Front Suspension
Removing and installing front drive shaft
Removing
Caution! Danger of injury and material damage if the wheel carrier is raised incorrectly!
^ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels)!
^ When raising, use a suitable intermediate layer (hard rubber)!
^ Do not damage the brake cover plate!
^ Vehicle may not be moved if drive shafts have not been fitted and tightened!
^ Before raising the vehicle, undo the drive shaft fastening at the wheel side! Operate the brake whilst doing so (2 workers required)!
1. Remove front wheel and underside panel.
2. Release fastening nut for drive shaft.
3. Push (press through) peg of drive shaft by approximately 20 mm - 25 mm into the wheel hub with universal drive shaft/wheel hub extractor 87-1.
4. Fix -top axle strut- with tension jack VW 552 (vehicle in illustration with conventional suspension). This involves tensioning axle strut slightly because top ball joint can otherwise get damaged. By doing this, the tension jack is mounted into the top opening of the wheel house (double panel) and in the axle strut.
5. Press out tie rod on wheel carrier with press-out tool T 10187.
6. Raise wheel carrier with a suitable lift to the extent that connecting rod and fastening pins for spring strut at the bottom are easy to remove. Use a suitable -lift with rubber base- in order to prevent slipping.
7. Release lower spring strut.
8. Press out wheel carrier at the top with press-out tool T 10187.
9. Unclip cable for wear monitor and release holder on wheel carrier.
10. Push protection over drive shaft. Undo the drive shaft on the transmission.
11. The first worker must carefully pull upper wheel carrier out and turn the steering. The second worker must carefully pull out drive shaft.
Installing
Caution! Danger of injury and material damage if the wheel carrier is raised incorrectly!
^ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels)!
^ When raising, use a suitable intermediate layer (hard rubber)!
^ Do not damage the brake cover plate!
^ Vehicle may not be moved if drive shafts have not been fitted and tightened!
Note!
^ The entire threaded parts of the axle must be tightened in vehicle position! Vehicle position means: vehicle standing on the wheels, or the wheel suspension is being raised with a universal vehicle lift! -Dimension X-, from lower edge of wing to middle of axle 502 mm ± 10 mm corresponds to vehicle position!
^ Use an intermediate layer (hard rubber)! Do not damage the brake cover plate!
^ Screws are Dacromet-coated and must not be greased!
^ Grease axle nut with a little Optimoly TA aluminum paste only at mounting-face ring!
^ Grease the toothing of the drive shaft slightly with Optimoly TA aluminum paste!
^ Drive shafts must not be left hanging from the joint stop! Tie up!
^ Use new screws and fastening nuts!
^ Ensure that ball joint rod conical seats are clean! If necessary, clean with lint-free cloth! Do not use cleaning agent!
^ Use correct tightening torques!
1. Grease toothing with a little Optimoly TA aluminum paste and insert drive shaft. When doing this, press inner joint together tightly.
2. Grease mounting-face ring of axle nut with a little Optimoly TA aluminum paste. Screw on axle nut in order to prevent shaft from slipping out. If it is not possible to push shaft in all the way, use assembly fixture T10206 to pull drive shaft in.
3. Insert upper wheel carrier and tie rod and mount with fastening nuts. Pay attention to inner joint of drive shaft.
4. Raise wheel carrier with a suitable lift to the extent that connecting rod and fastening pins for spring strut at the bottom are easy to push in. Use a suitable -lift with rubber base- in order to prevent slipping.
5. Engage cable for wear monitor and mount holder on wheel carrier.
6. Secure drive shaft at transmission.