SKODA Rapid 2011 Workshop Manual

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Service

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Workshop Manual

Rapid 2011 ➤

Axles, steering

Edition 12.2018

Service Department. Technical Information

List of Workshop Manual Repair Groups

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Re pa ir G ro up

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

Service

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

Rapid 2011 ➤

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Axles, steering - Edition 12.2018

Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ii Contents

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

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

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

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Axles, steering - Edition 12.2018

iv Contents

00 – Technical data

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1 Accident vehicle assessment

(SRL001334; Edition 12.2018)

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

1.1 Checklist for assessing the chassis of accident vehicles

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

Visual inspection and check functional reliability of the steering system

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

cuts or bends

♦ Make sure hydraulic lines, thread connections and steering

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

steering range by turning the steering from one extreme angle

to the other; when applying constant pressure, the steering

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

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

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

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

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

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

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

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1. Accident vehicle assessment 1

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

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

spection and check functional reliability

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

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

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

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

2 Rep. gr.00 - Technical data

2 General Instructions

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

2.1 Steering gear

♦ Thoroughly clean all unions and the adjacent areas before

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

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

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

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

completed immediately.

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2.2 Seals and sealing rings

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

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

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

faces, making sure that no residual sealant gets into the

steering box housing.

2.3 Nuts and bolts

♦ Slacken and tighten securing bolts and nuts of covers and

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

with control unit. Loosen and tighten them diagonally in

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

2.4 Electrical components

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

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

nents. Please do not touch the connector contacts.

2. General Instructions 3

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40 – Front suspension

1 Front axle - Overview

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

laden weight position)”, page 5

1.1 Front axle - Overview of the repair chapter

Note

♦

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

♦

Always replace the self-locking screws and nuts.

♦

Always replace corroded self-locking nuts and screws.

♦

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

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

I - ⇒ “2 Repairing front axle”,

page 7

II - ⇒ “4 Repairing wheel bear‐

ing”, page 45

III - ⇒ “3 Repairing front sus‐

pension strut”, page 34

4 Rep. gr.40 - Front suspension

1.2 Raise the wheel-bearing housing in the

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rebound state (unladen weight position)

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

Note

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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DANGER!

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

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

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

1. Front axle - Overview 5

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

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

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

Caution

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

jack is positioned under the vehicle.

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

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

– Tighten up the corresponding screws fully to the specified

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

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

6 Rep. gr.40 - Front suspension

2 Repairing front axle

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

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

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

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

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

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

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

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Axles, steering - Edition 12.2018

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

Note

♦

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

♦

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

♦

Always replace the self-locking screws and nuts.

♦

Always replace corroded self-locking nuts and screws.

♦

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

2. Repairing front axle 7

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Axles, steering - Edition 12.2018

1 - Assembly carrier

❑ Removing and installing

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

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

2 - Screw

❑ Screws for anti-roll bar

clamps

❑ replace after each re‐

moval

❑ 20 Nm + 90°.

3 - Self-locking nut

❑ replace after each re‐

moval

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

❑ 40 Nm

4 - Anti-roll bar

❑ to remove and install

lower assembly carrier

❑ Removing and installing

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

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

5 - Rubber bearing

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

6 - Spring clip

❑ Assignment ⇒ Electronic Catalogue of Original Parts

7 - Self-locking nut

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

8 - Coupling rod

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

❑ replace after each removal 11 - Rubber-metal bearing

❑ Rear rubber-metal bearing for track control arm

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

❑ replace after each removal

❑ 20 Nm + 90°.

8 Rep. gr.40 - Front suspension

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Axles, steering - Edition 12.2018

13 - Screw

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

14 - Self-locking nut

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

15 - Steering joint

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

16 - Nut

❑ replace after each removal ❑ 100 Nm

17 - Screw

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

18 - Suspension link

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

19 - Screw

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

20 - Rubber-metal bearing

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

21 - Screw

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

22 - Dowel screws

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

23 - Screw

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

distance between the gearbox and the assembly carrier

❑ 30 Nm + 90°.

24 - Pendulum support

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

distance between the gearbox and the assembly carrier

❑ Assignment ⇒ Electronic Catalogue of Original Parts

2.2 Lower the assembly carrier in the ser‐ vice position

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

2. Repairing front axle 9

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Axles, steering - Edition 12.2018

Release the assembly carrier - remove:

Caution

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

– Secure the steering wheel with the wheels in straight ahead

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

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

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

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

10 Rep. gr.40 - Front suspension

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

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

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Axles, steering - Edition 12.2018

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

adapter.

Note

♦

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

♦

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

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

bolt of -T10096- and tighten to 20 Nm.

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

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

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

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

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

2. Repairing front axle 11

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Axles, steering - Edition 12.2018

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

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

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

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

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

from the fixing bolts.

Note

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

– Slowly lower the assembly carrier with engine/gearbox jack

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

touch both sides of the body.

Note

♦

Note the following work steps and absolutely ensure that you

follow the sequence.

♦

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

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

ened to the recommended torque.

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

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

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

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

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

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

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

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

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

tighten to the recommended tightening torque.

12 Rep. gr.40 - Front suspension

– Tighten up the rear right support bolts to the recommended

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tightening torque.

– Remove engine/gearbox jack with adapter .

– Mount pendulum support on the gearbox and tighten new

screws -1- and -2-.

Note

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

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

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

Rapid 2011 ➤

Axles, steering - Edition 12.2018

– Slide the universal joint of the steering column in the

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

ing and tighten with a new screw -1-.

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

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

Note

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

⇒ “2.2 Axle alignment”, page 129 .

2. Repairing front axle 13

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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.

Assembly carrier to body ♦ Use new screws!

Support to body ♦ Use new screws!

Hinged support to gearbox ♦ Use new screws!

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

70 Nm + 90°.

20 Nm + 90°.

30 Nm + 90°.

20 Nm + 90°.

2.3 Inspecting the suspension link

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Note

♦

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

♦

Observe the suspension link during the tests.

♦

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

suspension strut bearing.

♦

Inspect rubber bellows for damage, if necessary replace.

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

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Axles, steering - Edition 12.2018

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

2.4 Removing and installing the suspension

link

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

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Axles, steering - Edition 12.2018

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

Note

♦

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

♦

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

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

Note

♦

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

♦

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

♦

Always fit new nuts for the drive shafts.

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

steering

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

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

steering (is not available)

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

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

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

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

Note

♦

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Observe fitting position of the steering joints according to the

marking.

♦

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

incorrect.

– Screw new nut onto the steering joint and tighten.

While doing this secure steering joint against spinning, so that

the steering joint boot is not damaged.

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

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

Note

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

⇒ “2.2 Axle alignment”, page 129 .

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Axles, steering - Edition 12.2018

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Axles, steering - Edition 12.2018

Tightening torques - summaries of components

Note

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

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

Steering joint to track control arm ♦ Use new nuts!

Wheel bolts 120 Nm

20 Nm + 90°.

100 Nm

2.5 Removing and installing the track con‐

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trol arm

Removing:

Note

Before commencing work, determine the measurement -a- ⇒

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

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

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Axles, steering - Edition 12.2018

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

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

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

en.

Note

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

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

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

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Axles, steering - Edition 12.2018

Note

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

⇒ “2.2 Axle alignment”, page 129 .

Tightening torques - summaries of components

GETtheMANUALS.org

Note

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

Rapid 2011 ➤

Axles, steering - Edition 12.2018

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

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

Steering joint to track control arm ♦ Use new nuts!

Wheel bolts 120 Nm

70 Nm + 90°.

100 Nm

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Axles, steering - Edition 12.2018

2.6 Replacing the rubber-metal bearing for track control arm

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

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

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

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

the rubber-metal bearing.

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

trol arm.

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

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

Fitting position of rear bearing for track control arm

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

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

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

must always point towards the longitudinal vehicle axis.

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

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

Rapid 2011 ➤

Axles, steering - Edition 12.2018

Note

♦

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

♦

Do not use another grease!

2.7 Removing and installing the anti-roll bar

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

⇒ Engine; Rep. gr. 26 .

Continued for all vehicles

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Axles, steering - Edition 12.2018

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

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

rier -arrows-.

Note

♦

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

♦

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

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

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

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

– Insert wooden insert -1- in the adapter , e. g. -V.A.G 1359/2- .

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– 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

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

– Lower assembly carrier approx. 4 cm and through this slacken

from the fixing bolts.

Rapid 2011 ➤

Axles, steering - Edition 12.2018

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. – Turn the anti-roll bar upwards and remove towards the rear. Installing: – Insert the anti-roll bar.

– Insert new screws for the anti-roll bar clamps and tighten

-arrows-.

– Raise the assembly carrier onto the fixing bolts and simulta‐

neously fit the power steering gear onto the assembly carrier.

Note

♦

Before inserting the screws for fixing the assembly carrier to

body, position the power-steering gear on the assembly carrier

and tighten with the new screws for the power-steering gear.

♦

Check correct positioning of gasket for power steering gear

onto the footwell opening of the vehicle.

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Axles, steering - Edition 12.2018

– Insert screws -arrows- and tighten by hand. – Raise assembly carrier until the assembly carrier touches the

body.

– Tighten screws -arrows- of power steering gear/assembly car‐

rier to specified tighening torque and remove attachment (sus‐ pension) of the power steering gear.

Note

♦

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

♦

Unscrew the fixing bolts from -T10096- and -T10486/1- one at a time. It should be subsequently replaced by a new bolt tight‐ ened to the recommended torque.

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

and tighten to the recommended tightening torque.

– Unscrew right fixing bolt -1- from -T10096- (not shown in fig‐

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

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

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

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

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

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

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

tighten to the recommended tightening torque. – 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.

– Insert left and right coupling rod -3- into the stabilizer -2-.

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– Screw in the left and right nut -1- and tighten. Vehicles with the exhaust system below the assembly carrier – Install the pre-exhaust pipe ⇒ Engine; Rep. gr. 26 . For vehicles with exhaust pipe inserted on the assembly carrier – Install spring washer for exhaust system to assembly carrier

⇒ Engine; Rep. gr. 26 . Continued for all vehicles – Perform a test drive. – Check the steering wheel position during the test drive.

Note

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

⇒ “2.2 Axle alignment”, page 129 .

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Axles, steering - Edition 12.2018

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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.

Power-steering gear to assembly carrier ♦ Use new screws!

Assembly carrier to body ♦ Use new screws!

Support to body ♦ Use new screws!

Hinged support to gearbox ♦ Use new screws!

Coupling rod to anti-roll bar 40 Nm Clamp of anti-roll bar to assembly carrier

♦ Use new screws!

50 Nm + 180°.

70 Nm + 90°.

20 Nm + 90°.

30 Nm + 90°.

20 Nm + 90°.

2.8 Removing and installing the rubber

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bearing for the anti-roll bar

Removing – Remove right drive shaft from the gearbox and tie up. – Remove the screws -arrows- on both sides. – Detach the spring clip from the rubber bearing. – Detach the rubber bearing from the anti-roll bar. Installing

– Fit the rubber bearing with the spring clip -1- onto the anti-roll

bar.

Rapid 2011 ➤

Axles, steering - Edition 12.2018

Note

♦

Ensure that the rubber bearing is positioned at the stop -2-.

♦

Depending on the version, the stop -2- may be located at the

outer or inner side of the rubber bearing.

– Install the screws -arrows- on both sides. – Install right drive shaft on gearbox.

Tightening torques - summaries of components

Note

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

Clamp of anti-roll bar to assembly carrier ♦ Use new screws!

Drive shaft to gearbox flange “M8” ♦ Use new screws!

♦ Use new washers!

20 Nm + 90°.

40 Nm

♦ First tighten crosswise to 10 Nm

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Drive shaft to gearbox flange “M10” ♦ Use new screws!

♦ Use new washers!

♦ First tighten crosswise to 10 Nm

2.9 Removing and installing assembly car‐ rier

Special tools and workshop equipment required ♦ Engine and gearbox jack e.g. -V.A.G 1383/A- or -VAS6931♦ Extractor - MP6-425 (3283)♦ Polycarmade grease - G 052 142 A2Removing: – Remove the nuts for the steering joint -arrows-. – Pull the track control arm out of the steering joints.

70 Nm

– 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.

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

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

– Release the assembly carrier and lower ⇒ “2.2 Lower the as‐

sembly carrier in the service position”, page 9 (do not remove

the universal joint of the steering column from the input shaft

of the power-steering gear). – Remove assembly carrier. Remove screws for anti-roll bar clamps and anti-roll bar, if nec‐

essary. Installing:

Note

Before inserting the fixing screws of the assembly carrier, position

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the power-steering gear on the assembly carrier and tighten the screws for the power-steering gear.

If necessary install anti-roll bar and tighten screws for anti-roll bar clamps.

– Position the assembly carrier with engine/gearbox jack with

adapter.

– Raise the assembly carrier onto the fixing bolts and simulta‐

neously fit the power steering gear onto the assembly carrier.

– Insert screws -arrows- and tighten by hand. – Raise assembly carrier until it touches the body.

Note

Check correct positioning of gasket for power steering gear onto the footwell opening of the vehicle.

Rapid 2011 ➤

Axles, steering - Edition 12.2018

– Tighten screws -arrows- of power steering gear/assembly car‐

rier to specified tighening torque and remove attachment (sus‐ pension) of the power steering gear.

– Screw assembly carrier to body ⇒ “2.2 Lower the assembly

carrier in the service position”, page 9 .

– Insert left and right coupling rod -3- into the stabilizer -2-. – Screw in the left and right nut -1- and tighten.

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– Insert the nuts for the steering joint -arrows-. – Perform a test drive. – Check the steering wheel position during the test drive.

Note

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

⇒ “2.2 Axle alignment”, page 129 .

Tightening torques - summaries of components

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Note

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

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Power-steering gear to assembly carrier ♦ Use new screws!

Assembly carrier to body ♦ Use new screws!

Support to body ♦ Use new screws!

Coupling rod to anti-roll bar 40 Nm Steering joint to track control arm

♦ Use new nuts!

Wheel bolts 120 Nm

50 Nm + 180°.

70 Nm + 90°.

20 Nm + 90°.

100 Nm

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3 Repairing front suspension strut

⇒ “3.1 Installation general view of the suspension strut”, page 34

⇒ “3.2 Removing and installing the suspension strut”, page 35

⇒ “3.3 Repairing suspension strut”, page 40 ⇒ “3.4 Inspect shock absorber”, page 42 ⇒ “3.5 Disposing of the shock absorber”, page 43

3.1 Installation general view of the suspension strut

Note

♦

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

removal.

♦

The figure represents the wheel-bearing housing for disc brake FS-III. Different versions of the wheel-bear‐

ing housing do not influence the installation of the suspension strut.

1 - Wheel bearing housing 2 - Nut

❑ replace after each re‐

moval

❑ 60 Nm + 90°.

3 - Screw

❑ replace after each re‐

moval

4 - Shock absorber

❑ Removing and installing

⇒ “3.2 Removing and in‐ stalling the suspension strut”, page 35

❑ can be replaced individ‐

ually

❑ Check ⇒ “3.4 Inspect

shock absorber”, page 42

❑ disposing of ⇒ “3.5 Dis‐

posing of the shock ab‐ sorber”, page 43

❑ Assignment ⇒ Elec‐

tronic Catalogue of

Original Parts 5 - Spring stop 6 - Boot 7 - Cap 8 - Flange nut, self-locking ♦ replace after each removal

❑ 60 Nm

9 - Spring cap

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10 - Suspension strut dome

11 - Flanged nut

♦ replace after each removal

❑ 60 Nm 12 - Suspension strut bearing 13 - Axial grooved ball bearing 14 - Spring cap 15 - Coil spring

❑ check colour coding

❑ The surface of the spring coil must not be damaged

❑ replace axle-wise

❑ the coil springs fitted to the axle must be of the same manufacturer

❑ Removing and installing ⇒ “3.3 Repairing suspension strut”, page 40

❑ Assignment ⇒ Electronic Catalogue of Original Parts

3.2 Removing and installing the suspension

strut

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Special tools and workshop equipment required ♦ Engine and gearbox jack e.g. -V.A.G 1383/A- or -VAS6931♦ Spreader - 3424♦ Extractor - MP6-425 (3283)♦ Ball joint extractor - 3287A♦ Socket wrench insert WAF 21 - MP6-427 (3186)♦ Polycarbamide grease - G 052 142 A2Removing: – Remove the outer joint of the drive shaft from the wheel-bear‐

ing housing ⇒ “5.3 Removing and installing outer joint of drive

shaft”, page 63 and tie up drive shaft to body.

– Screw steering joint to the track control arm. To do so use the

removed nuts.

– Unscrew the nut of the coupling rod -arrow B- from the sus‐

pension strut.

– Unhook ABS speed sensor cable from the suspension strut

(vehicles with ABS).

3. Repairing front suspension strut 35

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– Screw up nut -1- sufficiently so that the ball joint extractor is

supported on the nut.

– Use the ball joint extractor to remove the track rod with track

rod end -2- from the steering lever. – Screw off the nut from the track rod end. – Pull track rod end out of the steering arm. – Tie up track rod. – Position the engine/gearbox jack with adapter below the

wheel-bearing housing.

– Separate the screwed connection wheel-bearing housing/sus‐

pension strut -arrow-.

– Insert the clamping device - 3424- into the nut in the wheel-

bearing housing. – Turn ratchet with spreader - 3424- by 90° and remove ratchet. – Press the brake disc by hand towards the suspension strut.

Otherwise the shock absorber tube can cant in the opening of

the wheel bearing housing. – Pull wheel-bearing housing downwards away from the shock-

absorber tube and lower with engine/gearbox jack with

adapter in such a way that the shock-absorber tube hangs

free. – Secure thee wheel-bearing housing on the assembly carrier

(attach). – Remove engine/gearbox jack with adapter.

– Unscrew the suspension strut from the body using the socket

wrench insert SW 21 - MP 6-427 (3186)- . – Remove the suspension strut. Installing: – Insert suspension strut and screw into the suspension strut

dome. – Tighten the nut to the specified tightening torque. – Position the engine/gearbox jack with adapter below the

wheel-bearing housing. – Insert suspension strut in the wheel-bearing housing. – Loosen the suspension for the wheel-bearing housing from the

assembly carrier. – Raise up the wheel-bearing housing using the engine/gearbox

jack with adapter to the point where the screw of the suspen‐

sion strut/wheel-bearing housing can be inserted.

Caution

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Never press on the steering joint with the engine/gearbox jack.

– Press the brake disc by hand towards the suspension strut and

make sure that the suspension strut tube does not clamp in the opening for the wheel-bearing housing.

– Remove spreader - 3424- .

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– Screw on the new nut and tighten up fully -arrow-. – Install track rod with track rod end into the steering arm and

tighten.

– Hook the ABS speed sensor cable into the clips of the sus‐

pension strut (vehicles with ABS).

– Mount the coupling rod on the suspension strut and tighten

-arrow B-.

– Undo nuts -arrows- and remove lower arm from steering joint. – Install the outer joint of the drive shaft into the wheel-bearing

housing ⇒ “5.3 Removing and installing outer joint of drive

shaft”, page 63 .

– Perform a test drive. – Check the steering wheel position during the test drive.

Note

3. Repairing front suspension strut 37

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

⇒ “2.2 Axle alignment”, page 129 .

Tightening torques - summaries of components

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Note

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

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Suspension strut to suspension strut dome ♦ Use new screws!

Wheel-bearing housing to suspension strut ♦ Use new screws and nuts!

Track rod end/track rod to steering arm ♦ Use new nuts!

Coupling rod to suspension strut 40 Nm Twelve-point nut for securing the drive shaft to wheel hub

♦ Use new nuts! ♦ Do not grease thread of the outer joint of the drive shaft.

Steering joint to track control arm ♦ Use new nuts!

Wheel bolts 120 Nm

60 Nm

60 Nm + 90°.

20 Nm + 90°.

50 Nm + 45°.

100 Nm

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3.3 Repairing suspension strut

Special tools and workshop equipment required ♦ Spring tensioner - V.A.G 1752/1♦ Spring holder , e.g. -V.A.G 1752/4♦ Socket wrench insert WAF 21 - MP6-427 (3186)-

Note

♦

Check correct seating of the helical spring in the spring ten‐ sioner , e.g. -V.A.G 1752/4- -arrow-.

♦

Do not use an impact screw driver when working with the spring tensioner.

Removing the coil spring: – Removing the suspension strut ⇒ “3.2 Removing and installing

the suspension strut”, page 35 .

– Preload the helical spring with the spring tensioner until the

spring cap ⇒ Item 14 (page 35) is relieved.

– Unscrew the nut from the piston rod using the socket wrench

insert SW 21 - MP6-427 (3186)- and counterhold with a

hexagon wrench -2-. 1 - Ratchet; when installing torque spanner – Remove the individual parts of the suspension strut and the

coil spring with the spring tensioner.

Installing the coil spring: – Insert the preloaded coil spring with the spring tensioner onto

the bottom coil spring bearing.

The thread end of the helical spring must lie against the

stop -arrow-. Further installation occurs in reverse order. – Assembly and summary of components of the suspension

strut ⇒ “3.1 Installation general view of the suspension strut”,

page 34 .

Tightening torques - summaries of components

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Note

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

Nut of suspension strut bearing on piston rod 60 Nm

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3.4 Inspect shock absorber

Leaks on the shock absorber Minor oil leakage (sweating) on the piston rod seal does not entail

the replacement of the shock absorber. If an oil leak is visible (but blunt, dull, possibly dried by dust) and

does not propagate any further than from the top shock-absorber screw plug (piston rod seal) to the bottom spring cap -arrow-, the shock absorber is deemed to be O.K.

Note

A slight oil leak is beneficial as the gasket is lubricated and this increases the life time. This applies for shock absorbers on the front as well as the rear axle.

Noises on the shock absorber There is reason to believe that in the event of noise complaints

the shock absorbers are all too often considered as the source. Possible causes of noise may be e.g.: ♦ defective shock absorber ♦ suspension strut/body attachment is loose ♦ defective axial grooved ball bearing ♦ poor operation of the suspension strut ♦ defective outer joint ♦ defective wheel bearing ♦ cracked welding points on body ♦ parts loosened or overtensioned when installed (exhaust sys‐

tem, attachments, flaps, etc.)

Note

In the event of complaints about noises interpreted as knocking or cracking noises, always first perform a test drive with the cus‐ tomer to determine where, when and how these noises occur (preferably on a bumpy dry road).

Inspecting the removed shock absorber without gas pressure Defective shock absorbers become noticeable while driving be‐

cause of the knocking noises caused by wheel hopping, more specifically on poor road surfaces and they must be replaced. The failure is mainly caused by the loss of oil. The shock absorber then compresses and/or expands in jolts. It exhibits “idle”, before it begins to operate.

Note

The shock absorbers are maintenance-free. It is not possible to top up the shock absorber oil.

Inspecting the removed shock absorber with gas pressure

Damaged shock absorbers with gas pressure become noticeable

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because of a laud banging sound, caused by wheel hopping, and also because a strong oil leak occurs.

Manual testing, as described below, can determine if the shock absorber is damaged or not:

– Compress the shock absorber by hand.

The piston rod must move evenly over the entire stroke without jolting.

– Release the piston rod. On sufficiently pressurized shock ab‐

sorbers it will automatically return to its original position. If this is not the case, the shock absorber need not necessarily

be replaced, as it will still operate as a conventional shock ab‐ sorber (see instructions below).

Note

♦

The absorbing function is still fully present without sufficient gas pressure as long as the oil leakage is not too large. How‐ ever, the noise level may increase. On older vehicles it is possible to continue using an operational yet pressureless shock absorber without problem.

♦

Adequate gas pressure in the shock absorber improves the noise behaviour and function when driving over poor road sur‐ faces.

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3.5 Disposing of the shock absorber

Special tools and workshop equipment required ♦ Drill ∅ 3 mm (commercially available) ♦ Drill ∅ 6 mm (commercially available) ♦ Safety goggles (commercially available) ♦ Oil catch container (commercially available) Degas front gas pressure shock absorber – Clamp gas-filled shock absorber vertically with the piston rod

pointing downwards in a vice.

WARNING

Wear safety goggles during the drilling procedure.

– Drill a hole ∅ 3 mm -A- through the outer pipe of the shock

absorber.

Note

Gas will escape during drilling.

– Drill further until the inner pipe has also been drilled through

(approx. 25 mm deep).

– Drill a second hole ∅ 6 mm -B- through the outer and inner

shock absorber pipes.

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– Hold the shock absorber over an oil catching pan. Move the

piston rod several times up and down over its entire stroke until

no more oil escapes. Degas rear gas pressure shock absorber

– Clamp the gas-filled shock absorber vertically in the vice.

WARNING

Wear safety goggles during the drilling procedure.

– Drill a hole ∅ 3 mm -A- through the outer pipe of the shock

absorber.

Note

Gas will escape during drilling.

– Drill further until the inner pipe has also been drilled through

(approx. 25 mm deep). – Drill a second hole ∅ 6 mm -B- through the outer and inner

shock absorber pipes. – Hold the shock absorber over an oil catching pan. Move the

piston rod several times up and down over its entire stroke until

no more oil escapes.

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4 Repairing wheel bearing

⇒ “4.1 Summary of components of the wheel bearing, suspension strut, drive shaft and brake C54”, page 45

⇒ “4.2 Removing and installing wheel bearing housing”, page 48

⇒ “4.3 Removing and installing the wheel hub with wheel bearing with the wheel-bearing housing fitted”, page 52

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

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 front wheel suspension.

♦

Always replace the self-locking screws and nuts.

♦

Always replace corroded self-locking nuts and screws.

4. Repairing wheel bearing 45

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1 - Suspension strut

❑ Removing and installing

⇒ “3.2 Removing and in‐ stalling the suspension strut”, page 35

❑ repairing ⇒ “3.3 Repair‐

ing suspension strut”, page 40

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

2 - Drive shaft with inner CV joint

❑ Removing and installing

⇒ “5.4 Removing and in‐ stalling drive shaft with CV joint”, page 66

❑ Check ⇒ “5.7 Inspecting

the CV joints”, page 72

❑ repairing ⇒ “5.6 Repair‐

ing drive shaft with CV joint”, page 69

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

3 - Supporting plate

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

4 - Fillister head screw with in‐ ternal serrations

❑ replace after each re‐

moval

❑ first pre-tighten all

screws crosswise up to 10 Nm and subsequently tighten crosswise to final tightening torque:

Screw M 8 = 40 Nm

Screw M 10 = 70 Nm

❑ Assignment ⇒ Electronic Catalogue of Original Parts

5 - Drive shaft with inner tripod joint

❑ Removing and installing ⇒ “6.2 Removing and installing inner drive shaft with tripod joint”, page 78 ❑ repairing ⇒ “6.3 Repairing drive shaft with inner tripod joint”, page 82 ❑ Assignment ⇒ Electronic Catalogue of Original Parts

6 - Circlip

❑ replace after each removal 7 - Brake disc, internally ventilated 8 - Wheel bolt

❑ Assignment ⇒ Electronic Catalogue of Original Parts

❑ 120 Nm 9 - Twelve-point nut

❑ replace after each removal

❑ Do not grease thread of the outer joint of the drive shaft.

❑ Removing and installing ⇒ “5.2 Removing and installing fixing nut of drive shaft”, page 61

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❑ Assignment ⇒ Electronic Catalogue of Original Parts ❑ 50 Nm + 45°.

10 - Screw

❑ 4 Nm

11 - Brake pad

❑ removing and installing ⇒ Brake systems; Rep. gr. 46

12 - Pad retaining plate

❑ always replace when changing the brake pads

❑ contained in the repair kit for brake pads 13 - Brake carrier with guide bolts and boots 14 - Brake caliper

❑ Assignment ⇒ Electronic Catalogue of Original Parts

❑ do not release brake hose when working on the front wheel suspension

❑ tie up with wire or anything similar

❑ repairing ⇒ Brake systems; Rep. gr. 46 15 - Screw

❑ replace after each removal

❑ 30 Nm 16 - Track rod and track-rod ends

❑ Removing and installing ⇒ “5.4 Removing and installing track rods”, page 162 17 - Wheel hub with wheel bearing

❑ for vehicles with ABS the sensor ring is built into the wheel hub

❑ The wheel hub and the wheel bearing are a single unit; it does not need servicing and is free of play; it

is not possible to undertake any kind of adjustment or repair work on it. ❑ The sensor ring for ABS cannot be replaced individually ❑ replace after each disassembly, wheel hub with wheel bearing is destroyed during removal ❑ Removing and installing ⇒ “4.3 Removing and installing the wheel hub with wheel bearing with the wheel-

bearing housing fitted”, page 52

❑ Assignment ⇒ Electronic Catalogue of Original Parts

18 - Screw

❑ 10 Nm

19 - Protection plate 20 - Nut

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

21 - Screw

❑ clean ribbing on underside each time removed ❑ 125 Nm

22 - Nut

❑ replace after each removal ❑ 60 Nm + 90°.

23 - Wheel bearing housing

❑ Removing and installing ⇒ “4.2 Removing and installing wheel bearing housing”, page 48 ❑ Assignment ⇒ Electronic Catalogue of Original Parts

24 - Screw

❑ replace after each removal ❑ the tip of bolt must point in the direction of travel

4. Repairing wheel bearing 47

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25 - ABS wheel speed sensor

❑ Assignment ⇒ Electronic Catalogue of Original Parts

26 - Hexagon socket head bolt

❑ for ABS speed sensor ❑ 8 Nm

27 - Nut

❑ Assignment ⇒ Electronic Catalogue of Original Parts ❑ 40 Nm

28 - Coupling rod

❑ Assignment ⇒ Electronic Catalogue of Original Parts

4.2 Removing and installing wheel bearing housing

Special tools and workshop equipment required ♦ Engine and gearbox jack e.g. -V.A.G 1383/A- or -VAS6931♦ Spreader - 3424♦ Extractor - MP6-425 (3283)♦ Ball joint extractor - 3287A♦ Polycarmade grease - G 052 142 A2Removing: – Unscrew twelve-point nut for securing the drive shaft ⇒

“5.2 Removing and installing fixing nut of drive shaft”, page

61 .

– Remove wheel. – Turn the nut -1-. – Pull out coupling rod -3- from the anti-roll bar -2-.

– Remove ABS speed sensor (vehicles with ABS) ⇒ Brake sys‐

tems; Rep. gr. 45 . – Unscrew bolts -1-. – Remove brake caliper or brake carrier with brake caliper and

secure with wire in such a way that the weight of the brake

caliper does not burden or damage the brake line. – Remove the outer joint of the drive shaft from the wheel-bear‐

ing housing ⇒ “5.3 Removing and installing outer joint of drive

shaft”, page 63 and tie up drive shaft to body.

– Screw up nut -1- sufficiently so that the ball joint extractor is

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supported on the nut.

– Use puller to remove track rod/track rod end -2- from the steer‐

ing arm. – Screw off the nut from the track rod end. – Pull track rod end out of the steering arm. – Tie up track rod.

– Remove steering joint from wheel-bearing housing ⇒ “2.4 Re‐

moving and installing the suspension link”, page 15 .

– Position the engine/gearbox jack with adapter below the

wheel-bearing housing.

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– Separate the screwed connection wheel-bearing housing/sus‐

pension strut -arrow-.

– Insert the clamping device - 3424- into the nut in the wheel-

bearing housing. – Turn the spreader - 3424- with ratchet 90° and remove ratchet. – Press the brake disc by hand towards the suspension strut.

Otherwise the shock absorber tube can cant in the opening of

the wheel bearing housing. – Remove the wheel-bearing housing from the shock-absorber

tube and lower with engine/gearbox jack with adapter. Installing: – Raise up the wheel-bearing housing using the engine/gearbox

jack with adapter and position on the shock absorber pipe.

Note

Never press on the steering joint with the engine/gearbox jack with adapter.

– Insert the new suspension strut/wheel-bearing housing screw.

4. Repairing wheel bearing 49

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– With one's hand on the brake disc press in the direction of the

suspension strut and make sure that the shock-absorber tube in the bore hole of the wheel-bearing housing does not be‐ come tilted.

– Remove spreader - 3424- .

– Tighten the screwed connection wheel-bearing housing/sus‐

pension strut with a new nut -arrow-.

– Install track rod with track rod end into the steering arm and

tighten.

– Install brake caliper in reverse order to removal depending on

brake caliper type and tighten.

– Install ABS speed sensor (vehicles with ABS) ⇒ Brake sys‐

tems; Rep. gr. 45 .

– Insert the outer joint of the drive shaft into the wheel-bearing

housing ⇒ “5.3 Removing and installing outer joint of drive

shaft”, page 63 .

– Insert coupling rod -3- into the stabilizer -2-. – Tighten the nut -1-. – Install steering joint ⇒ “2.4 Removing and installing the sus‐

pension link”, page 15 .

– Installing and tightening the wheel. – Screw in twelve-point nut for securing the drive shaft ⇒

“5.2 Removing and installing fixing nut of drive shaft”, page

61 .

Note

It is necessary to perform an axle alignment in the event of: ⇒

“2.2 Axle alignment”, page 129 .

– Perform a test drive. – Check the steering wheel position during the test drive.

Note

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

⇒ “2.2 Axle alignment”, page 129 .

Tightening torques - summaries of components

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Note

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

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Wheel-bearing housing to suspension strut ♦ Use new screws and nuts!

Twelve-point nut for securing the drive shaft to wheel hub ♦ Use new nuts!

♦ Do not grease thread of the outer joint of the drive shaft.

Track rod end to steering arm ♦ Use new nuts!

Steering joint to track control arm ♦ Use new nuts!

Brake carrier with brake caliper to wheel bearing housing 125 Nm ABS speed sensor to wheel-bearing housing 8 Nm Coupling rod to anti-roll bar 40 Nm Wheel bolts 120 Nm

60 Nm + 90°.

50 Nm + 45°.

20 Nm + 90°.

100 Nm

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4.3 Removing and installing the wheel hub

with wheel bearing with the wheel-bear‐ ing housing fitted

Special tools and workshop equipment required ♦ Assembly tool - MP6-414 (3253)♦ Assembly tool - T10064♦ Assembly tool - T10178♦ Ball joint extractor - 3287A♦ Socket insert SW 36 - T10125♦ Engine and gearbox jack e.g. -V.A.G 1383/A- or -VAS6931♦ Molykote grease - G 052 723 A2Removing the wheel hub with wheel bearing: – Unscrew twelve-point nut for securing the drive shaft ⇒

“5.2 Removing and installing fixing nut of drive shaft”, page

61 .

Note

♦

If the fixing nut of the drive shaft is loose on the wheel side,

the wheel bearings must not be loaded.

♦

If the wheel bearings are loaded through the vehicle's own

weight, the wheel bearing will be initially damaged. This short‐

ens the life of the wheel bearing.

♦

It is not permissible to turn cardan shaft screw more than 90°

anti-clockwise if vehicle is standing on its wheels.

♦

The vehicles without drive shaft must not be moved, otherwise

the wheel bearing will be damaged If you still want to move the

vehicle, please note the following: install the outer joint instead

of the PTO shaft. Tighten outer CV joint to 25 Nm.

– Remove wheel. – Unscrew nut -1- and remove coupling rod -3- from anti-roll bar

-1-. – Pull out coupling rod -3- from the anti-roll bar -2-. – Disconnect the brake line and electrical lines from the wheel

bearing housing and expose them.

– Remove ABS speed sensor (vehicles with ABS) ⇒ Brake sys‐

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tems; Rep. gr. 45 . – Unscrew bolts -1- from the brake caliper and remove. – Remove brake carrier with brake caliper and secure with wire

in such a way that the weight of the brake caliper does not pull

on or damage the brake hose.

– Screw out nut for track-rod ends -1- sufficiently so that the ball

joint extractor is supported on the nut.

Note

♦

To protect the thread, screw the nut a couple of thread turns

onto the track-rod end.

♦

While pressing out the tie rod end, be aware of the injury risk:

the ball joint puller may fall out when the tie rod end stud is

loosened.

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– Use puller to remove track rod/track rod end -2- from the steer‐

ing arm. – Screw off the nut from the track rod end. – Pull track rod end out of the steering arm. – Tie up track rod. – Remove the outer joint of the drive shaft from the wheel-bear‐

ing housing ⇒ “5.3 Removing and installing outer joint of drive

shaft”, page 63 and tie up drive shaft to body.

– Screw steering joint to the track control arm. To do so use the

removed nuts. – Unscrew the securing screw of the brake disc and remove

brake disc. – Remove splash plate for brakes.

Note

♦

Mount the assembly device - MP6-414 (3253)- at right angles

to the centre axle of the wheel hub with wheel bearing. Do not

tilt the wheel hub with wheel bearing when removing and in‐

stalling.

♦

Place engine and transmission jack , e.g. -V.A.G 1383/A- or -

VAS6931- underneath (risk of injury from falling parts when

removing the wheel hub with the wheel bearing).

♦

The wheel hub is pulled out with the wheel bearing as follows,

whereby the wheel bearing housings differ visually depending

on the brake variant.

Push out wheel hub with wheel bearing

Note

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To avoid injury from falling parts when pulling the wheel hub with the wheel bearing out of the wheel bearing housing, place the motor and gear jack underneath.

– Assemble the device as illustrated. 1 - Clamp - MP6-414/2 (3253/2)2 - Pipe - MP6-414/1 (3253/1)3 - Pressure element - MP6-414/6 (3253/6)4 - Screw - MP6-414/10 (3253/3)5 - Assembly tool - T101786 - Thrust bearing -MP6-414 (3253)7 - Pressure element - MP6-414/5 (3253/5)- (used with small

diameter in thrust bearing position 6) 8 - Nut - MP6-414/10 (3253/3)– Pull the wheel hub with wheel bearing out of the wheel bearing

housing (device must be held in place).

Installing the wheel hub with wheel bearing:

Note

♦

Clean the bore of the wheel bearing housing (wheel bearing housings differ visually depending on the brake variant).

♦

Clean the bore in the wheel bearing housing.

– Coat the entire surface of the hole with Molykote grease - G

052 723 A2- .

– Screw in wheel bolts -2- in the hub as shown. – Screw grippers - T10064/6A- together with wheel bolts -2- and

wheel hub. 1 - Wheel hub with wheel bearing 2 - Wheel bolts 3 - Grippers - T10064/6AThe wheel bolts -2- must not protrude from the rear of the grip‐

pers. Pressing in wheel hub with wheel bearing

Note

Do not tilt the wheel hub with wheel bearing while inserting.

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– Pull the wheel hub with wheel bearing into the wheel-bearing

housing. 1 - -MP6-414/5 (3253/5)2 - -T10064/13 - -T10064/6A4 - -MP6-414/10 (3253/3)5 - -T10064/4– Pull in the wheel hub with wheel bearing until the circlip is

heard to click into position.

– Unscrew screws -3- and remove grippers -1- from the wheel

hub with wheel bearing -2-.

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– Release fixing nuts -arrows-. – Unhook steering joint out of the suspension link. – Insert the outer joint of the drive shaft into the wheel-bearing

housing ⇒ “5.3 Removing and installing outer joint of drive

shaft”, page 63 .

– Screw the steering joint to the track control arm with new nuts

-arrows-. – Install splash plate for brakes. – Install brake disc and secure with screw. – Install track rod with track rod end into the steering arm and

tighten.

– Install brake caliper in reverse order to removal depending on

brake caliper type and tighten.

– Connect the plug connection for the brake pad wear indicator

(where the vehicle is fitted with this).

– Install ABS speed sensor (vehicles with ABS) ⇒ Brake sys‐

tems; Rep. gr. 45 .

– Secure brake line and electric lines to wheel bearing housing.

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– Insert coupling rod -3- into anti-roll bar -2- and tighten nut -1-

to the specified tightening torque.

– Install retaining nut of drive shaft ⇒ “5.2 Removing and in‐

stalling fixing nut of drive shaft”, page 61 .

– Attach the wheel. – Tighten retaining nut of drive shaft ⇒ “5.2 Removing and in‐

stalling fixing nut of drive shaft”, page 61 .

– Perform a test drive.

Note

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

⇒ “2.2 Axle alignment”, page 129 .

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Tightening torques - summaries of components

Note

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

Cover plate to wheel-bearing housing 10 Nm Phillips head screw of brake disc to wheel hub with wheel bearing 4 Nm Twelve-point nut for securing the drive shaft to wheel hub

♦ Use new nuts! ♦ Do not grease thread of the outer joint of the drive shaft.

50 Nm + 45°.

Track rod/track rod end to steering arm ♦ Use new nuts!

Steering joint to track control arm ♦ Use new nuts!

Brake carrier with brake caliper to wheel bearing housing 125 Nm ABS speed sensor to wheel-bearing housing 8 Nm Coupling rod to anti-roll bar 40 Nm Wheel bolts 120 Nm

20 Nm + 90°.

100 Nm

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5 Drive shafts with inner CV joint

⇒ “5.1 Summary of components of drive shaft with inner CV joint”, page 58

⇒ “5.2 Removing and installing fixing nut of drive shaft”, page 61

⇒ “5.3 Removing and installing outer joint of drive shaft”, page 63

⇒ “5.4 Removing and installing drive shaft with CV joint”, page 66

⇒ “5.6 Repairing drive shaft with CV joint”, page 69 ⇒ “5.7 Inspecting the CV joints”, page 72

5.1 Summary of components of drive shaft with inner CV joint

Note

♦

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

removal.

♦

Assignment of the drive shafts ⇒ Electronic Catalogue of Original Parts .

♦

Grease the joint if necessary, when replacing the joint boot.

♦

Spread the grease mass evenly in the joint.

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1 - Right joint boot (tubular shaft)

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

2 - Screw

❑ replace after each re‐

moval

❑ first of all pre-tighten all

screws crosswise up to 10 Nm and subsequent‐ ly tighten crosswise to fi‐ nal torque:

Screw M 8 = 40 Nm

Screw M 10 = 70 Nm

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

3 - Supporting plate

❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

4 - Clamp

❑ Replacing ❑ tensioning ⇒ “5.6 Re‐

pairing drive shaft with CV joint”, page 69

5 - Joint boot for inner joint

❑ inspect for tears and

chafing points

❑ drive off from joint with a

drift

❑ before installation coat

the inside of the cap with sealant - D 454 300 A2-

❑ Assignment ⇒ Electronic Catalogue of Original Parts

6 - Disc spring

❑ Fitting position ⇒ page 71

7 - Inner joint

❑ must be replaced completely ❑ remove ⇒ page 71 ❑ inserting ⇒ page 71 ❑ grease ⇒ page 60 ❑ Check ⇒ “5.7.2 Disassembling, inspecting and assembling the inner CV joint”, page 73 ❑ Assignment ⇒ Electronic Catalogue of Original Parts

8 - Seal

❑ The adhesive surface must be free of grease and oil ❑ replace after each removal ❑ Pull off protective foil and stick in joint ❑ Assignment ⇒ Electronic Catalogue of Original Parts

9 - Circlip

❑ Replacing

5. Drive shafts with inner CV joint 59

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❑ use circlip pliers , e.g. -VW 161 A- , for removing and installing ❑ Assignment ⇒ Electronic Catalogue of Original Parts

10 - Left drive shaft (solid shaft)

❑ Assignment ⇒ Electronic Catalogue of Original Parts

11 - Clamp

❑ Replacing ❑ tensioning ⇒ “5.6 Repairing drive shaft with CV joint”, page 69

12 - Boot

❑ inspect for tears and chafing points ❑ Assignment ⇒ Electronic Catalogue of Original Parts

13 - Clamp

❑ Replacing ❑ tension with tensioning pliers , e. g. -V.A.G 1682 A- ⇒ “5.6 Repairing drive shaft with CV joint”, page

14 - Disc spring

❑ Fitting position ⇒ “5.6 Repairing drive shaft with CV joint”, page 69

15 - Thrust ring

❑ Fitting position ⇒ “5.6 Repairing drive shaft with CV joint”, page 69

16 - Circlip

❑ Replacing ❑ insert in the shaft groove

17 - Outer CV joint

❑ must be replaced completely ❑ Remove constant velocity joint ⇒ page 70 ❑ before installing grease the serration with polycarbamide grease - G 052 142 A2❑ carefully drive onto the shaft with a plastic hammer until the compressed circlip expands ❑ grease ⇒ page 60 ❑ Check ⇒ “5.7.1 Disassembling, inspecting and assembling the outer CV joint”, page 72 ❑ Assignment ⇒ Electronic Catalogue of Original Parts

18 - Thrower ring

❑ Assignment ⇒ Electronic Catalogue of Original Parts

19 - Twelve-point nut

❑ Removing and installing fixing nut of drive shaft ⇒ “5.2 Removing and installing fixing nut of drive shaft”,

page 61

❑ replace after each removal ❑ 50 Nm + 45°.

Grease quality and grease quantity

Note

♦

The outer joints of the drive shaft are filled with grease for op‐ erating at normal temperatures, e.g. -N 052 738 00- .

♦

Only use the appropriate high-temperature grease from the relevant repair kit for the grease filling of the inner CV joint ⇒ Electronic Catalogue of Original Parts .

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∅ Joint

(mm)

Outer joint

∅ 103

Inner joint

∅ 100

Total grease

quantity

(g)

±10

125

±10

110

Grease quantity distribution

Outer joint (g) Inner joint and

joint boot (g)

40 Residual amount

80 Residual amount

5.2 Removing and installing fixing nut of drive shaft

Note

♦

If the fixing nut of the drive shaft is loose on the wheel side, the wheel bearings must not be loaded.

♦

If the wheel bearings are loaded through the vehicle's own weight, the wheel bearing will be initially damaged. This short‐ ens the life of the wheel bearing.

♦

The vehicles without drive shaft must not be moved, otherwise the wheel bearing will be damaged If you still want to move the vehicle, please note the following: install the outer joint instead of the PTO shaft. Tighten outer CV joint to 25 Nm.

Remove nut: – Remove wheel trim cap, for light-alloy wheels (depending on

version) remove the cap on the removed wheel.

– Slacken the nut -arrow- by max. 90° on the vehicle while it is

standing on its wheels, otherwise the wheel bearing may be

damaged. If the wheel is removed, also slacken the wheel bolts. – Raise the vehicle until the wheels are fully off the ground. – Depress brake pedal (assistance of second mechanic re‐

quired). – Release nut -arrow- and release brake pedal. Install nut: – Install new nut.

Note

The wheels should not touch the ground when tightening the fix‐ ing nut of the drive shaft, otherwise the wheel bearings will be damaged.

– Depress brake pedal (assistance of second mechanic re‐

quired). – Tighten the new nut to 50 Nm and release the brake pedal. – Place vehicle onto its wheels. – Tighten nut and torque a further 45°.

5. Drive shafts with inner CV joint 61

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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.

Twelve-point nut for securing the drive shaft to wheel hub ♦ Use new nut!

♦ Do not grease thread of the outer joint of the drive shaft.

Wheel bolt 120 Nm

50 Nm + 45°.

5.3 Removing and installing outer joint of

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drive shaft

Special tools and workshop equipment required ♦ Polycarbamide grease - G 052 142 A2Removing: – Unscrew twelve-point nut for securing the drive shaft ⇒

“5.2 Removing and installing fixing nut of drive shaft”, page

61 .

– Remove front wheel. – Unscrew the nuts -arrows-. – Remove track control arm from steering joint. – Swivel out the wheel-bearing housing with the suspension

strut and take the drive shaft out of the wheel-bearing housing.

Tie up drive shaft.

Note

♦

The drive shaft must not hang down! The inner joint can be

damaged by excessive offset.

♦

If the cardan shaft cannot be removed from the wheel hub, it

can be pressed out using the extractor ⇒ “5.5 Push the cardan

shaft out of the wheel hub.”, page 69 .

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Installing:

Note

Remove possible corrosion and grease residue from the thread and from the serration of the outer joint as well as from the ser‐ ration of the wheel-bearing housing.

– Grease the serration on the propeller shaft with polycarbamide

grease - G 052 142 A2- .

Do not grease thread on the outer joint of the drive shaft. – Grease the serration in the wheel-bearing housing with poly‐

carbamide grease - G 052 142 A2- . – Slide the outer joint into the serration of the wheel-bearing

housing. – Secure the outer joint of the drive shaft with a new twelve-point

nut.

Note

♦

Use new nuts to screw the track control arm/steering joint.

♦

Make sure the steering joint boot is neither damaged nor twist‐

ed.

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– Screw steering joint to the track control arm -arrows-. – Tighten new twelve-point nut for securing the drive shaft ⇒

“5.2 Removing and installing fixing nut of drive shaft”, page

– Tighten wheel. – Perform a test drive.

Note

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

⇒ “2.2 Axle alignment”, page 129 .

Tightening torques - summaries of components

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Note

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

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Twelve-point nut for securing the drive shaft to wheel hub ♦ Use new nut!

♦ Do not grease thread of the outer joint of the drive shaft.

Steering joint to track control arm ♦ Use new nuts!

Wheel bolts 120 Nm

50 Nm + 45°.

100 Nm

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5.4 Removing and installing drive shaft with

CV joint

Special tools and workshop equipment required ♦ Polycarbamide grease - G 052 142 A2Removing: – Unscrew twelve-point nut for securing the drive shaft ⇒

“5.2 Removing and installing fixing nut of drive shaft”, page

61 .

– Remove front wheel. – Remove the sound dampening system ⇒ Body Work; Rep.

gr. 50 . – Remove the inside heat shield above the joint (if present). – Unscrew the drive shaft from the flange shaft of the gearbox. – Unscrew the nuts -arrows-. – Remove track control arm from steering joint. – Swivel out the wheel-bearing housing with the suspension

strut and simultaneously remove drive shaft from flange shaft

and from the wheel-bearing housing.

Note

♦

The drive shaft must not hang down! The inner joint can be

damaged by excessive offset.

♦

If the cardan shaft cannot be removed from the wheel hub, it

can be pressed out using the extractor ⇒ “5.5 Push the cardan

shaft out of the wheel hub.”, page 69 .

– Remove cardan shaft from the vehicle. Installing:

Note

Remove possible corrosion and grease residue from the thread and from the serration of the outer joint as well as from the ser‐ ration of the wheel-bearing housing.

– Grease the serration on the propeller shaft with polycarbamide

grease - G 052 142 A2- .

Do not grease thread on the outer joint of the drive shaft. – Grease the serration in the wheel hub with polycarbamide

grease - G 052 142 A2- . – Insert the drive shaft into the serration of the wheel-bearing

housing. – Screw the drive shaft onto the flange shaft/gearbox and tighten

first of all crosswise to 10 Nm. – Secure the outer joint of the drive shaft with a new twelve-point

nut. – Tighten crosswise the screws of the drive shaft on the flange

shaft - gearbox to the prescribed torque or install protection

plate for inner joint.

– Secure the outer joint of the drive shaft with a new twelve-point

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nut.

– Position the track control arm onto the steering joint of the

wheel bearing housing and tighten the nuts -arrows-.

– Install protection plate for inner joint of drive shaft to engine (if

present). – Install the noise insulation ⇒ Body Work; Rep. gr. 50 . – Tighten new twelve-point nut for securing the drive shaft ⇒

“5.2 Removing and installing fixing nut of drive shaft”, page

– Tighten wheel. – Perform a test drive.

Note

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

⇒ “2.2 Axle alignment”, page 129 .

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Tightening torques - summaries of components

Note

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

Drive shaft to flange shaft/gearbox ♦ Pre-tighten all screws crosswise up to 10 Nm and subsequently tighten crosswise to final torque.

♦ Use new screws!

Screw of protective plate for inner joint of drive shaft 25 Nm Twelve-point nut for securing the drive shaft to wheel hub

♦ Use new nut! ♦ Do not grease thread of the outer joint of the drive shaft.

Steering joint to track control arm ♦ Use new nuts!

Wheel bolts 120 Nm

M 8 = 40 Nm

M 10 = 70 Nm

50 Nm + 45°.

100 Nm

5.5 Push the cardan shaft out of the wheel

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hub.

Special tools and workshop equipment required ♦ Extractor - T10520A- or -T10520- with -T10520/5If the cardan shaft cannot be removed by pulling it out of the wheel

hub, it can be pressed out using the extractor.

Note

Before using extractor - T10520A- , make sure that the thrust piece -1- is inserted.

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– Secure the extractor - T10520A- -1- with 3 wheel bolts -2- to

the wheel hub in order to be able to press out the cardan shaft

-3-.

The following order must therefore always be observed:

– Tighten the knurled nut -1- by hand. – Turn the screw -2- and press out the cardan shaft from the

wheel hub.

Note

At the end of the procedure or for pressing out cardan shaft further the spindle must be moved to its original position in order to de‐ ploy the hydraulic force!

– Remove cardan shaft from wheel hub.

5.6 Repairing drive shaft with CV joint

Special tools and workshop equipment required ♦ Pressure plate - MP3-406 (VW 401)♦ Pressure plate - MP3-407 (VW 402)-

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♦ Drift - MP3-448 (VW 408A)♦ Support bushing - MP6-428 (VW 522)♦ Clamping device - MP6-429 (40-204A)♦ Workshop press , e.g. -VAS 6654♦ Tensioning pliers , e.g. -V.A.G 1682A♦ Sealant - D 454 300 A2Remove the outer CV joint of the drive shaft: – Remove cardan shaft ⇒ “5.4 Removing and installing drive

shaft with CV joint”, page 66 .

– Clamp the cardan shaft in a vice with protective jaws. – Pull back the bellows. – Remove the CV joint from the cardan shaft using a drift -A-. The drift must be positioned exactly at the tripod spider of the CV

join. – Remove circlip ( ⇒ Item 16 (page 60) ). – Remove the disc spring and thrust ring from the drive shaft. Remove outer CV joint of the drive shaft: – Push the new joint boot onto the drive shaft.

– Fit the disc spring -1- and the thrust ring -2- onto the drive

shaft.

Pay attention to correct installation position. – Insert new circlip in the groove of the drive shaft. – Carefully drive CV joint onto the drive shaft with a plastic ham‐

mer until the compressed circlip expands. – Grease the CV joint and the joint boot ⇒ page 60 . – Fit joint boot on the outer joint.

Note

♦

In view of the hard material (as opposed to rubber) of the joint

boot, which requires the use of a stainless steel-open warm-

type clamp, the latter can only be tightened with tensioning

pliers , e. g. -V.A.G 1682 A- .

♦

Tightening torque 20 Nm.

♦

Make sure that the thread of the spindle -A- of the pliers moves

freely. Lubricate with grease if necessary.

♦

If it is not smooth, e.g. if the thread is dirty, the necessary

clamping force of the open warm-type clamp is not reached at

the given torque.

– Tighten the open warm-type clamp on the outer joint (at the

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large diameter).

– Fit tensioning pliers , e.g. -V.A.G 1682 A- , as shown Make

sure the cutting edges of the pliers are positioned in the cor‐ ners -arrows B- of the warm-type clamp.

– Tighten the warm-type clamp by turning the spindle with a

torque wrench . Do not tilt the pliers during this process. A - Spindle of tensioning pliers B - Cutting edges of tensioning pliers

– Tighten the warm-type clamp at the small diameter. – Fit tensioning pliers , e.g. -V.A.G 1682 A- , as shown Make

sure the cutting edges of the pliers are positioned in the cor‐

ners -arrows B- of the warm-type clamp. – Tighten the warm-type clamp by turning the spindle with a

torque wrench . Do not tilt the pliers during this process. A - Spindle of tensioning pliers B - Cutting edges of tensioning pliers C - Torque wrench – Install drive shaft ⇒ “5.4 Removing and installing drive shaft

with CV joint”, page 66 .

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Remove the inner CV joint of the drive shaft: – Remove cardan shaft ⇒ “5.4 Removing and installing drive

shaft with CV joint”, page 66 .

– Open warm-type clamp. – Remove joint boot from CV joint with drift. – Remove the circlip from the drive shaft. – Press CV joint off the drive shaft (fig. S40-0098). – Do this while supporting the steering joint. – Remove the disc spring from the drive shaft.

Install the inner CV joint of the drive shaft: – Fit the disc spring -1- onto the drive shaft.

Pay attention to correct installation position. – Push the new joint boot onto the drive shaft.

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– Press CV joint onto the drive shaft up to the stop.

Note

Chamfer (chamfered edge) on inner diameter of the ball hub (ser‐ ration) must point towards the bearing collar of the drive shaft.

– Fit new circlip on the drive shaft. For this use e.g. the circlip

pliers - VW 161 A- .

– Coat the edge of the inner joint boot cap with sealant -

D 454 300 A2- .

– Fit joint boot on the constant velocity joint.

Note

♦

In view of the hard material (as opposed to rubber) of the joint boot, which requires the use of stainless steel open warm-type clamps, these can only be tightened with tensioning pliers , e.g. -V.A.G 1682 A- .

♦

Tightening torque 20 Nm.

♦

Make sure that the thread of the spindle -A- of the pliers moves freely. Lubricate with grease if necessary.

♦

If it is not smooth, e.g. if the thread is dirty, the necessary clamping force of the open warm-type clamp is not reached at the given torque.

– Install drive shaft ⇒ “5.4 Removing and installing drive shaft

with CV joint”, page 66 .

5.7 Inspecting the CV joints

5.7.1 Disassembling, inspecting and assem‐ bling the outer CV joint

Disassembling and inspecting the outer CV joint: Disassemble the joint to replace badly soiled grease or if the con‐

tact surfaces of the balls must be inspected for wear and damage. – With an electric stylus or rubstone mark the position of the ball

hub relatively to the ball cage and housing before disassem‐

bling -arrow-. – Rotate the ball hub and ball cage. – Remove the balls one after the other.

– Turn the cage until two rectangular cage windows -arrow- rest

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on the joint part.

– Remove cage with hub.

– Turn the hub segment in opening of the cage. – Tilt hub out of the cage.

Note

♦

The 6 balls of each joint belong to a tolerance group. Inspect the axle studs, hub, cage and balls for small depressions (pit‐ ting = point erosion) and seizing marks. Load alteration shocks indicate too much torsional clearance in the joint. If this is the case, replace the joint. Smoothing and bearing marks do not justify a joint replacement.

♦

Inspect the cage for tears.

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Assembling the outer CV joint: – Press the required grease mass into the joint part ⇒ page

60 .

– Insert the cage and hub in the joint body.

Note

The cage must be inserted in the correct position.

– Press in opposite balls one after the other, during this process

observe the prior position of the ball hub relatively to the ball

cage and to the joint part. – Insert new circlip in the groove of the shaft. – Installing the joint boot ⇒ “5.6 Repairing drive shaft with CV

joint”, page 69 .

5.7.2 Disassembling, inspecting and assem‐

bling the inner CV joint

Disassembling and inspecting the inner CV joint: Disassemble the joint to replace badly soiled grease or if the con‐

tact surfaces of the balls must be inspected for wear and damage.

Note

The ball hub and joint part are paired and must be marked before removing. Do not interchange the bearing track assignment.

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– Rotate the ball hub and ball cage. – Press the ball hub and ball cage out of the joint part in the

direction of the arrow.

– Successively press out the balls from the cage.

– Tilt the ball hub out of the ball cage over the ball bearing track

-arrows-.

– Inspect the joint part, ball hub, ball cage and balls for small

broken out depressions (pitting = point corrosion) and seizing marks.

Note

Load alteration shocks indicate too much torsional clearance in the joint. If this is the case, replace the joint. Smoothing and bear‐ ing marks do not justify a joint replacement.

Assembling the inner CV joint:

– Insert the ball hub in the ball cage over the two chamfers. The

fitting location is random. Press the balls into the cage.

– Insert the hub with cage upright into the joint part.

Note

When inserting make sure the greatest distance -a- on the joint part is close to the short distance -b- on the hub after it has been swivelled in -arrow-.

– Swivel in the ball hub, to do so swivel the hub out of the cage

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-arrows- until the balls are at bearing track distance.

– Lock the hub with the balls into position by exerting consider‐

able pressure on the cage -arrow-. Inspecting the operation of the CV joint: The CV joint is correctly assembled if the ball hub can be rolled

by hand up and down the entire linear compensation. – Press the required grease mass into the joint part ⇒ page

60 .

– Spread any residual grease in the joint boot ⇒ page 60 . – Installing the joint boot ⇒ “5.6 Repairing drive shaft with CV

joint”, page 69 .

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6 Drive shafts with inner tripod joint

⇒ “6.1 Summary of components of drive shaft with inner tripod joint”, page 76

⇒ “6.2 Removing and installing inner drive shaft with tripod joint”, page 78

⇒ “6.3 Repairing drive shaft with inner tripod joint”, page 82 ⇒ “6.4 Check outer joint”, page 84 ⇒ “6.5 Repairing outer CV joint”, page 84

6.1 Summary of components of drive shaft with inner tripod joint

Note

♦

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

♦

Assignment of the drive shafts ⇒ Electronic Catalogue of Original Parts .

♦

Grease the joint if necessary, when replacing the joint boot.

♦

On tripod joints, only apply grease in the joint; on no account must any grease enter the joint boot. Of all of the grease used, half should be pressed into the front side of the joint and the other half on the rear side of the tripod joint.

1 - Self-locking twelve-point

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nut

❑ Removing and installing

fixing nut of drive shaft

⇒ “5.2 Removing and in‐ stalling fixing nut of drive shaft”, page 61

❑ replace after each re‐

moval

❑ 50 Nm + 45°. 2 - Thrower ring 3 - Outer CV joint complete

❑ must be replaced com‐

pletely

❑ removing ⇒ “5.6 Repair‐

ing drive shaft with CV joint”, page 69

❑ Installation: carefully

drive onto the shaft with a plastic hammer until the compressed circlip

expands ❑ grease ⇒ page 78 ❑ Check ⇒ “6.4 Check

outer joint”, page 84

❑ Do not grease thread of

the outer joint of the

drive shaft. ❑ Assignment ⇒ Elec‐

tronic Catalogue of

Original Parts

4 - Circlip

❑ Replacing ❑ insert in the shaft groove

5 - Thrust ring

❑ Fitting position ⇒ “5.6 Repairing drive shaft with CV joint”, page 69

6 - Disc spring

❑ Fitting position ⇒ “5.6 Repairing drive shaft with CV joint”, page 69

7 - Clamp

❑ Replacing ❑ tensioning ⇒ “5.6 Repairing drive shaft with CV joint”, page 69

8 - Joint boot

❑ inspect for tears and chafing points ❑ Assignment ⇒ Electronic Catalogue of Original Parts

9 - Clamp

❑ Replacing ❑ tensioning ⇒ “5.6 Repairing drive shaft with CV joint”, page 69

10 - Drive shaft

❑ Assignment ⇒ Electronic Catalogue of Original Parts

11 - Clamp

❑ Replacing ❑ tensioning ⇒ “5.6 Repairing drive shaft with CV joint”, page 69

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6. Drive shafts with inner tripod joint 77

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12 - Joint boot for tripod joint

❑ inspect for tears and chafing points ❑ Assignment ⇒ Electronic Catalogue of Original Parts

13 - Clamp

❑ Replacing ❑ tensioning ⇒ “5.6 Repairing drive shaft with CV joint”, page 69

14 - Tripod spider with rollers

❑ Chamfer -arrow- points towards the drive shaft serration

15 - Circlip

❑ Replacing ❑ insert in the shaft groove

16 - Driver

❑ grease ⇒ page 78 ❑ Assignment ⇒ Electronic Catalogue of Original Parts

17 - Circlip

❑ Replacing ❑ insert in the shaft groove

Grease quality and grease quantity

Note

♦

The outer joints of the drive shaft can be filled with grease for operating at normal temperatures, e.g. -N 052 738 00- .

♦

Only use the high-temperature grease from the relevant repair kit for the grease filling of the tripod joint ⇒ Electronic cata‐ logue of original parts .

∅ Joint

(mm)

Outer joint

∅ 103

Inner joint

∅ 90

Total grease

quantity

(g)

±10

125

+10

105

Grease quantity distribution

Outer joint (g) Inner joint and

joint boot (g)

40 Residual amount

105

+10

---

6.2 Removing and installing inner drive shaft with tripod joint

Special tools and workshop equipment required ♦ Extractor - MP6-425 (3283)♦ Wedge - T10161♦ Polycarbamide grease - G 052 142 A2Removing: – Unscrew twelve-point nut for securing the drive shaft ⇒

“5.2 Removing and installing fixing nut of drive shaft”, page

61 .

– Remove front wheel. – Remove the sound dampening system ⇒ Body Work; Rep.

gr. 50 .

– Remove protection plate for inner joint of drive shaft from en‐

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gine (if present). – Unscrew the nuts -arrows-. – Remove track control arm from steering joint. – Swivel out wheel bearing housing with suspension strut out‐

wards and at the same time pull out the driveshaft from the

wheel bearing housing. – Secure the removed drive shaft to the an structure.

Note

♦

The drive shaft must not hang down! The inner joint can be

damaged by excessive offset.

♦

If the drive shaft cannot be pulled out of the wheel-bearing

housing, e.g. for removal use the extractor - MP6-425 (3283)- .

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– Fit wedge - T10161- between gearbox housing and inner tri‐

pod joint. – Press inner joint with a knock from a hammer onto the wedge

- T10161- out of the gearbox. – Remove the cardan shaft. Installing:

Note

Remove possible corrosion and grease residue from the thread and from the serration of the outer joint as well as from the ser‐ ration of the wheel-bearing housing.

– Grease the serration on the propeller shaft with polycarbamide

grease - G 052 142 A2- . Do not grease thread on the outer joint of the drive shaft.

– Grease the serration in the wheel hub with polycarbamide

grease - G 052 142 A2- . – Insert new circlip in the recess of the shaft for inner joint. – Adjust the serration of the shaft for inner joint and gearbox until

they engage. – Grasp the drive shaft with the hand and slide it up to the stop

in the inner joint part. – Now slide the inner joint part with the drive shaft in the gearbox

abruptly.

Caution

6. Drive shafts with inner tripod joint 79

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Never use a hammer or other driving tools.

– Check safe seating of the drive shaft in the gearbox by pulling

the inner joint part against the resistance of the circlip.

Note

For this inspection pull only on the joint part and not on the drive shaft.

– Loosen the drive shaft from the body. – Insert drive shaft into teething of wheel bearing housing as far

as possible.

– Secure the outer joint of the drive shaft with a new twelve-point

nut.

– Position the track control arm onto the steering joint of the

wheel bearing housing and tighten the nuts -arrows-.

– Install protection plate for inner joint of drive shaft to engine (if

present). – Install the noise insulation ⇒ Body Work; Rep. gr. 50 . – Tighten new twelve-point nut for securing the drive shaft ⇒

“5.2 Removing and installing fixing nut of drive shaft”, page

– Tighten wheel. – Perform a test drive.

Note

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

⇒ “2.2 Axle alignment”, page 129 .

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Tightening torques - summaries of components

Note

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

Screw of protective plate for inner joint of drive shaft 25 Nm Twelve-point nut for securing the drive shaft to wheel hub

♦ Use new nut! ♦ Do not grease thread of the outer joint of the drive shaft.

50 Nm + 45°.

Steering joint to track control arm ♦ Use new nuts!

Wheel bolts 120 Nm

100 Nm

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6.3 Repairing drive shaft with inner tripod

joint

Dismantling Special tools and workshop equipment required ♦ Pressure plate - MP3-406 (VW 401)♦ Pressure plate - MP3-407 (VW 402)♦ Thrust washer - MP3-455 (VW 447H)♦ Drift - MP3-448 (VW 408A)♦ Drive bushing - MP6-405 (VW 411)♦ Pipe section - MP3-4012 (VW 416B)♦ Circlip pliers , e.g. -VW 161A♦ Tensioning pliers , e.g. -V.A.G 1682A♦ Assembly tool - T10065Removing and installing drive shaft ⇒ “6.2 Removing and in‐

stalling inner drive shaft with tripod joint”, page 78 .

– Open both warm-type clamps at inner joint and push back the

joint boot. – Remove the joint part from the cardan shaft. – Remove circlip with circlip pliers -1-. – Insert the cardan shaft in the press.

– Press tripod spider off the cardan shaft. – Remove the joint boot from the shaft. – Clean the shaft, the joint part and the slot for the gasket ring. Assembling – Push a small open warm-type clamp for the joint boot onto the

drive shaft. – Push the joint boot onto the shaft. – Push the joint piece onto the cardan shaft. Install tripod spider: Cardan shaft in conical version The chamfer of the tripod spider points towards the shaft and as‐

sists installation. – If necessary, coat the serration of the drive shaft and the tripod

spider with joint grease.

– Insert the tripod spider onto the shaft and press it up to the

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stop. – Make sure that the force of pressure does not exceed 3.0 kN! – Insert circlip and pay attention to correct position. – Press 70 grams of grease for the drive shaft from the repair kit

in the tripod joint. – Slide the joint part over the rollers and hold down. – Press 60 grams of grease for the drive shaft from the repair kit

in the rear side of the tripod joint. Grease ⇒ page 78 . – Installing the joint boot. Install tripod spider: Cardan shaft in cylindrical version – If necessary, coat the serration of the drive shaft and the tripod

spider with joint grease.

– Insert the tripod spider onto the shaft and press it up to the

stop. – Make sure that the force of pressure does not exceed 3.0 kN! – Insert circlip and pay attention to correct position. – Press 70 grams of grease for the drive shaft from the repair kit

in the tripod joint. – Slide the joint part over the rollers and hold down. – Press 60 grams of grease for the drive shaft from the repair kit

in the rear side of the tripod joint. Grease ⇒ page 78 . – Installing the joint boot.

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Note

♦

In view of the hard material (as opposed to rubber) of the joint

boot, which requires the use of a stainless steel-open warm-

type clamp, the latter can only be tightened with tensioning

pliers , e. g. -V.A.G 1682A- .

♦

Tightening torque 20 Nm.

♦

Make sure that the thread of the spindle -A- of the pliers moves

freely. Lubricate with grease if necessary.

♦

If it is not smooth, e.g. if the thread is dirty, the necessary

clamping force of the open warm-type clamp is not reached at

the given torque.

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– Tighten the open warm-type clamp on the outer joint (at the

large diameter).

– Fit tensioning pliers , e.g. -V.A.G 1682A- , as shown Make sure

the cutting edges of the pliers are positioned in the corners

-arrows B- of the warm-type clamp.

– Tighten the warm-type clamp by turning the spindle with a

torque wrench . Do not tilt the pliers during this process. A - Spindle of tensioning pliers B - Cutting edges of tensioning pliers

– Tighten the warm-type clamp at the small diameter. – Fit tensioning pliers , e.g. -V.A.G 1682A- , as shown Make sure

the cutting edges of the pliers are positioned in the corners

-arrows B- of the warm-type clamp.

– Tighten the warm-type clamp by turning the spindle with a

torque wrench . Do not tilt the pliers during this process. A - Spindle of tensioning pliers B - Cutting edges of tensioning pliers C - Torque wrench

6.4 Check outer joint

⇒ “5.7.1 Disassembling, inspecting and assembling the outer CV joint”, page 72

6.5 Repairing outer CV joint

⇒ “5.6 Repairing drive shaft with CV joint”, page 69

42 – Rear suspension

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1 Rear axle

⇒ “1.1 Raise the wheel-bearing of the rear axle in the rebound state (unladen weight position)”, page 85

⇒ “1.2 Summary of components of rear axle”, page 86 ⇒ “1.3 Fitting location of the shock absorber on the rear axle”,

page 90 ⇒ “1.4 Removing and installing rear suspension”, page 90

1.1 Raise the wheel-bearing of the rear axle in the rebound state (unladen weight po‐ sition)

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

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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: Unladen weight of the vehicle ready for driving (full fuel tank and

washer fluid/headlight cleaning system reservoir, spare wheel and jack (if the vehicle was fitted at the factory with them), 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 on the lift platform can be simulated by lifting out the corresponding wheel suspension with the engine/gearbox jack e.g. -V.A.G 1383/A- or -VAS6931- and the support - 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 for tightening the

screws/nuts.

1. Rear axle 85

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Before the corresponding wheel suspension is lifted, the vehicle must be lashed securely at the supporting arms of the lift platform with the tensioning straps - T10038- .

DANGER!

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

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

is located at the top.

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

– Raise up the wheel suspension using the engine/gearbox jack

e. g. or -V.A.G 1383/A- -VAS6931- until dimension -a- is achieved.

Caution

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

jack is positioned under the vehicle.

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

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

– Tighten up the corresponding screws/nuts fully to the specified

tightening torque. – Lower the wheel suspension. – Pull out the engine/gearbox jack e. g. -V.A.G 1383/A- or -

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

1.2 Summary of components of rear axle

Note

♦

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

removal.

♦

Welding and straightening on axle body and axle studs not allowed.

♦

Always replace the self-locking screws and nuts.

♦

Always replace corroded self-locking nuts and screws.

♦

Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.

86 Rep. gr.42 - Rear suspension

1 - Wheel bolt

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❑ Assignment ⇒ Elec‐

tronic Catalogue of Original Parts

❑ 120 Nm

2 - Screw

❑ 4 Nm

3 - Brake drum

❑ Brake drum diameter,

wear limit ⇒ Brake sys‐ tems; Rep. gr. 00

❑ Clean carefully and

check for wear, dam‐ age, dimensional accu‐ racy and flawless brake surface.

❑ before removing the

brake drum, reset the brake ⇒ Brake sys‐ tems; Rep. gr. 46

❑ Thoroughly clean the

centering hole of the drum before installing and subsequently treat it with approx. 0.5 g of anti-corrosion agent AKR 322 000-

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Note

The anti-corrosion agent - AKR 322 000- must not get into the threads of the wheel screws!

4 - Cap

❑ replace after each re‐

moval

❑ extracting and inserting ⇒ “3.2 Removing and installing the wheel hub with wheel bearing”, page 119

5 - Self-locking twelve-point nut

❑ replace after each removal ❑ 70 Nm + 30°.

6 - Wheel hub with wheel bearing

❑ for vehicles with ABS ❑ Sensor ring for ABS is built into the wheel hub ❑ wheel hub and wheel bearing form one unit; it does not need servicing ❑ The sensor ring for ABS cannot be replaced individually ❑ Removing and installing ⇒ “3.2 Removing and installing the wheel hub with wheel bearing”, page

119

❑ Assignment ⇒ Electronic Catalogue of Original Parts ❑ Before installing the brake drum, thoroughly clean the centering shoulder for the brake drum and sub‐

sequently treat it with approx. 0.5 g of anti-corrosion agent - AKR 322 000-

Note

The anti-corrosion agent - AKR 322 000- must not get into the threads of the wheel screws!

1. Rear axle 87

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7 - Wheel hub with wheel bearing

❑ for vehicles without ABS ❑ wheel hub and wheel bearing form one unit; it does not need servicing ❑ Removing and installing ⇒ “3.2 Removing and installing the wheel hub with wheel bearing”, page

119

❑ Assignment ⇒ Electronic Catalogue of Original Parts ❑ Before installing the brake drum, thoroughly clean the centering shoulder for the brake drum and sub‐

sequently treat it with approx. 0.5 g of anti-corrosion agent - AKR 322 000-

Note

The anti-corrosion agent - AKR 322 000- must not get into the threads of the wheel screws!

8 - Screw

❑ replace after each removal ❑ 30 Nm + 90°.

9 - Brake carrier with brake shoes

❑ repairing ⇒ Brake systems; Rep. gr. 46

10 - Holder for hand-brake cable

❑ replace after each removal ❑ Fitting position ⇒ Brake systems; Rep. gr. 46

11 - Hand-brake cable

❑ removing and installing ⇒ Brake systems; Rep. gr. 46

12 - Screw

❑ replace after each removal ❑ insert from the inside of the vehicle ❑ tighten in unladen condition (unladen weight position) - do not load vehicle ⇒ “1.1 Raise the wheel-bearing

of the rear axle in the rebound state (unladen weight position)”, page 85

❑ 45 Nm + 90°.

13 - Self-locking screw

❑ replace after each removal ❑ if thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying

attention to the notes of the manufacturer ❑ the rework of the thread for the weld nut is permissible on maximum 2 screw points per vehicle side ❑ 50 Nm + 45°.

14 - Self-locking nut 15 - Mount for rear axle

❑ avoid slackening in order to remove the rear axle ❑ check the overall track of the rear axle after installation and adjust if necessary

16 - Holder for hand-brake cable 17 - Rubber-metal bearing

❑ Removing and installing ⇒ “2.6 Replacing the rubber-metal bearing”, page 102

18 - Welded axle

❑ Assignment ⇒ Electronic Catalogue of Original Parts ❑ The locating face and the threaded holes for axle studs must be free from enamel and dirt ❑ Removing and installing ⇒ “1.4 Removing and installing rear suspension”, page 90

19 - ABS wheel speed sensor

❑ only on vehicles with ABS

88 Rep. gr.42 - Rear suspension

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❑ Assignment ⇒ Electronic Catalogue of Original Parts

20 - Screw

❑ 8 Nm

21 - Bottom spring seat

❑ inspect for damage (visual inspection)

22 - Coil spring

❑ Removing and installing ⇒ “2.5 Removing and installing coil spring”, page 101 ❑ check for paint damage, if necessary eliminate paint damage ❑ check colour coding ❑ Assignment ⇒ Electronic Catalogue of Original Parts ❑ replace axle-wise ❑ per rear axle only use helical springs of the same make

23 - Top spring seat

❑ installing ⇒ “2.5 Removing and installing coil spring”, page 101

24 - Screw

❑ replace after each removal ❑ insert from the inside of the vehicle ❑ tighten in unladen condition (unladen weight position) - do not load vehicle ⇒ “1.1 Raise the wheel-bearing

of the rear axle in the rebound state (unladen weight position)”, page 85

This operation can be skipped if the shock absorber with rear suspension has already been assembled

⇒ “1.3 Fitting location of the shock absorber on the rear axle”, page 90

❑ 40 Nm + 90°.

25 - Screw

❑ replace after each removal ❑ if thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying

attention to the notes of the manufacturer ❑ the rework of the thread for the weld nut is permissible on maximum 2 screw points per vehicle side ❑ 30 Nm + 90°.

26 - Shock absorber

❑ Removing and installing ⇒ “2.4 Removing and installing shock absorber”, page 98 ❑ Check ⇒ “2.2 Inspect shock absorber”, page 98 ❑ disposing of ⇒ “2.3 Disposing of the shock absorber”, page 98 ❑ can be replaced separately ❑ Assignment ⇒ Electronic Catalogue of Original Parts ❑ per rear axle only use shock absorbers of the same make

27 - Self-locking nut

❑ replace after each removal

28 - Brake line

❑ Tightening torque of the pipe screws: 14 Nm

29 - Axle stud

❑ Straightening work is prohibited ❑ Re-cutting the thread is not allowed! ❑ Removing and installing ⇒ “3.3 Removing and installing axle studs”, page 124

1. Rear axle 89

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1.3 Fitting location of the shock absorber on the rear axle

♦ If shock absorber -1- is preassembled to rear suspension -2-,

pay attention to the installation angle -α- = 104°.

♦ Tighten up the screws fully to the specified tightening torque.

1.4 Removing and installing rear suspen‐ sion

Special tools, test equipment as well as aids required Special tools and workshop equipment required ♦ Spring tensioning device , e.g. -V.A.G. 1752/1♦ Spring holder , e.g. -V.A.G 1752/3♦ Engine and gearbox jack e.g. -V.A.G 1383/A- or -VAS6931♦ Tensioning strap , e.g. -T10038♦ Brake filling and bleeding device , e. g. -VAS 5234♦ Remove plugs for brake line ♦ Brake fluid ⇒ Brake systems; Rep. gr. 00 ♦ Assembly paste - G 052 150 A2-

Caution

All screws must always be tightened firmly in the unladen con‐ dition (unladen weight position) to the chassis parts with rub‐ ber-metal bearings - do not load the vehicle ⇒ “1.1 Raise the

wheel-bearing of the rear axle in the rebound state (unladen weight position)”, page 85

Removing:

Note

♦

When removing the rear axle, the right bracket for the rubbermetal bearing must be removed from the body.

♦

After removing and installing the bracket for bonded rubber bush, the overall track of the rear axle must be checked, ad‐ justed if necessary.

♦

Before commencing work, determine the measurement -a- ⇒

“1.1 Raise the wheel-bearing of the rear axle in the rebound state (unladen weight position)”, page 85

90 Rep. gr.42 - Rear suspension

– Put hand-brake back.

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– Remove storage compartment or arm rest ⇒ Body Work; Rep.

gr. 68 . – Actuate the brake pedal and insert the brake pedal load. This prevents the brake line and the ABS hydraulic unit from run‐

ning empty of brake fluid. – Release resetting nut -3- and unhook hand-brake cables -1-

from compensating clamp -2-. – Remove wheels.

– Unhook handbrake cables from the holders -arrow B-.

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– Pull hand-brake cable -2- in -the direction of the arrow- out of

the guide tube -1-. Vehicles with ABS – Remove ABS speed sensor screw, take out speed sensor and

unclip the cable on the axle. Continued for all vehicles – Remove coil springs ⇒ “2.5 Removing and installing coil

spring”, page 101 .

DANGER!

Before removing the rear suspension, the vehicle must be lashed securely on both sides at the supporting arms of the lift platform.

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

1. Rear axle 91

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– Remove the plugs from the frame side rail and the pull in the

tensioning strap.

– Lash the vehicle on both sides to the supporting arms.

– Separate the left brake line -arrow A- and pull out the fuse

-arrow B-.

– Pull the left brake hose -1- out of the support at the bracket for

the rubber-metal bearing.

– Separate the right brake line -arrow A- and pull out the fuse

-arrow B-.

– Pull the right brake hose -1- out of the support at the axle.

– Support the rear axle with engine/gearbox jack e.g. -V.A.G

1383/A- or -VAS6931- -2- with mount -1-.

– Secure the rear axle with tensioning strap at engine/gearbox

jack-adapter.

– Remove screws -arrows- at the bottom shock absorber mount‐

ing/axle.

Note

A second person is required for the further removal operations.

92 Rep. gr.42 - Rear suspension

– Unscrew the nuts of the fixing screws -1- from the axle.

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– Remove the screws -2- of the bearing bracket for the axle on

the right vehicle side from the body.

Note

Before removing the screws of the bearing brackets for the axle, mark the position of the bearing bracket on the body.

– Remove the fixing screw -1- for the axle on the left vehicle side

from the bearing bracket for the axle. – Slightly lower the rear axle out of the bearing brackets so that

the brake line is not damaged. – Remove the fixing screw -1- for the axle on the right vehicle

side from the bearing bracket for the axle. – Remove the bearing bracket from the axle. – Lower the rear axle with engine/gearbox jack with adapter.

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Installing: Installation is carried out in the reverse order. Pay attention to the

following: – Before inserting the rear suspension, grease the kidney-

shaped cavities of the rubber-metal bearing with assembly

paste - G052 150 A2- .

Note

When tightening the rubber-metal bearing screws and nuts, the bottom shock absorber mounting, the axle body must be in the laden position (unladen condition) ⇒ “1.1 Raise the wheel-bearing

of the rear axle in the rebound state (unladen weight position)”, page 85

– Position the bearing bracket for the axle on the right vehicle

side on the rubber-metal bearing.

1. Rear axle 93

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– Insert a new fixing screw -1- from the inside of the vehicle into

the bearing bracket for the axle.

– Carefully raise the rear axle so that the rubber-metal bearing

engages on the left vehicle side in the bearing bracket for the axle.

– Ensure that the bearing bracket for the axle on the right vehicle

side rests at the same time against the body in the marked position.

– Screw the new fixing screws -2- of the bearing bracket for the

axle on the right vehicle side into the body and tighten.

– Insert the new fixing screw on the left vehicle side in the bear‐

ing bracket for the axle.

– Screw new nuts onto the fixing screws for bearing brackets of

the rear axle and do not tighten yet.

– Fit screws at the bottom shock absorber mounting and do not

tighten yet.

Note

Absolutely pay attention to the fitting position of the helical springs

⇒ “2.5 Removing and installing coil spring”, page 101 .

– Installing the helical springs ⇒ “2.5 Removing and installing

coil spring”, page 101 .

– Tighten screws of rear axle with bearing brackets and screws

on the bottom shock absorber mounting with axle to the spec‐ ified tightening torque - the vehicle must be in the laden condition (unladen weight position) ⇒ “1.1 Raise the wheel-

bearing of the rear axle in the rebound state (unladen weight

position)”, page 85 .

– Install the hand-brake cables and fasten in the holders. – Connect the brake line. – Install new locking clips of brake line. – Remove brake pedal load. – Bleeding brake system ⇒ Brake systems; Rep. gr. 47 . – Setting the hand-brake ⇒ Brake systems; Rep. gr. 46 . Vehicles with ABS – Install and screw on ABS speed sensor and clip cable onto the

axle. – Install wheel and tighten bolts or nuts. – Install storage compartment or arm rest ⇒ Body Work; Rep.

gr. 68 . – Carry out axle alignment ⇒ “2.2 Axle alignment”, page

129 .

– Perform a test drive. – Check the steering wheel position during the test drive.

Note

94 Rep. gr.42 - Rear suspension

SKODA Rapid 2011 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

00 – Technical data

1 Accident vehicle assessment

1.1 Checklist for assessing the chassis of accident vehicles

2 General Instructions

2.1 Steering gear

2.2 Seals and sealing rings

2.3 Nuts and bolts

2.4 Electrical components

40 – Front suspension

1 Front axle - Overview

1.1 Front axle - Overview of the repair chapter

2 Repairing front axle

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

2.3 Inspecting the suspension link

2.6 Replacing the rubber-metal bearing for track control arm

2.7 Removing and installing the anti-roll bar

3 Repairing front suspension strut

3.1 Installation general view of the suspension strut

3.3 Repairing suspension strut

3.4 Inspect shock absorber

3.5 Disposing of the shock absorber

4 Repairing wheel bearing

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

4.2 Removing and installing wheel bearing housing

5 Drive shafts with inner CV joint

5.1 Summary of components of drive shaft with inner CV joint

5.2 Removing and installing fixing nut of drive shaft

5.6 Repairing drive shaft with CV joint

5.7 Inspecting the CV joints

6 Drive shafts with inner tripod joint

6.1 Summary of components of drive shaft with inner tripod joint

6.2 Removing and installing inner drive shaft with tripod joint

6.4 Check outer joint

6.5 Repairing outer CV joint

42 – Rear suspension

1 Rear axle

1.2 Summary of components of rear axle

1.3 Fitting location of the shock absorber on the rear axle