
Subframe to body
1)
1)
Always use new nuts and bolts
2)
Tighten bolts and nuts in curb weight position
130 Nm plus an additional 1 / 4 turn (90
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.
Стр. 1 из 31II - Link, tie rod, air spring strut, assembly overview
42 - 4
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
Стр. 2 из 31II - Link, tie rod, air spring strut, assembly overview
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
Hex nut
80 Nm plus an additional
turn (90 )
Self-locking
Always replace
80 Nm plus an additional
1
/
4
1
/
4
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
Стр. 3 из 31II - Link, tie rod, air spring strut, assembly overview
Bracket
Hex nut
50 Nm plus an additional 1 /
turn (90 )
Self-locking
Always replace
Lift wheel bearing housing
before fastening
Hex nut
Self-locking
Always replace
Hex head bolt
4
80 Nm plus an additional
turn (90
Always replace
Lift wheel bearing housing
before fastening
Hex head bolt
1
/
4
Стр. 4 из 31II - Link, tie rod, air spring strut, assembly overview
80 Nm plus an additional
Always replace
Lift wheel bearing housing
Bracket
Hex bolt
10 Nm
Hex bolt
Lift wheel bearing housing
1
/
turn (90
before fastening
before fastening
replace after every removal
4
Hex bolt
Always replace
Hex nut
Self-locking
Always replace
Connecting link for vehicle level
sensor
Do not pull connecting link
from ball joint!
Hex bolt
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
Multi-point socket head bolt
25 Nm
Stabilizer bar clamp
Stabilizer bar
Removing and installing
42-4, Stabilizer bar, removing
and installing
Hex bolt
Стр. 5 из 31II - Link, tie rod, air spring strut, assembly overview
65 Nm plus an additional
turn (90 )
Always replace
Cable channel
Hex bolt
80 Nm plus an additional
turn (90 )
Always replace
Upper link
Removing and installing
42-4, Upper link, removing
and installing
1
/
4
1
/
4
Hex nut
Self-locking
Always replace
Eccentric bolt
For toe adjustment
Bolt
Bolt
Tie rod
Removing and installing
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42
-4, Tie rod, removing and
installing
Eccentric washer
Hex nut
95 Nm
Self-locking
Always replace
Lift wheel bearing housing
before fastening
Стр. 6 из 31II - Link, tie rod, air spring strut, assembly overview
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
80 Nm plus an additional
turn (90
Always replace
Hex nut
Self-locking
1
/
4
Always replace
Eccentric bolt
For camber adjustment
Air spring strut, removing and installin
Special tools, testers and auxiliary items required
Стр. 7 из 31II - Link, tie rod, air spring strut, assembly overview
Torque wrench V.A.G 1331
Removing
During assembly work, make sure that no indentations
form on boot of air spring strut!
- Remove level control system sensor bolt
from lower
- 2 -
link.
- Remove nut
strut
to center of vehicle.
- 3 -
, remove bolt
- 1 -
- Remove wheel housing liner
and press air spring
- 2 -
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.
Стр. 8 из 31II - Link, tie rod, air spring strut, assembly overview
- Remove reservoir
nuts
- arrows -
- Disconnect damper adjustment switching valve electrical
connector.
Right rear
.
by removing air line
- A -
and hex
- 1 -
- Remove hex screw
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
and move tank
- 1 -
as far down
- B -
that the strut can be removed.
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If air spring strut is to be replaced, first read the following
42-4, Air spring strut, filling .
Стр. 9 из 31II - Link, tie rod, air spring strut, assembly overview
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
10 Nm
level sensor to lower link
Air spring strut to lower link
1)
2)
80 Nm plus an additional 1 / 4 turn (90 )
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 use new nuts and bolts
2)
Tighten bolts and nuts in curb weight position
Air spring strut, fillin
Special tools, testers and auxiliary items required
Стр. 10 из 31II - Link, tie rod, air spring strut, assembly overview
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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- Become familiar with relevant rules for prevention of
accidents for pressurized containers and technical gases.
Стр. 11 из 31II - Link, tie rod, air spring strut, assembly overview
- 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.
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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.
Стр. 12 из 31II - Link, tie rod, air spring strut, assembly overview
- 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 installin
Special tools, testers and auxiliary items required
Torque wrench V.A.G 1331
Стр. 13 из 31II - Link, tie rod, air spring strut, assembly overview
Torque wrench V.A.G 1332
Removing
- Remove wheels.
- Remove heat shield
- 1 -
.
from spare wheel well
- arrows -
- Remove stabilizer bar
links
- arrow -
.
from left and right connecting
- 1 -
- Remove tie rod 42-4, Removing .
Стр. 14 из 31II - Link, tie rod, air spring strut, assembly overview
- Remove nut
strut
to center of vehicle.
- 3 -
- Remove bolts
, remove bolt
- 1 -
- arrows -
- 2 -
evenly on both sides.
- Turn stabilizer bar so that clamps
of notches on subframe.
- Remove clamps
from stabilizer bar brackets.
- 1 -
and press air spring
can be guided out
- 1 -
- 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.
Стр. 15 из 31II - Link, tie rod, air spring strut, assembly overview
- Turn stabilizer bar in subframe so that clamps
into subframe notches.
- Install bolts
and tighten to specified torque.
- Move air spring strut
upward.
- Insert bolt
- arrows -
and tighten nut
- 2 -
hand-tight evenly on both sides
outward on link bracket and
- 3 -
to specified torque.
- 1 -
- 1 -
project
- Install tie rod 42
- Tighten stabilizer bar
- arrow -
.
-4, Installing .
at left and right connecting links
- 1 -
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