SKODA Rapid 2011 Workshop Manual

Service

Workshop Manual

Rapid 2011

Axles, steering

Edition 12.2018

Service Department. Technical Information

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Service

List of Workshop Manual Repair Groups

Repair Group

00 - Technical data

40 - Front suspension

42 - Rear suspension

44 - Wheels, tyres, vehicle geometry

48 - Steering

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

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	Rapid 2011
	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

5.5Push 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

Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents i

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Rapid 2011
Axles, steering - Edition 12.2018
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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	Rapid 2011
	Axles, steering - Edition 12.2018
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

Contents iii

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Axles, steering - Edition 12.2018

iv Contents

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Rapid 2011

Axles, steering - Edition 12.2018

00 – Technical data

1Accident vehicle assessment

(SRL001334; Edition 12.2018)

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

1.1Checklist 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 spectiveoftheaxlealignmentbeingcarriedout.Ifyoucannotfind anydeviationsfromthenominalvaluesduringaxlealignment,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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Axles, steering - Edition 12.2018

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 systemsconcernedmustbere-examinedtomakesurenoentries are in the event memory in order to make sure proper operation has been restored.

2 Rep. gr.00 - Technical data

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Axles, steering - Edition 12.2018

2General Instructions

“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

2.1Steering 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.

♦Useonlythegreaseandsealantswithspecifiedpartnumbers.

♦Carefullycoverorcloseopenedcomponentsiftherepairisnot completed immediately.

2.2Seals 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.

2.3Nuts 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.

♦Tighteningtorquesareforunlubricatednuts,boltsandscrews.

♦Always replace the self-locking screws and nuts.

2.4Electrical 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.

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Axles, steering - Edition 12.2018

40 – Front suspension

1Front 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

1.1Front 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

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Axles, steering - Edition 12.2018

1.2Raise the wheel-bearing housing in the 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 jacke.g.-V.A.G1383/A-or-VAS6931-andtheuptake-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- .

DANGER!

Ifthevehicleisnotlashed,thereisariskofthevehicletoppling 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 - T10149with wheel bolt at the wheel hub.

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Axles, steering - Edition 12.2018

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 - T10149until 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 -

VAS6931from underneath the vehicle.

–Remove support - T10149- .

–Remove tensioning strap - T10038- .

6 Rep. gr.40 - Front suspension

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2Repairing front axle

“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

2.1Summary 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.

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Axles, steering - Edition 12.2018

1 - Assembly carrier

Removing and installing“2.9Removingandin 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“2.7Removingandin 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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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

2.2Lower 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-

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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

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

–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.

–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 - T10096or - T10486/1- into the corresponding openings of the assembly car rier, the following measures must be carried out:

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–Prepare the inlet openings in the lower area of the assembly carrier e.g. with a file so that the fixing devices - T10096or - T10486/1- can be inserted into the openings.

–Treatpreparedopeningstoprotectagainstcorrosion,e.g.with zinc spray - D 007 500 04- .

For vehicles with exhaust pipe inserted on the assembly carrier

–RemovespringwasherforexhaustsystemtoassemblycarrierEngine; Rep. gr. 26 .

Continued for all vehicles

–Lowerassemblycarrierapprox.4cmandthroughthisslacken 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.

–Unscrewleftfixingbolt-1-from-T10096-,screwinnewscrew 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

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–Tighten up the rear right support bolts to the recommended 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 carrierEngine; Rep. gr. 26 .

Continued for all vehicles

–Install the noise insulation Body Work; Rep. gr. 50 .

–Slide the universal joint of the steering column in the -direction of the arrowonto 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 aheadthesteeringwheelisoffstraight,performanaxlealignment“2.2 Axle alignment”, page 129 .

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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		70 Nm + 90°.
♦	Use new screws!

Support to body		20 Nm + 90°.
♦	Use new screws!

Hinged support to gearbox		30 Nm + 90°.
♦	Use new screws!

Universal joint of the steering column to power-steering gear		20 Nm + 90°.
♦	Use new screw!

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2.3Inspecting the suspension link

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.

Inspecting radial play

– Forcefully push the wheel towards the inside and the outside.

2.4Removing and installing the suspension link

Special tools and workshop equipment required

♦ Ball joint extractor - 3287A-

Removing:

–Remove wheel.

–Release fixing nuts -arrows-.

–Releasetrackcontrolarmfromthescrewsofthesteeringjoint.

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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.

Fittingpositionaccordingtotheidentificationonthesteeringjoint: 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-markstheleftsteeringjointforvehiclewithmechanicalsteer 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 aheadthesteeringwheelisoffstraight,performanaxlealignment“2.2 Axle alignment”, page 129 .

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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.

Steering joint to wheel-bearing housing		20 Nm + 90°.
♦	Use new nut!

Steering joint to track control arm		100 Nm
♦	Use new nuts!

Wheel bolts		120 Nm

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2.5Removing and installing the track con 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-.

–Unscrew screw -arrow 1- and screw with nut -arrow 2-.

–Releasetrackcontrolarmfromthescrewsofthesteeringjoint.

–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

Thetighteningofthescrewforsteeringjointandassemblycarrier 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 aheadthesteeringwheelisoffstraight,performanaxlealignment“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.

Track control arm to assembly carrier	70 Nm + 90°.
♦ 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	100 Nm
♦ Use new nuts!

Wheel bolts	120 Nm

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2.6Replacing 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 A1to 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:

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

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Fitting position of rear bearing for track control arm

–The marking -2- of the rubber-metal bearing must be posi tionedtooneaxlewiththemarking-1-onthetrackcontrolarm.

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

Note

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

♦Do not use another grease!

2.7Removing 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 - T10096-

Removing:

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

–RemovespringwasherforexhaustsystemtoassemblycarrierEngine; Rep. gr. 26 .

Continued for all vehicles

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

–Unscrewtheclampsoftheanti-rollbarfromtheassemblycar rier -arrows-.

Note

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

♦Thebottomscrewoftherightclampcanonlyberemovedonce 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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