Volkswagen VAS 5051 User Manual

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Volkswagen Phaeton

Стр. 1 из 6Front suspension, servicin

40 - 2

Front suspension, servicin

AS 5051, connecting and selecting functions

Special tools, equipment, testers, measuring
instruments and auxiliary items required

 VAS 5051 Vehicle diagnosis, testing and information

system

Diagnostic cable VAS 5051/1 or VAS 5051/3



Warning!



During a test drive you must always secure
testing and measuring equipment on the back
seat.



These devices may be operated only by a
passenger during a test drive.

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- Connect diagnosis cable connector VAS 5051/1 or VAS
5051/3 to diagnosis connection.

Стр. 2 из 6Front suspension, servicin

- Switch on tester

- arrow -

.

The tester is operational when it displays a picture of a car.

- Switch on ignition.

- Touch button/field for "Guided Fault Finding" on screen.

- Select one after another:
Brand



 Type

 Model year

 Version

 Engine code

- Confirm data entered.

Note:

Wait until tester has checked all control modules in



vehicle.

- Press Goto button and select "Function/component

selection" function
Follow information given on screen to start the desired

functions.

Front axle, overview

Стр. 3 из 6Front suspension, servicin

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A - Mounting bracket, upper links, air
spring strut, and wheel bearing
housing 40

-3, A - Mounting bracket,
upper links, air spring strut and wheel
bearing housings, assembly overview

B - Subframe, lower links, and
stabilizer bar 40-4, B - Subframe,

lower link, and stabilizer bar, assembly
overview

Note:

 If vehicles with drive axle removed must be moved,

an outer joint must be installed first. Tighten outer
joint to 50 Nm, otherwise the wheel bearings will be
damaged.

 Welding and straightening work on supporting or

wheel carrying components of suspension is not
permitted.

Стр. 4 из 6Front suspension, servicin

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Always replace self-locking nuts.



 Always replaced corroded nuts/bolts.

Wheel bearing, lifting to curb weight position

Special tools, testers and auxiliary items
required

 engine/transmission jack V.A.G

1383 A

 Tightening strap T10038

 Wheel hub support T10149

Note:

 Always tighten all connecting bolts to suspension

p

y

!

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parts with bonded rubber bushings in curb weight
position (unloaded).

Bonded rubber bushings have a limited twisting range.
Axle components with bonded rubber bushings must be

brought into installation position before tightening, which
corresponds to curb weight position when driving.

Otherwise, if you stress the bonded rubber bushing it will
lead to a shorter life span.

By raising the suspension on one side using the
engine/transmission jack V.A.G 1383 A and support
T10149 , this position will be simulated on the hoist.

Стр. 5 из 6Front suspension, servicin

- Before beginning assembly, measure dimension

- a -

from
center of wheel to lower edge of wheelhousing using a tape
measure.

The measurement must be taken in the curb weight

osition (unloaded).

- Note measured value. This is needed for tightening bolts
and nuts.

Before the individual suspension is raised on one side, the
vehicle must be secured to the lifting arms on the hoist
using tensioning straps T10038 .

Caution!
If the vehicle is not secured, it ma

slip off the hoist

- Turn wheel hub until one of the wheel bolt holes is at 12
o'clock position. .

- Attach Wheel Hub Support T10149 to wheel hub with a
wheel bolt.

Only tighten respective bolts and nuts after dimension

- a - between wheel hub center and lower edge of wheel
housin

, measured before beginning of assembly, is

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Стр. 6 из 6Front suspension, servicin

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achieved

Topic 40-2

.

- Raise wheel bearing housing using engine/transmission

ack V.A.G 1383 A until dimension

is achieved.

- a -

Lift wheel bearing housin

Caution!



Do not raise or lower the hoist if the
engine/transmission jack is under the vehicle.



Do not leave engine/transmission jack V.A.G 1383
A under vehicle any longer than necessary.

- Tighten respective nuts/bolts.

- Lower wheel bearing housing.

- Move engine/transmission jack V.A.G 1383 A below
vehicle away.

- Remove wheel hub support T10149 .

A - Mounting bracket, upper links, air spring strut

g

and wheel bearin

housings, assembly overview

Note:

 If a vehicle has to be moved after removing the drive

axle, first install an outer joint and tighten this to 50
Nm, otherwise you will damage the wheel bearings.

 Welding and straightening work on supporting or

wheel carrying components of the suspension is not
permitted.

Always replace self-locking hex head nuts.



Стр. 1 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over...

40 - 3

 Always replaced corroded bolts and nuts.



Hex socket head bolt

 200 Nm plus an additional

g

1

180 (

 Always replace

/ 2 turn)

Vehicle must not be raised
when tightenin



Torx bolt

 9 Nm



Cover plate



Air spring strut

Стр. 2 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over...

 Protective boot must not have

any indentations (be pressed
inward)

 Removing and installing

40-3, Air spring strut removing
and installing



Wheel acceleration sensor

 Left front wheel acceleration

sensor G337

 Right front wheel acceleration

sensor G338

 Check with Vehicle Diagnosis,

Testing and Information
System VAS 5051 in "Guided
Fault Finding"



Hex bolt

 10 Nm



Air supply line

 5 Nm
 Clean connection before

loosening

 Air escapes when

connections are loosened
Protect threaded connection



from dirt



Multi-point socket head bolt

 70 Nm
 M 10 x 20

Pre-tighten to 10 Nm in



diagonal sequence



Drive axle



Hex nut

 50 Nm
 Self-locking

Стр. 3 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over...

 Always replace



Upper front link

 Can only be removed

together with mounting
bracket

Mounting bracket, removing



and installing 40-3,

Mounting bracket, removing
and installing

 Bonded rubber bushings,

replacing 40-3, Upper link

bonded rubber bushing,
replacing



Hex bolt

 Always replace



Mounting bracket

Removing and installing



40-3, Mounting bracket,
removing and installing



Washer



Multi-point socket head bolt

 Observe tightening sequence

40-3, Tightening sequence,







Hex nut

 23 Nm



Hex bolt

 Always replace



Hex nut

 50 Nm and 90 (

air spring damper to body

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

Always replace

1

/ 4 turn)

Стр. 4 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over...

Self-locking



 Replace after every removal



Upper rear link

Can only be removed



together with mounting
bracket

 Mounting bracket, removing

and installing 40-3,

Mounting bracket, removing
and installing

Bonded rubber bushings,



replacing 40-3, Upper link

bonded rubber bushing,
replacing



Hex bolt

 On aluminum wheel bearing



Tie rod



Hex bolt



Hex bolt

 7 Nm

housings, tighten against
driving direction

 Always replace

g



Hex nut

50 Nm



 Self-locking
 Always replace



Wheel bearing housing

 Removing and installing

40-3, Wheel bearing housing,
removing and installing

 Aluminum or steel, application

Parts catalog

Стр. 5 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over...

Air spring strut removing and installin

Special tools, testers and auxiliary items
required

Стр. 6 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over...

 Torque wrench V.A.G 1331

Torque wrench V.A.G 1332



 Engine/transmission jack V.A.G

1383 A

 Wheel hub support T10149

Removing

Remove air spring strut together with mounting
bracket and upper links.

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

- Remove front wheel.

- Clean air line connection

- Remove air line

from air spring strut and then seal off

- A -

- arrow -

to air spring strut.

both connections.

- Open air line cable ties at air spring strut.

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Стр. 7 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over...

- Loosen connecting link to stabilizer bar
link

- Attach Wheel Hub Support T10149 to wheel hub with a
wheel bolt.

- Raise wheel bearing housing with engine/transmission

ack V.A.G 1383 A and Wheel Hub Support T10149 until

connecting link is "stress free" .

- 1 -

.

and to lower

- 2 -

- Remove connecting link from stabilizer bar.

- Lower wheel bearing housing.

- Move engine/transmission jack V.A.G 1383 A away from
under vehicle.

- Remove both upper links from wheel bearing housing.

V

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Стр. 8 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over...

- Remove air spring strut from lower link

- Remove Wheel Acceleration Sensor
strut.

- Remove plenum chamber cover.

Repair Manual, Body Exterior, Repair Group 64,

Stationary windows; Plenum chamber cover, removing and
installing

- 1 -

.

-1-

from air spring

- Unclip cable

- Disconnect strut adjustment switching valve electrical
connector

ehicles with Adaptive Cruise Control

- Remove Brake Booster Membrane Position Sensor G420

.

- 1 -

Repair Manual, Brake System, Repair Group 47, Brake

booster/brake master cylinder, assembly overview; Brake
Booster Membrane Position Sensor G420, removing and
installing

Left side air spring strut, removin

- 2 -

- 3 -

.

.

Стр. 9 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly over...

- Turn steering gear left to stop.

Continue removing air spring strut on right side

- Turn steering gear right to stop.

Continue for both sides

- Remove Level Control System Sensor connecting link

arrow -

from lower link.

-

- Remove air spring strut multi-point socket head bolts

from air spring strut.

2, 3 -

- 1,

- Pull wheel bearing housing as far downward as possible
and then remove from air spring strut.

- Remove mounting bracket from air spring strut.
If air spring strut is to be replaced, first read the following

40

-3, Air spring strut, filling .

Installing

Installation is in reverse order of removal. Note the
following:

- Check threaded bushings (3 pieces, as part of mounting
bracket) are located properly in body.

- Observe tightening sequence for multi-point socket head
bolts.

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Tightening sequence, air spring damper to bod

Стр. 10 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

- Push upper link
tightening.

- Raise wheel bearing housing and then tighten hex bolt

40-2, Lift wheel bearing housing

-

- Check basic setting of level control system Vehicle
Diagnosis, Testing and Information System VAS 5051 .

as far down as possible when

- 3 -

- 1

Tightening torques

Air line to air spring strut 5 Nm

Connecting link to stabilizer bar

90 Nm plus an additional 1 / 4 turn (90

1)

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2)

Стр. 11 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

)

Connecting link to lower link

1)

2)

90 Nm plus an additional 1 / 4 turn (90

)

Upper link to wheel bearing housing 50 Nm

Wheel acceleration sensor to air spring strut 10 Nm

Connecting link from vehicle level sensor to lower

8 Nm

link

Air spring strut to lower link

1)

2)

Mounting bracket to body

1)

90 Nm plus an additional 1 / 4 turn (90

)

50 Nm plus an additional 1 / 4 turn (90

)

Air spring strut to mounting bracket 20 Nm

1)

Use new bolts/nuts

2)

Tighten bolts/nuts in curb weight position

Air spring strut, fillin

Special tools, testers and auxiliary items required

 Adapter T10157

 Air suspension strut charger VAS 6231 , not depicted

 Steel gas cylinder filled with Argon or Corgon, not

illustrated

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.

Стр. 12 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

- Remove bolt

- arrow -

from residual pressure retaining

valve.

- Close steel gas bottle pressure valve.

- Become familiar with the 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 the illustration.

 Air spring strut with packaging

Steel gas bottle for argon, corgon with gauges



 Air spring filler unit VAS 6231
 Adapter T10157

Стр. 13 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

- 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 display does not climb over 4.5 bar when
filling.

- Disconnect air spring filler unit VAS 6231 from adapter
T10157 . This dissipates gas above an internal pressure of

3.5 bar.
Minimum pressure is now set. Remove air spring strut from

packaging.

- After installation, first drive the vehicle at high ride height
and then at normal ride height. Repeat this sequence once
more.

Move twice to different ride heights, the gas is replaced
with cleaned air from air supply unit.

- Install air spring strut 40-3, Installing .

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Mounting bracket, removing and installin

Special tools, testers and auxiliary items required

Стр. 14 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

Torque wrench V.A.G 1332



Removing

- Remove air spring strut 40-3, Air spring strut removing

and installing .

- Remove mounting bracket from air spring strut

Installing

Installation is in reverse order of removal.

-1-

.

Стр. 15 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

- Install mounting bracket to air spring strut

-1-

.

- Install air spring strut 40-3, Installing .

Tightening torque

Air line to air spring strut 5 Nm

Connecting link to stabilizer bar

1)

2)

Connecting link to lower link

1)

2)

90 Nm plus an additional 1 / 4 turn (90

)

90 Nm plus an additional 1 / 4 turn (90

)

Upper link to wheel bearing housing 50 Nm

Wheel acceleration sensor to air spring strut 10 Nm

Connecting link from vehicle level sensor to lower

8 Nm

link

Air spring strut to lower link

1)

2)

90 Nm plus an additional

)

1

/ 4 turn (90

Mounting bracket to body

1)

50 Nm plus an additional 1 / 4 turn (90

)

Air spring strut to mounting bracket 20 Nm

1)

Always use new nuts and bolts

2)

Tighten bolts and nuts in curb weight position

Upper link, removing and installing

Special tools, testers and auxiliary items required

Стр. 16 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

 Torque wrench V.A.G 1332

Removing

- Remove air spring strut 40-3, Air spring strut removing

and installing .

- Compress air spring strut in a vise with protective covers.

- Remove mounting bracket 40-3, Mounting bracket,

removing and installing .

- Remove both links from mounting bracket.

Links, setting

- Set upper front link to dimension
Dimension

= 81 2 mm

- a -

and tighten.

- a -

Стр. 17 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

- Set upper rear link to dimension
Dimension

Installing

= 69 2 mm

- a -

and tighten.

- a -

Installation is in reverse order of removal, note the
following:

- Attach both links to mounting bracket.

- Adjust both links before tightening. 40-3, Links, setting

Tightening torque

Air line to air spring strut 5 Nm

Connecting link to stabilizer bar

1)

2)

Connecting link to lower link

1)

2)

90 Nm plus an additional 1 / 4 turn (90

90 Nm plus an additional 1 / 4 turn (90

)

)

Upper link to wheel bearing housing 50 Nm

Wheel acceleration sensor to air spring strut 10 Nm

Connecting link from vehicle level sensor to lower

8 Nm

link

Air spring strut to lower link

1)

2)

Mounting bracket to body

1)

90 Nm plus an additional 1 / 4 turn (90

)

50 Nm plus an additional 1 / 4 turn (90

)

Air spring strut to mounting bracket 20 Nm

Upper link to mounting bracket

1)

1)

Use new bolts and nuts

50 Nm plus an additional 1 / 4 turn (90

)

2)

g

p

g

Tighten bolts in curb weight position

Upper link bonded rubber bushing, replacin

Special tools, testers and auxiliary items required

Стр. 18 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

 Assembly tool 3301

Front and Rear Bearing Tool 3348



Bonded rubber bushing, removing

Clam

link only in vise with protective covers!

Removing bonded rubber bushin

Стр. 19 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

Bonded rubber bushing, seating

Bonded rubber bushing installation location

A =90 5

Seating bonded rubber bushing

Bushing

- A -

Wheel bearing housing, removing and installing

Special tools, testers and auxiliary items required

 Torque wrench V.A.G 1332

Стр. 20 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

 Ball joint puller T40010

Removing

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

- Remove drive axle hex bolt. Vehicle must be on ground to
do this

- risk of accident -

- Remove front wheel.

.

- Secure brake disc using wheel bolt

- arrow -

.

- Remove brake caliper and disengage from wire to body

Repair Manual, Brake System, Repair Group 46, Front

brakes, servicing

.

- Remove brake disc and cover plate.

- Loosen lower link hex nut and guide link on wheel bearing
housing 2 turns.

j

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- Press lower link guide pins away from tapered seat using
ball joint puller T40010 .

Стр. 21 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

Do not damage protective joint boot when doing this!

- Remove level control system sensor connecting link from
lower link

- arrow -

.

- Separate guide link guide pin from tapered seat using ball

oin puller T40010 .

Do not damage protective joint boot when doing this!

p

Стр. 22 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

- Remove hex bolt

- Remove tie rod end.

- 3 -

and nut

- 4 -

.

- Remove nut
links

- 2 -

upward.

and remove hex bolt. Then remove both

- 1 -

- Remove lower link and guide link from wheel bearing
housing.

- Remove wheel bearing housing.

Installing

Installation is in reverse order of removal, note the
following:

During assembly work, make sure that no indentations
form on boot of air s

- Insert wheel bearing housing.

ring strut!

- Slide drive axle outer joint into wheel hub and hand­tighten new hex socket head bolt.

- Insert lower link and guide link guide pins in wheel
bearing housing.

- Insert upper link in wheel bearing housing.

- Press both upper links down as far as possible when

Стр. 23 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

tightening!

- Install tie rod.

- Check basic setting of level control system.

- Measure vehicle after installation. 44-3, Wheel

alignment

Tightening torque

Drive axle to wheel hub

1)

.

Brake caliper to wheel bearing housing

200 Nm plus an additional 1 / 2 turn (180 )

Repair Manual, Brake System, Repair Group 46,

Front brakes, servicing

Cover plate to wheel bearing housing 10 Nm

Lower link to wheel bearing housing

1)

120 Nm

Guide link to wheel bearing housing

1)

Connecting link from vehicle level
sensor to lower link

Upper link to mounting bracket

1)

Tie rod to wheel bearing housing

1)

1)

Always use new nuts and bolts

Wheel bearing, assembly overview

120 Nm

8 Nm

50 Nm

50 Nm

Стр. 24 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...



Wheel bearing housing



Multi-point socket head bolt

 80 Nm plus an additional

turn (90 )
Always replace





Wheel bearing

 Removing and installing

40-3, Wheel bearing,
removing and installing

Installed location:



 Larger diameter of wheel

bearing faces wheel hub

1

/ 4



Wheel hub

Pressing out 40-3, Wheel

g



bearing, removing and
installing

 Pull off bearing inner ring from

hub 40-3, Pressing off

bearing inner ring

 Pressing in 40-3, Wheel

bearing, removing and
installing

Wheel bearing, removing and installin

Стр. 25 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

Special tools, testers and auxiliary items
required

 Thrust plate VW 401

 Thrust plate VW 402

p

Стр. 26 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

 Punch VW 407

Punch VW 412



 Thrust pad VW 512

Special tools, testers and auxiliary items required

Torque wrench V.A.G 1332



 3 - Separating tool Kukko 17/2

Removing

During assembly work, make sure that no indentations
form on boot of air s

- Remove drive axle hex bolt.

ring strut!

Note:

 Only loosen when vehicle is resting on the wheels

danger of accident -

-

Стр. 27 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

- Remove front wheel.

- Secure brake disc using a wheel bolt

-arrow-

.

- Remove brake caliper and tie to body using wire.

Repair Manual, Brake System, Repair Group 46, Front

brakes, servicing

.

- Remove ABS speed sensor

Repair Manual, Brake System, Repair Group 46, Front

brakes, servicing

.

- Remove brake disc and cover plate.

- Press drive axle as far out of wheel hub as possible (in
direction of final drive).

- Turn steering gear toward right.

- Remove wheel bearing unit from wheel bearing housing.

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 strut!

- Insert wheel bearing unit and tighten.

- Press upper links down as far as possible when
tightening!

Tightening torque

Стр. 28 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

Drive shaft to wheel hub

1)

.

Brake caliper to wheel bearing
housing

200 Nm plus an additional 1 / 2 turn (180 )

Repair Manual, Brake System, Repair Group 46, Front

brakes, servicing

Cover plate to wheel bearing housing 10 Nm

Wheel bearing unit to wheel bearing

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

housing 1)

1)

Always use new nuts and bolts

Pressing out hub

- Press out wheel hub.

- Insert separating tool in bearing inner race ring groove

arrow -

and hub and tension threaded spindle.

Note:

 Use a commercially available separating tool , such

as Kukko 17/2.

-

- Press bearing inner race off wheel hub.

g

Стр. 29 из 29A - Mounting bracket, upper links, air spring strut and wheel bearing housings, assembly o...

Pressing off bearing inner rin

Pressing in wheel hub

- Press wheel hub into wheel bearing to stop.

B - Subframe, lower link, and stabilizer bar,

y

assembl

overview

Стр. 1 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

40 - 4



Subframe

 Removing and installing

 Application See Parts



Hex bolt

 M 12 x 1.5 x 120
 70 Nm plus an additional 180

 Always replace

40-4, Subframe, removing
and installing

Catalog

( 1 / 2 turn)



Guide link

 Removing and installing



Hex nut

 120 Nm



 Always replace



Hex nut

Стр. 2 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

40-4, Guide link, removing
and installing

Self-locking



 Self-locking
 Always replace



Hex nut

 70 Nm plus an additional 180

 Lift wheel bearing housing

 Self-locking
 Always replace



Hex bolt

Lift wheel bearing housing
before fastening 40-2, Lift

wheel bearing housing

( 1 / 2 turn)

before fastening 40

-2, Lift

wheel bearing housing



Hex nut

 M 12 x 1.5 x 70
 Lift wheel bearing housing

before fastening 40-2, Lift

wheel bearing housing

 Always replace

 90 Nm plus an additional 90

( 1 / 4 turn)

 Self-locking
 Always replace



Lower link

 Removing and installing

40-4, Lower link, removing
and installing



Hex nut

 120 Nm
 Self-locking
 Always replace

Стр. 3 из 17B - Subframe, lower link, and stabilizer bar, assembly overview



Hex head bolt

 M 12 x 1.5 x 85
 Lift wheel bearing housing

before fastening 40-2, Lift

wheel bearing housing

 Always replace



Subframe support plate



Hex bolt

 M10 x 25

40 Nm plus an additional 90



( 1 / 4 turn)
Always replace





Washer



Hex bolt



 130 Nm plus an additional 90

 Always replace



Hex nut

M14 x 1.5 x 90

( 1 / 4 turn)

 90 Nm plus an additional 90

( 1 / 4 turn)

 Self-locking
 Always replace



Connecting link

 Left and right connecting links

are identical

Стр. 4 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

Installed location

40-4,

Installed location of connecting
link

Arrow on connecting link points
in direction of travel

Larger diameter of connecting
link is at stabilizer bar and lower
link



Hex bolt

 M 12 x 1.5 x 65
 90 Nm plus an additional 90

( 1 / 4 turn)

 Lift wheel bearing housing

before fastening 40-2, Lift

wheel bearing housing

 Always replace



Stabilizer bar

 Removing and installing

40-4, Stabilizer bar, removing
and installing



Multi-point socket head bolt

 50 Nm



Multi-point socket head bolt

 50 Nm



Mounting bracket



g

Engine carrier



Repair Manual, Engine Mechanical,
Fuel Injection Ignition, Repair Group 10,
Engine, removing and installing



Hex bolt

 M 12 x 1.5 x 95

Стр. 5 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

Always replace





Hex bolt

 M14 x 1.5 x 135

130 Nm plus an additional 90



( 1 / 4 turn)

Always replace





Washer



Subframe support



Hex bolt

 M10 × 40
 50 Nm plus an additional 90

1

(

/ 4 turn)



Self-locking hex nut

Always replace



Subframe, removing and installin

Special tools, testers and auxiliary items required

Стр. 6 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

Torque wrench V.A.G 1332



 Engine/transmission jack V.A.G 1383 A

Removing

- Remove stabilizer bar 40-4, Stabilizer bar, removing

and installing .

- Remove front wheels.

- Remove both guide links 40-4, Guide link, removing

and installing .

- Loosen both lower links at subframe.

Стр. 7 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

- Loosen hex bolt

but do not remove.

- 1 -

- Disconnect all electrical wires from body to front axle.

- Remove connecting link

- arrow -

from level control

system sensor to lower link.

- Mark installation position of subframe to body with felt-tip
pen.

- Support subframe with engine/transmission jack V.A.G
1383 A and universal mount.

- Remove hex bolts

- 1, 2 -

and

in sequence shown.

- 3 -

- Lower subframe as far as possible and then remove both
lower links from subframe.

- Slowly lower subframe and remove.

Installing

Installation is in reverse order of removal, note the
following:

- When installing subframe, align with help of markings on
body.

- Install subframe with old hex bolts. Replace with new
ones after vehicle alignment.

- When doing so, tighten hex bolts to specified tightening

g

Стр. 8 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

torque without additional tightening.

- Place vehicle on wheels or raise wheel bearing housing to
tighten lower link and guide link 40-2, Lift wheel bearing

housing

- Check basic setting of self-levelling suspension.

- Measure vehicle after installation 44-3, Wheel

alignment .

Tightening torque

Stabilizer bar to engine carrier 50 Nm

Connecting link to stabilizer bar

1)

2)

Connecting link to lower link

1)

2)

Guide link to subframe

1)

2)

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

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

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

Guide link to wheel bearing housing 120 Nm

Air spring strut to lower link

1)

2)

Connecting link from vehicle level sensor to lower

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

8 Nm

link

Subframe to body, bolts M14

1)

Subframe to body, bolts M10

1)

1)

Always use new nuts and bolts

2)

Tighten screws and nuts in curb weight position

Stabilizer bar, removing and installin

130 Nm plus an additional 90 ( 1 / 4

turn)

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

Special tools, testers and auxiliary items required

Стр. 9 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

 Torque wrench V.A.G 1332

Removing

Note:

 Vehicle must rest on wheels for removal and

installation of stabilizer bar. Otherwise, ther e is a risk
that the stabilizer bar or other components may be
damaged.

- Remove front and rear noise insulation.

Repair Manual, Body Exterior, Repair Group 50, Noise

insulation; noise insulation - assembly overview

- Loosen hex bolt

and remove hex bolt

- 1 -

.

-2-

Стр. 10 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

- Loosen stabilizer bar

on both sides.

- 1 -

- Align stabilizer bar so that the multi-point socket head
bolts

- arrows -

- Remove stabilizer bar.

Installing

can be turned easily by hand.

Installation is in reverse order of removal, note the
following:

- Insert stabilizer bar.

- Install multi-point socket head bolts

- arrows -

by hand on

both sides.

- Align stabilizer bar

so that the multi-point socket head

- 1 -

bolts can be turned by hand easily.

- Alternately tighten multi-point socket head bolts to
stabilizer bar mounting bracket.

- Attach stabilizer bar to connecting link.

- Tighten connecting links.

k

Стр. 11 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

Installed location of connecting lin

Tightening torque

Stabilizer bar to engine carrier 50 Nm

Connecting link to stabilizer bar

1)

2)

Connecting link to lower link

1)

2)

1)

Always use new nuts and bolts

2)

Tighten bolts and nuts in curb weight position

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

90 Nm plus an additional

1

/ 4 turn (90 )

Lower link, removing and installing

Стр. 12 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

Special tools, testers and auxiliary items
required

Torque wrench V.A.G 1332



 Engine/transmission jack V.A.G

1383 A

 Wheel hub support T10149

 Ball joint puller T40010

Removing

- Remove hex bolt for drive axle. (Only loosen when vehicle
is resting on the wheels

-danger of accident -

).

- Remove front wheel.

Стр. 13 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

- Secure brake disk using a wheel bolt

- Remove brake caliper and tie to body using wire.

Repair Manual, Brake System, Repair Group 46, Front

brakes, servicing

- Remove brake disc and cover plate.

- Remove front and rear noise insulation

Repair Manual, Body Exterior, Repair Group 50, Noise

insulation; Noise insulation - assembly overview

.

- Raise wheel bearing housing until connecting link is
"stress free" 40-2, Lift wheel bearing housing

-arrow-

.

- Loosen connecting link at stabilizer bar
link

- Remove connecting link from stabilizer bar.

- Lower wheel bearing housing.

- Move engine/transmission jack away from under the

- 1 -

.

and to lower

- 2 -

vehicle.

ge p

- Remove both upper links from wheel bearing housing.

- Remove hex bolt from lower link guide pin. Then press
guide pin away from tapered seat with ball join puller
T40010 .

Стр. 14 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

Do not dama

- Remove Level Control System Sensor connecting link

arrow -

from lower link.

rotective joint boot when doing this!

-

- Remove air spring strut

- Turn steering gear toward right.

- Pull wheel bearing housing down as far as possible and
swing lower link out of air spring strut fork.

from lower link.

-1 -

Стр. 15 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

- Remove lower link from subframe.

- Mark installation position of subframe to body using a felt­tip pen.

- Lower subframe to remove hex bolt.

- Remove lower link.

Installing

Installation is in reverse order of removal, note the
following:

- Align subframe with help of markings on body.

- Tighten subframe with bolts originally installed. Replace
these with new bolts after vehicle alignment.

- Tighten bolts originally installed to specified torque
without additional tightening.

- Raise wheel bearing housing for fastening to subframe

40-2, Lift wheel bearing housing

- Check basic setting of level control system.

- Measure vehicle after installation 44-3, Wheel

alignment .

Tightening torque

Drive shaft to wheel hub

1)

.

Brake caliper to wheel bearing housing

200 Nm plus an additional 1 / 2 turn (180 )

Repair Manual, Brake System, Repair Group 46,

Front brakes, servicing

Cover plate to wheel bearing housing 10 Nm

Connecting link to stabilizer bar

1)

2)

Connecting link to lower link

1)

2)

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

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

upper link to mounting bracket

1)

Lower link to wheel bearing housing

1)

Connecting link from vehicle level
sensor to lower link

50 Nm

120 Nm

8 Nm

Стр. 16 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

Air spring strut to lower link

1)

2)

Subframe to body, bolts M14

1)

Subframe to body, bolts M10

1)

Lower link to subframe

1)

2)

1)

Always use new nuts and bolts

2)

Tighten bolts and nuts in curb weight position

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

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

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

70 Nm plus an additional 1 / 2 turn (180 )

Guide link, removing and installing

Special tools, testers and auxiliary items required

 Torque wrench V.A.G 1332

 Ball joint puller T40010

Removing

Стр. 17 из 17B - Subframe, lower link, and stabilizer bar, assembly overview

- Remove front wheel.

- Loosen guide link hex nut at wheel bearing housing 2
turns.

- Separate guide link guide pins away from tapered seat
using ball joint puller T40010 .

Do not damage protective joint boot when doing this!

- Remove guide link from subframe.

Installing

Installation is in reverse order of removal, note the
following:

- Raise wheel bearing housing for tightening to subframe

40-2, Lift wheel bearing housing

- Measure vehicle after installation 44-3, Wheel

alignment .

Tightening torque

Guide link to subframe

1)

2)

Guide link to wheel bearing housing

1)

1)

Always use new nuts and bolts

70 Nm plus an additional

120 Nm

1

/ 2 turn (180 )

2)

Tighten bolts and nuts in curb weight position

g

j

j

g

Стр. 1 из 32Drive shaft, servicin

g

40 - 5

Drive shaft, servicin

Drive axles, overview

I - Drive axle with triple-roller joint AAR

40

2900, assembly overview

-5, I ­Drive axle with triple-roller joint AAR
2900, assembly overview

II - Drive axle with peened triple-roller

oint AAR 3300i, assembly overview

40-5, II Drive axle with peened triple roller

oint AAR 3300i, assembly overview

Drive axles, removing and Installin

Removing

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

Caution!

-

)

g

g

Remove drive axle hex bolts (only loosen if vehicle is
standing on wheels -danger accident

- Loosen drive axle at transmission flange.

.

Стр. 2 из 32Drive shaft, servicin

- Remove front wheel.

- Remove noise insulation

Repair Manual, Body Exterior, Repair Group 50, Noise

insulation; Noise insulation - assembly overview

.

- Remove ABS speed sensor.

- Remove cover plate

Repair Manual, Brake System, Repair Group 46, Front

brakes, servicing

.

- Remove both upper links from wheel bearing housing.

- Remove drive axle heat shield
can not be seen in illustration.

Left drive axle

- Turn steering gear toward left.

ht drive axle

Ri

- Turn steering gear toward right.

Continued for both drive axles

- Disconnect drive axle from transmission flange and

- arrows -

. The third bolt

Стр. 3 из 32Drive shaft, servicin

g

remove.

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 strut!

- Press upper links as far down as possible when
tightening!

Tightening torque

Drive axle to wheel hub

1)

Cover plate to wheel bearing

200 Nm plus an additional 1 / 2 turn (180 )

10 Nm

housing

ABS speed sensor to wheel bearing
housing

Repair Manual, Brake System, Repair Group 46, Front

brakes, servicing

Upper link to mounting bracket

1)

Drive axle to transmission, pre-

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

10 Nm

tighten

1)

Drive shaft to transmission, tighten 70 Nm

Heat shield to transmission housing 23 Nm

1)

Always use new nuts and bolts

I - Drive axle with triple-roller joint AAR 2900, assembly
overview

Стр. 4 из 32Drive shaft, servicin

g



Hex head bolt

 Always replace

M16 screw tightening torque:

 200 Nm plus an additional

turn (180 )

2



Outer constant velocity
protective joint boot

 Check for tears and chafing
 Before clamping hose clamp,

raise protective joint boot
briefly to balance pressure

40

-5, Protective joint boot,

ventilating

 Different version in rubber or

Hytrel

1

/



Clamp

Different versions for



protective joint boot in rubber
or Hytrel

 Always replace
 Tighten rubber protective joint

boots 40-5, Clamping

sleeves on rubber protective
joint boots are clamped with

Tighten Hytrel protective joint

g



boots 40-5, Clamping

sleeves on Hytrel protective
joint boots are clamped with



Axle shaft



Clamp

 Always replace
 Tensioning 40-5, Clamping

sleeves on Hytrel protective
joint boots are clamped with



Joint piece

Стр. 5 из 32Drive shaft, servicin



Multiple point socket head bolt,
70 Nm

 Pre-tighten to 10 Nm



Triple roller star
Chamfer - arrow - faces splines

axle shaft splines

 Installed location Topic 40-

5



Circlip

 Replace each time it is

removed
Insert in shaft groove





O-ring
A new seal is in repair kit and

must be replaced.



Cover

Replace each time it is



removed

Destroyed when disassembling.
A modified cover is included in

the repair kit.

g



Clamp

 Always replace

Tensioning 40-5, Clamp



large clamping sleeve to inner
joint with

 Different hose clamps are

possible depending on
construction. Can also be
assembled with pliers 3340

Electronic Parts Catalog
"ETKA" .



Protective joint boot for triple
roller joint

Стр. 6 из 32Drive shaft, servicin



Clamp

 Always replace
 Tensioning 40-5, Clamp

small clamping sleeve to inner
joint with



Spring washer

 Installed location 40-5,

Installation location of thrust
washer and spring washer
(wheel side)



Thrust washer

Installed location 40-5,



Installation location of thrust
washer and spring washer
(wheel side)



Circlip

 Always replace
 Insert before mounting in ring

groove (not visible with joint
installed)



Outer constant velocity joint

 Replace only as a unit

 Pressing off 40-5, Pressing

g

off outer constant velocity
joint

 Installing: Drive joint onto

shaft with a plastic hammer
until circlip engages.

Checking 40-5, Outer



constant velocity (CV) joint,
checking

Triple-roller joint AAR 2900, disassembling and assembling

Стр. 7 из 32Drive shaft, servicin

Special tools, testers and auxiliary items
required

 Sleeve VW 416 B

 Punch VW 412

Стр. 8 из 32Drive shaft, servicin

g

 Sleeve VW 426

 Sleeve 3110

 Puller Kukko 12/1

 Press piece 2050

Special tools, testers and auxiliary items
required

 CV joint boot clamp tool V.A.G

1275

 Circlip pliers VW 161 A

 Pressure spindle 3207

Disassemblin

g

j

g

Стр. 9 из 32Drive shaft, servicin

- Line cover.

Note:

 Use old screw to line cover.

 When doing so, hold shaft at a 20 angle .

Use a plastic hammer and sleeve 3110 .

- Remove any shavings in cover area.

- Open large clamping sleeve.

- Open small clamping sleeve on shaft and slide protective

oint boot back.

- Identify installation location for parts

- 1 -

to

- 3 -

with

lines.
If parts are not marked when assembling, the components

are not brought back to their previous installation position

g

g

then it is possible that it will be noisy when driving.
A waterproof felt tipped pen is suitable for marking.

Стр. 10 из 32Drive shaft, servicin

- Remove O-ring
1 - Joint piece

2 - Triple roller star
3 - Axle shaft

- Remove circlip.
1 - Pliers (commercially available)

- arrow -

from groove.

- Remove triple roller star from axle shaft. Use puller Kukko
12/1 (commercially-available) to do this.

- Remove grease in sealing ring groove and on shaft
splines.

- Check roller body and ball cage for wear.

- Clean shaft and housing.

Assemblin

- Slide small protective joint boot clamping sleeve onto
shaft.

- Slide new protective joint boot onto shaft.

Стр. 11 из 32Drive shaft, servicin

g

- Slide joint onto shaft.

- Slide protective joint boot onto joint.

Mount triple roller star

The chamfer

- arrow -

on star faces toward shaft, this is

used as an assembly aid.

- Place triple roller star onto shaft corresponding to marking
and drive to stop.

- Install circlip. Ensure proper seating.

- Press half of grease G 000 605 from repair kit into triple
roller joint.

- Slide joint over rollers.

Note:

 Make sure protective joint boot does not twist.

- Press half of grease G 000 605 from repair kit into rear
side of triple roller joint.

Стр. 12 из 32Drive shaft, servicin

g

- Carefully clean sealing ring groove

- Lay O-ring

- 1 -

in groove

- 4 -

.

- 4 -

.

The individual parts are shown disassembled for sake of
better illustration.

1 - Circlip
2 - Cover from repair kit
3 - O-ring
4 - Groove in triple roller joint

- Lay axle shaft in press.

- Lightly press on cover

from repair kit so circlips from

- 1 -

repair kit can engage.

- Place circlip from repair kit around circumference below
edge.

Note:

Make sure you hear circlip engage.



Стр. 13 из 32Drive shaft, servicin

g

- Position joint in middle position, see "min" - "max"
position.

Note:

 When positioning joint in middle position, it is

necessary to bleed protective joint boot, e.g. with a
screwdriver

- arrow -

.

- Install clamping sleeve

-2 -

.

Note:

 For a better alignment of multi-point socket head

bolts when installing axle shaft, clamping sleeve
connecting tube
connecting flanges

must be between joint

- 2 -

.

- 1 -

V

Стр. 14 из 32Drive shaft, servicin

g

Clamp large clamping sleeve to inner joint with pliers

1275

.

Clamp small clamping sleeve to inner joint with pliers

1275

.

Outer constant velocity joint, servicing

V.A.G

V.A.G

Clamping sleeves on rubber protective joint boots are
clamped with pliers

.A.G 1275

.

g

Clamping sleeves on Hytrel protective joint boots are
clamped with clamping tool V.A.G 1682 .

- Install clamping tool V.A.G 1682 as shown in illustration.
When doing so, make sure clamping tool jaws are in
corners

- arrow B -

of clamping sleeves.

Стр. 15 из 32Drive shaft, servicin

- Clamp clamping sleeve by turning spindle with torque
wrench (when doing so, do not tilt pliers).

 Torque specification: 20 Nm

 Use torque wrench with 5 to 50 Nm range (e.g. V.A.G

1331 ).

 Be sure thread of spindle of clamp tool moves freely.

Grease with MoS 2 grease if necessary.

 If thread is tight e.g. dirty, the required tensioning

force for the hose clamp will not be achieved in spite
of correct torque specification settings.

Pressing off outer constant velocity joint

j

j

g

(

)

g

- Clamp drive shaft in vise with protective covers.

- Remove large clamping sleeve and turn back protective

oint boot.

- Screw on pressure spindle 3207 onto guide pins until CV

oint can be removed.

Стр. 16 из 32Drive shaft, servicin

Protective joint boot, ventilatin

Only for rubber protective joint boot:
A vacuum can form in joint when installing protective joint

boot.
This vacuum pulls a fold in when driving
Observe the following:

- Before clamping, clamping sleeves, balance pressure by
raising protective joint boot.

-arrow-

.

Installation location of thrust washer and spring washer

wheel side

1 - Spring washer
2 - Thrust washer (plastic)

Outer constant velocity (CV) joint, checking

g

j

g

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.

Removin

Стр. 17 из 32Drive shaft, servicin

- Mark ball hub position to ball cage and housing using an
electric scriber or oil stone, before disassembling.

- Pivot ball hub and ball cage.

- Remove balls one after another.

- Turn cage until two rectangular windows

- arrow -

contact

oint body.

- Lift out cage together with hub.

- Swing hub segment into rectangular window on cage.

g

y

g

Стр. 18 из 32Drive shaft, servicin

- Tip hub out of cage.
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.

Installin

- Press half of total amount of grease into joint body.

- Insert cage with hub into joint body.

- Press in opposite balls one after the other. Reestablish
old position of ball hub to ball cage and to joint body.

- Insert new circlip in hub.

- Distribute remaining grease in cover.

II Drive axle with peened triple roller joint AAR 3300i,
assembl

overview

Стр. 19 из 32Drive shaft, servicin

g

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru

огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi



Clamp

Always replace



 Tensioning 40-5, Clamp

large clamping sleeve to inner
joint with



Protective joint boot for triple
roller joint

 Protective joint boot must fit in

groove and on joint contour.



Clamp

Always replace



 Tensioning 40-5, Clamp

small clamping sleeve to inner
joint with



g

Circlip

 Always replace
 Insert before mounting in ring

groove (not visible with joint
installed)



Outer constant velocity joint

 Replace only as a unit
 Removing Topic 40-5
 Checking 40-5, Outer

constant velocity (CV) joint,
checking

Стр. 20 из 32Drive shaft, servicin

 installing Topic 40-5



Collar screw

 Always replace
 200 Nm plus an additional

180 ( 1 / 2 turn)



Clamp

 Always replace
 Tensioning 40-5, Clamping

sleeves on Hytrel protective
joint boots are clamped with



Outer constant velocity
protective joint boot

 Check for tears and chafing



Clamp

Always replace



 Tensioning 40-5, Clamping

sleeves on Hytrel protective
joint boots are clamped with



Driveshaft



Circlip

 Application Electronic Parts

g

Catalog "ETKA"

Стр. 21 из 32Drive shaft, servicin



Triple roller star
Chamfer - arrow - faces splines

axle shaft splines



Circlip

 Always replace
 Insert in shaft groove



Bolt, 70 Nm

 Pre-tighten to 10 Nm



Joint piece

Triple roller joint AAR 3300i, disassembling and assembling

Стр. 22 из 32Drive shaft, servicin

g

Special tools, testers and auxiliary items
required

Thrust plate VW 401



 Thrust plate VW 402

 Punch VW 408 A

 Punch VW 411

 Tube VW 416 B

Thrust pad VW 447 H



q

p

Стр. 23 из 32Drive shaft, servicin

g

Special tools, testers and auxiliary items

uired

re

 CV joint boot clamp tool V.A.G

1275

 Torque wrench V.A.G 1331

Torque wrench V.A.G 1332



 CV joint boot clamp tool V.A.G

1682

 Assembly tool T10065

S

ecial tools, testers and auxiliary items required

g

Стр. 24 из 32Drive shaft, servicin

g

 Slide hammer - complete set VW 771

 Assembly tool T40018

 Brass or copper drift

Peened triple roller joint AAR 3301, disassemblin

- Clamp joint horizontally in vise.

Note:

Use protective vise covers.



 Make sure joint is not damaged.

- Mark location of joint to axle shaft.
If parts are not marked when assembling, the components

are not brought back to their previous installation position
then it is possible that it will be noisy when driving.

A waterproof felt tipped pen is suitable for marking.

Стр. 25 из 32Drive shaft, servicin

g

- Open clamping sleeves

-arrows -

- Slide protective joint boot back.

.

- Insert assembly device T40018 behind joint.
Guide pins

must contact joint.

- 1 -

- Bring assembly device T40018 into contact with joint by
turning knurled thumb screws

- 2 -

.

Note:

 Secure joint in assembly device T40018 with no play.

 Only hand-tighten screws

- 2 -

.

- Screw slide hammer VW 771 into assembly device

g

T40018 .

- Remove joint horizontally with slide hammer VW 771 .
Lower joint in assembly device T40018 .

Стр. 26 из 32Drive shaft, servicin

- Identify installation location for parts
lines.

If parts are not marked when assembling, the components
are not brought back to their previous installation position
then it is possible that it will be noisy when driving.

A waterproof felt tipped pen is suitable for marking.
1 - Axle shaft

2 - Triple roller star

- Remove grease with a lint-free cloth.

- 1 -

and

- 2 -

with

- Remove circlip with pliers

(commercially-available).

- 1 -

p

g

Стр. 27 из 32Drive shaft, servicin

g

- Press triple roller star off axle shaft.
Assembly tool T10065/4 must not be applied to roller body.

- Remove protective joint boot.

- Remove grease on shaft splines.

- Check roller body and ball cage for wear.

- Clean axle shaft and housing.

le roller joint AAR 3300i, assemblin

Tri

- Slide new protective joint boot onto axle shaft.

- Press circlip

onto center of splines.

- 1 -

Стр. 28 из 32Drive shaft, servicin

g

- To press on circlips
illustration.

Instead of T10065/2 conical axle shafts, cylindrical axle
shafts T10065/3 are used Topic 40-5 .

Triple roller star, pressing onto axle shaft

, use special tool shown in

- 1 -

This illustration only applies to conical axle shafts ­arrow - .

The chamfer on star faces toward axle shaft, this is used as
an assembly aid.

- Use special tool shown in illustration.
Special tool T10065/2 must not come in contact with roller

body.

- Place triple roller star onto shaft corresponding to marking
and drive to stop.

Circlip must engage audibly, triple roller star must lie
against circlip with no gap.

Стр. 29 из 32Drive shaft, servicin

g

This illustration is only for cylindrical axle shaft - arrow

- .

The chamfer on star faces toward axle shaft, this is used as
an assembly aid.

- Use special tool shown in illustration.
Special tool T10065/3 must not come in contact with roller

body.

- Place triple roller star onto shaft corresponding to marking
and drive to stop.

Circlip must engage audibly, triple roller star must lie
against circlip with no gap.

- Install circlip with pliers

- Press half of high-temperature grease from repair kit into
triple roller joint.

- Lightly lubricate roller body.
Make sure roller body does not tilt!

(commercially-available).

-1 -

g

- Press joint over triple roller bar with a plastic hammer.

- Press rest of grease into protective joint boot.

- Ensure correct seating of boot on joint.

Стр. 30 из 32Drive shaft, servicin

Boot must fit in groove and on joint contour.

- Position joint in middle position, see "min - max" position.

Note:

When positioning joint in middle position, it is



necessary to bleed protective joint boot, e.g. with a
screwdriver

- arrow -

.

- Install clamping sleeve.

Note:

g

 For a better alignment of multi-point socket head

bolts when installing axle shaft, clamping sleeve
connecting tube
connecting flanges

must be between joint

- 2 -

.

- 1 -

Стр. 31 из 32Drive shaft, servicin

- Clamp clamping sleeves on triple roller joint 40-5,

Clamp small clamping sleeve to inner joint with

Outer constant velocity joint, servicing

Outer CV joint, removing

- Clamp axle shaft in vise with protective covers.

- Open both clamping sleeves and remove protective joint
boot from CV joint.

- Strike a copper or brass drift

on CV joint inner race

- A -

with a hammer.

- Remove joint and protective joint boot.

Outer CV joint, installing

- Guide protective joint boot with small clamping sleeve
onto joint.

Joints and protective joint boots must be free of grease.

Стр. 32 из 32Drive shaft, servicin

g

- Always replace circlip

- Position protective joint boot in outer groove
Inner groove

groove" (for correct installation of protective joint boot).

- Press half of grease from repair kit into inner joint.

- Screw old axle shaft screw into joint as shown in
illustration.

- arrow A -

.

- 1 -

-arrow B-

must remain visible "identifying

.

- Drive joint onto axle shaft with a plastic hammer until
circlip engages.

- Press rest of grease into protective joint boot.

- Slide protective joint boot onto joint.

- Ensure correct seating of protective joint boot on joint.
Protective joint boot must fit in groove and on joint contour.

- Clamp clamping sleeves onto outer joint 40

Clamping sleeves on Hytrel protective joint boots are
clamped with

-5,