Suspension - Front End Knock When Driving on Rough Roads
GROUP: 40NUMBER: 95-01
DATE: Jan 31, 1995
SUBJECT:
Correcting Front End Knock While Driving Over Rough Road Surfaces
MODEL(s):
Golf/Jetta (Exc. GLX)
File this Technical Bulletin in Repair Manual No.: W42 011 294 113
This Technical Bulletin Supersedes Technical Bulletin 40, No. 90-01, May, 5, 1994, due to a Part No. change.
CONDITION
Customer complains of a dull clunking noise from the front end when driving slowly over small dips and rises such as a driveway apron. This could be caused by greater than normal free play in the upper strut bearings.
PRODUCTION
No Change.
SERVICE
With vehicle resting on ground, remove upper strut cap (ARROW).
Make sure slotted nut (ARROW 1) is fully torqued to 40 Nm (30 ft-lb), using special tool VvV524. Also clean any dirt and torque-seal paint residue from bearing surface under strut cap (ARROW 2).
Thoroughly lubricate rubber shim, part number 191 881 493, and install so it fits around the slotted nut and rests on the bearing surface (ARROW). Use a high quality Teflon or silicone based grease which will not wash out easily (such as plastilube).
Install a new bearing cap, Part No. 357412 319B. This has a padded rubber insulator ring instead of plastic (ARROW). BE SURE TO USE SPECIAL TOOL 3078 in conjunction with a 7 mm Allen wrench when reinstalling the bearing cap to prevent the slotted nut from backing off during the tightening procedure. This would create unwanted play and negate the effectiveness of this repair. Torque nut to 60 Nm (44 ft-lb). The original plastic dust covers do not fit on these bearing caps and should be discarded.
Labor Operation: 40 88 51 0
Time Units: 20
Caution
Part numbers are for reference only. Always check with your Parts Department for the latest parts information