SUSPENSION - FRONT. Volkswagen Technical Site -

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1 SUSPENSION - FRONT Volkswagen Technical Site - ARTICLE BEGINNING SUSPENSION Volkswagen - Front : Cabrio, Golf, GTI, Jetta, Passat 1998: Beetle DESCRIPTION FWD suspension system is equipped with MacPherson struts. Steering knuckles are supported by lower control arms and vertically mounted strut assemblies. See Figs. 1 and 2. Base suspension is used on 4-cylinder models, plus suspension is used on VR6 models. Fig. 1: Exploded View Of Front Suspension (Typical)

2 Fig. 2: Exploded View Of Front Suspension (1998 Passat) ADJUSTMENTS & INSPECTION WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT section. WHEEL BEARING Wheel bearing is not adjustable. BALL JOINT CHECKING Raise and support vehicle. Inspect ball joints for excessive play and damaged rubber boots. There should be no vertical or horizontal ball joint play. Replace ball joint if any play is present. REMOVAL & INSTALLATION Procedures listed are for base suspension. Plus suspension is similar. HUB & KNUCKLE ASSEMBLY Use exploded view illustration when removing or installing hub and knuckle assembly. See Figs. 1 and 2.

3 LOWER CONTROL ARM & BALL JOINT Removal (Beetle) 1) Raise and support vehicle. Remove wheel. Remove noise insulation panel and left noise insulation. Remove intake air duct between charge air cooler and turbocharger if available. Remove right side insulation. 2) Mark installation position of ball joint bolts on control arm. Remove bolts. 3) Install Hub Puller (3283) and press drive axle out. Ensure that there is sufficient clearance available when pressing axle out. Pull wheel bearing housing together with ball joint out from control arm. Swing wheel together with suspension strut outward and support. 4) Install Ball Joint Puller (3287-A) and press out ball joint. If control arm is to be removed disconnect drive axle from transmission drive flange. Pull wheel bearing housing with ball joint out from control arm. Remove control arm. 5) For vehicles with automatic transmission, push engine/transmission assembly forward using lever. Remove hex bolt and remove control arm. To installation, reverse removal procedure. Removal (Except Beetle & 1998 Passat) 1) Raise and support vehicle. Remove ball joint-to-steering knuckle bolts. Separate ball joint from housing. Leave control arm hanging in mounts at subframe. On vehicles with automatic transmission, engine may have to be lifted slightly to gain access to pivot bolts. 2) If ball joint is to removed, remove ball joint bolts. Remove ball joint. If control arm is to be removed from vehicle, remove stabilizer bar link rod nut, washers, and bushings. Remove pivot bolt and "U" bracket housing inner pivot pin. Slide out control arm. Slide new ball joint into slot in control arm. Install and tighten ball joint bolts. Install lower control arm to subframe. Install ball joint into steering knuckle. To complete installation, reverse removal procedure. Tighten control arm bolts with vehicle on ground. Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS. Check wheel alignment. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT section. Removal (1998 Passat) 1) Raise and support vehicle. Remove wheel. Remove nut from support control arm ball joint, then press joint pin out of tapered seat. Ensure no damage occurs to joint boot. To prevent damage to upper control arm ball joints, support with Engine/Transmission Jack (VGA-1383A) or equivalent to prevent spring from over extending. 2) Remove bolt, ribbed nuts and connecting link. Remove support control arm. Inspection Check lower or support control arm bushings for excessive wear, cracks or contamination. Replace bushings if necessary. To replace bushings, press out worn bushing. Select new bushing and press

4 into position. Ensure bushing does not twist when seating into place. To installation, reverse removal procedure. STRUT ASSEMBLY Removal (Beetle) 1) Raise and support vehicle. Remove wheel. Remove both guide pins from brake calipers. Disconnect and wire caliper aside. Remove connecting link from control arm. Disconnect ABS wheel speed sensor wiring from suspension strut, where applicable. 2) For right side strut only, remove noise insulation panel. Remove intake air duct between charge air cooler and turbocharger, if available. 3) Remove right side noise insulation. Disconnect drive axle from transmission drive flange. Remove bolt and insert Spreader (3424) into slot between wheel bearing housing/suspension strut connection. 4) Turn ratchet 90 degrees and remove ratchet from spreader. Press brake disc in direction of suspension strut by hand to prevent shock absorber tube from canting in wheel bearing housing hole. Pull wheel bearing housing from shock absorber downward. 5) Remove wiper arms. Remove external plenum chamber cover. Remove hex nut from upper shock absorber mount. For disassembly and reassembly of suspension strut, See Fig. 3. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS. Check wheel alignment. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT section. Fig. 3: Exploded View Of Front Suspension Strut (Beetle Shown, Other Models Similar)

5 Removal (Except Beetle & 1998 Passat) 1) Raise and support vehicle. Remove wheel. Disconnect and wire caliper aside. Remove strut-to-steering knuckle bolts. 2) Support front suspension arm and components. Pry strut from steering knuckle. Remove upper strut nuts from inside engine compartment. Remove strut. For disassembly and reassembly of suspension strut, See Fig. 3. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS. Check wheel alignment. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT section. Removal (1998 Passat) 1) Raise and support vehicle. Remove wheel. Remove rubber grommets in plenum chamber. Unbolt suspension strut at body. 2) Pull ABS wheel speed sensor wiring out of retainer on brake caliper. Remove bolts and pull arms out upward. Move swing arm/wheel bearing housing to the side. Remove nut attaching strut to support control arm. Remove suspension strut. For disassembly and reassembly of suspension strut, See Fig. 3. 1) Install suspension strut so that hole in lower spring retainer points to center of vehicle. Bolt suspension strut to support control arm, using a new nut. Insert upper control arm into swing arm and tighten new nut, when tightening press upper control arm downward as far as possible. 2) Insert ABS wheel speed sensor wiring into retainer on brake caliper. Install new nuts for suspension strut and tighten. To complete installation reverse removal procedure. FRONT SUSPENSION ASSEMBLY Removal 1) Raise and support vehicle at center with safety stands. Disconnect brake line and plug openings. Leave flex line in place. Remove stabilizer link rod nut, bushings and washers. 2) Remove tie rod nut. Separate tie rod from steering knuckle. Disconnect inner portion of constant velocity joint from transaxle drive flange. On vehicles with automatic transmission, engine may have to be lifted slightly to gain access to pivot bolts. 3) Remove lower control arm front pivot bolt. Remove "U" shaped bracket bolts at control arm rear pivot. 4) Support suspension assembly. Remove upper strut nuts. Remove suspension assembly from vehicle. To install, reverse removal procedure. Ensure convex side of thrust washer faces pivot bolt head. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS. Check wheel alignment. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT section. WHEEL BEARING Removal (Beetle & 1998 Passat) 1) Remove axle shaft bolt. Remove wheel. Remove and wire aside brake caliper, DO NOT disconnect brake hydraulic line to

6 caliper. Pull ABS wheel speed sensor wiring out of retainer on brake caliper. 2) Remove brake disc. Remove splash plate if available. Pull ABS wheel speed sensor from swing arm/wheel bearing housing. Remove nuts attaching swing arm/wheel bearing housing to support control arm and to locating control arm. 3) Pull out rubber grommet and separate connector. Pull ABS wheel speed sensor wiring from retainers. Guide wiring through opening in swing arm/wheel bearing housing. DO NOT damage rubber grommet. 4) Pull out tie rod end. Remove nut from locating control arm ball joint. Press locating control arm ball joint out of tapered seat. DO NOT damage joint boot. Loosen support control arm ball joint nut, DO NOT remove completely. Press support control arm ball joint out of tapered seat. DO NOT damage joint boot. 5) Pull both control arms out in an upward position. Move swing arm/wheel bearing housing to side and pull axle shaft out of wheel hub. Remove nut from support control arm ball joint. Remove swing arm/wheel bearing housing. 6) For Passat, press wheel hub out of 3" (75 mm) diameter wheel bearing housing using Remover Set (VW-412, VW-416-B, VW-401 and VW-402) and for 3.23" (82 mm) diameter wheel bearing housing using Remover Set (VW-412, , VW-401 and VW-402). For Beetle, press wheel hub out of wheel bearing housing using Remover Set (VW-408A, , 3252, 3253/1 and VW-401). 7) For Passat, press wheel bearing out of 3" (75 mm) diameter wheel bearing housing using Remover Set (VW-412 and VW-519) and for 3. 23" (82 mm) diameter wheel bearing housing using Remover Set (VW-412, VW-432, VW-447-I, 3291/2, VW-402 and VW-401). For Beetle, press wheel bearing out of wheel bearing housing using Remover Set (VW-498-A, VW- 447-I, 3252 and 3253/1). 8) For Passat, press bearing inner race of wheel hub using Remover Set (VW-402, VW-401 and VW-407). For Beetle, pull bearing inner race out of wheel hub using Remover Set (Kukko-18-0, and 3423). 1) For Passat, press wheel bearing into 3" (75 mm) diameter wheel bearing housing using Installing Set (VW-412, 3005, A, 3345 and VW-401) and for 3.23" (82 mm) diameter wheel bearing housing using Installing Set (VW-412, 3124, A, 3345 and VW-401). For Beetle, press wheel bearing into wheel bearing housing using Installing Set (VW-412, VW-432, VW-442 and VW-459/2). 2) For Passat, press wheel hub into 3" (75 mm) diameter wheel bearing housing using Installing Set (VW-412, VW-519 and VW-401) and for 3.23" (82 mm) diameter wheel bearing housing using Installing Set (VW-412, VW-432, VW-447-I and VW-402). For Beetle, press hub into wheel bearing using Installing Set (VW-407 and VW-447-I). 3) Install swing arm/wheel bearing housing into pins of support and locating control arms. Install new self-locking nut. 4) Slide axle shaft outer joint into wheel hub and tighten new bolt hand tight. For Passat, insert both upper control arm ball joint into swing arm/ wheel bearing housing. To complete installation, reverse removal procedure. Removal (Except Beetle & 1998 Passat) 1) Remove axle shaft nut with front wheels on ground. Raise and support vehicle. Allow suspension to hang free. Remove wheel. Remove brake caliper bolts. Remove caliper and wire aside. Remove brake disc screw and remove disc. 2) Disconnect tie rod from steering knuckle. Remove ball joint clamp nut and bolt. Disconnect ball joint from steering knuckle. Remove steering knuckle. 3) Remove 2 wheel bearing circlips. Using Hub Remover (VW 295-A), press wheel bearing out of steering knuckle. See Fig. 4. Using

7 a bearing puller, remove wheel bearing inner race from hub assembly. See Fig. 5. Using Bearing Remover (40-105), press wheel bearing from outboard side of steering knuckle. Fig. 4: Pressing Wheel Bearing Out Of Steering Knuckle Fig. 5: Removing Wheel Bearing Inner Race When installing hub, ensure press adapter contacts inner bearing race only. 1) Press new wheel bearing race onto hub. Using Bearing & Hub Installer (VW 412), and Adapter (VW 511 on 1997 Passat or VW 472/1 on all models except 1997 Passat), press new bearing into steering knuckle from outboard side. Using same installer and adapter, press wheel hub into steering knuckle. See Fig. 6. Apply a small bead of locking compound to axle splines before installing axle into hub. 2) To complete installation, reverse removal procedure. Always replace self-locking axle shaft nut. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS. Check wheel alignment. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT section. Fig. 6: Pressing Wheel Hub Into Steering Knuckle

8 TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Ft. Lbs. (N.m) Axle Bolt M14 Bolt (115) M16 Bolt (190) Axle Nut Except 1997 Passat (50) plus 30 degree turn 1997 Passat (90) plus 1/8 turn Axle Shaft-To-Transaxle Bolt Beetle (40) Except Beetle & 1998 Passat (45) 1998 Passat 8 X (40) 10 X (80) Ball Joint Nut Beetle (20) plus 1/4 turn Except Beetle (35) Ball Joint-To-Control Arm Bolt (45) Caliper Pin Bolt Beetle (27.5) Except Beetle (25) Control Arm Front Bushing Bolt Beetle (70) plus 1/4 turn Except Beetle (50) plus 1/4 turn Control Arm-To-Subframe Rear Bushing Bolt Beetle (70) plus 1/4 turn Except Beetle (65) Locating Control Arm Nut (100) Strut Piston Rod Nut Except 1998 Passat (60) 1998 Passat (50) Strut-To-Steering Knuckle Bolt Beetle (50) plus 1/4 turn Except Beetle (95) Strut-To-Support Control Arm (90) Subframe Bolts Beetle (100) Except Beetle & 1998 Passat Long Bolts (70) plus 1/4 turn Short Bolts (65) 1998 Passat (110) Subframe-To-Locating Control Arm (90) Subframe-To-Support Control Arm (90) Sway Bar Clamps (25) Sway Bar Link (25) Tie Rod Castle Nut (35) Vibration Damper Bolts (25) Wheel Lug Bolt Beetle & 1998 Passat (120) Except Beetle & 1998 Passat (110) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ END OF ARTICLE

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