400619 Removing and installing front-axle carrier
WM 400619 Removing and installing front-axle carrier
Tools
Preliminary work
Preliminary work for removing and installing front-axle carrier
1. Support the engine on the body. -> 1001IN Supporting the engine on the body
2. Remove engine guard. -> 108019 Removing and installing engine guard - section on "Removing"
3. On vehicles with 19-inch brake system:
Remove the air guide. -> 407719 Removing and installing front stabilizer (PDCC) - section on "Removing"
4. Remove front wheels. -> 440519 Removing and installing wheel - section on "Removing"
Tools and materials
The following tools are described in Tools and Equipment.
Lifting platform
Tool overview
Complete structure of the base carrier with mounting mandrels
Removing front-axle carrier
CAUTION
Heavy components
- Risk of squashing
-> Wear personal protective gear.
-> Get someone to help if necessary.
Information
- The spring struts are not removed in order to remove the front axle carrier.
- Fix upper axle strut. The lower control arms are loosened on the front axle carrier and remain with the spring struts in the vehicle.
Information
- The pictures shown in this document may differ from the original.
- However, this does not affect the validity and relevance of the pictures.
1. Fix the upper trailing arm -2- in place using spring tensioner VW 552, -1-.
The spring tensioner is engaged in the top opening of the wheel housing and in the upper trailing arm and is tensioned slightly to avoid damaging the upper ball joint -3-.
Securing upper trailing arm
2. To make it easier to remove the outer tie rod joint, swivel the relevant wheel carrier so that the tie rod is fully extended. Remove the outer tie rod using press-out tool T10187. When pressing out, screw lock nut on flush (protects the ball joint thread).
Pressing off tie rod
3. Loosen fastening screws -1- on the heat shield -2- at the steering gear.
Heat shield for steering gear
Remove the heat shield.
4. Loosen the clamping screw -1- on the steering column -2- at the steering gear -3-.
Loosening steering column at the steering gear
Press the steering column -3- up -arrow- out of the steering gear -A-.
5. Remove the upper hydraulic line -1- (pressure line) at the steering gear -2-.
Collect hydraulic fluid in a suitable container.
Hydraulic line - steering gear
6. On hybrid vehicles:
The pressure line must be disconnected at the connection point -1- on the longitudinal member on hybrid vehicles.
Opening pressure line connection point
7. Loosen the clamp -1- on the hydraulic line -2- (intake pipe) in the front left wheel housing and pull off the line.
Front left hydraulic line
Close off the line and connection piece using suitable stoppers.
8. Loosen the cardan shaft at the transfer gear using a mounting lever and tie it up. -> 390219 Removing and installing cardan shaft - section on "Removing"
9. Unscrew fastening screws -1- from the drive shaft at the front-axle final drive.
Make sure that the drive shafts do not become kinked (tie them up).
Screws securing drive shaft to transmission
10. Mark the eccentric screws -1- for the adjusting camber and caster on the chassis subframe with a coloured pen -A, B- (facilitates fitting during re-installation).
Marking on eccentric screws
11. Remove the eccentric screws. Make sure that the eccentric screws do not damage the bellows. For this purpose, raise the wheel bearing housing using a suitable jack.
12. Pull (press) the lower trailing arm out of the front-axle carrier -A-.
Removing trailing arm (shown as an example)
13. Remove fastening screw -1- for the connecting link -2- at the bottom of the anti-roll bar -3-.
Connecting link for anti-roll bar
14. Mark the installation position of the front-axle carrier diagonally at at least two places on the body using a felt-tip pen. This makes it easier to correctly position the front-axle carrier on the body during reinstallation. => Marking installation position of front-axle carrier
Marking installation position of front-axle carrier
15. Set up the lifting platform according to instructions -> 100119 Removing and installing V8 4.8-litre DFI engine - section on "Tools and materials" . Then position it under the engine and raise it. When you do this, ensure that the positioning guides of the lifting platform are inserted into the body. => Lifting platform under engine
Lifting platform under engine
16. The -arrows- show the mounting points for the mounting frame in the front-axle carrier (view from below here).
Mounting points for front-axle carrier
17. Position lifting platform in the front-axle carrier in the mounting points provided -(arrows)- , -4 into the body-.
Lifting platform
18. Mark the final position of the lifting platform -1- on the workshop floor -A-.
Position of lifting platform
19. Remove the 4 fastening screws -(arrows)- on the front-axle carrier.
Fastening screws on front-axle carrier
20. Lower the front-axle carrier with steering, final drive and anti-roll bar. Be careful not to damage adjacent parts (e.g. cardan shaft, oil pan, body).
Installing front-axle carrier
CAUTION
Heavy components
- Risk of squashing
-> Wear personal protective gear.
-> Get someone to help if necessary.
Information
- All screws and bolts on the axle must be tightened in vehicle position. Vehicle position means: vehicle resting on its wheels, or the wheel suspension is lifted with a universal jack. -Dimension X- from lower edge of wing to centre of axle corresponds to vehicle position. For the current height values, please refer to the adjustment values for suspension alignment -> 4495TW Adjustment values for suspension alignment .
Dimension -X-: lower edge of wing to centre of axle (shown as an example)
- Visually inspect all parts.
- Replace self-locking nuts.
- Replace all expansion screws (screws fitted using torque angle tightening procedure).
- Use correct tightening torques and torque angle. -> 4X00IN Tightening torques for front axle
1. Position the -front-axle carrier- on the mounting frame.
Front-axle carrier
2. Position the lifting platform -1- on the markings -A-.
Position of lifting platform
3. Position the front-axle carrier back in its original, marked installation position and be careful not to damage adjacent parts.
4. Fit the four fastening screws -arrows-.
Fastening screws on front-axle carrier
5. Remove the -lifting platform- using the assembly frame.
Front-axle carrier
6. Fit the connecting link -2- on the anti-roll bar -3- and screw in the fastening screw -1-.
Connecting link for anti-roll bar
7. Press the trailing arm into the mounting points on the front-axle carrier -A-.
Installing trailing arm (shown as an example)
8. Insert and fit the eccentric screws -1-. Fit according to the markings -A, B-.-> 4X00IN Tightening torques for front axle
Raise the wheel bearing housing slightly using a suitable jack to avoid damaging the dust bellows for the steering when tightening the eccentric screws.
Marking on eccentric screws
9. Fit fastening screws -1- for securing drive shaft to transmission. -> 4X00IN Tightening torques for front axle
Screws securing drive shaft to transmission
10. Fit the rear cardan shaft. -> 390119 Removing and installing rear final drive - section on "Installing"
11. Fit the steering column at the steering gear. -> 481519 Removing and installing steering column - section on "Installing"
Use a new clamping screw.
Installing steering column
11.1. Press the steering column -2- onto the steering gear -3- ( -A- ).
11.2. Insert a new clamping screw -1- and fit without tension.
12. Position hydraulic line (intake pipe) -2- and fit the clamp -1-.
Front left hydraulic line
13. Fit the upper hydraulic line -1- (pressure line) at the steering gear - 2-.
Hydraulic line - steering gear
14. On hybrid vehicles:
Connect and secure the pressure line for the hydraulic pump -1- to the connection point with the pressure line for the steering gear.
Joining connection point for hydraulic pressure line
15. Position the heat shield -2- on the steering gear and fit the fastening screws -1-.
Heat shield for steering gear
16. Fit the tie rod on the wheel bearing housing. -> 487919 Removing and installing tie rod - section on "Installing"
17. Spring tensioner VW 552 -1- can now be removed from the upper trailing arm -2-.
Fixing point for upper trailing arm
Subsequent work
Subsequent work for removing and installing front-axle carrier
1. On vehicles with 19-inch brake system:
Fit the air guide. -> 407719 Removing and installing front stabilizer (PDCC) - section on "Installing"
2. Fit engine guard. -> 108019 Removing and installing engine guard - section on "Installing"
3. Fit the front wheels. -> 440519 Removing and installing wheel - section on "Installing"
4. Remove engine support at the body. -> 1001IN Supporting the engine on the body
5. Bleed the power steering. -> 4890IN Test and assembly work on power steering
6. Perform suspension alignment. -> 449503 Suspension alignment, complete