Volkswagen Phaeton - Volkswagen Technical Site

Transcription

Rear axle (front and all wheel drive), servicing
Стр. 1 из 2
Volkswagen Phaeton
42 - 2
Note :

If components with bonded rubber bushings were
replaced or bolts/nuts on these components were
loosened, corresponding wheel suspension must be
lifted into curb weight position 40-2, Wheel
bearing, lifting to curb weight position .

Always replace self-locking nuts.

Always replaced corroded nuts and bolts.
I - Subframe, assembly overview 423, I - Subframe, assembly overview
II - Link, tie rod, air spring strut,
assembly overview 42-4, II - Link, tie
rod, air spring strut, assembly
overview
III - Wheel bearing, assembly overview
42-5, III - Wheel bearing, assembly
overview
IV - Driveshaft, assembly overview
42-6, IV - Drive axle, assembly
overview
Стр. 2 из 2
I - Subframe, assembly overview
Стр. 1 из 8
42 - 3
On vehicles with front wheel drive, only
subframe and mounting components are
installed.

Final drive

Removing and installing
Repair Manual, Automatic
Transmission, Repair Group 39, Rear
final drive, removing and installing

Hex bolt

Washer

Hex nut

40 Nm

Self-locking

Always replace
Hex bolt

130 Nm plus an additional 90
( 1 / 4 turn)

Always replace

Washer

Subframe

Steel version
This version is replaced in 2004
with the aluminum version

Application Electronic Parts
Catalog "ETKA"
Subframe

Aluminum version

Catalog "ETKA"
Hex socket head bolt

55 Nm

Washer

Hex nut

40 Nm

Self-locking

Always replace
Cross member
Стр. 2 из 8

Hex bolt

Final drive support

For vehicles with V6 and W12
drivetrain

Catalog "ETKA"
Final drive support

For vehicles with V8 and V10
drivetrain

Catalog "ETKA"
Hex bolt

( 1 / 4 turn)

Always replace
Multi-point socket head bolt

20 Nm
Brace

Between rear final drive and
final drive support

For vehicles with V8 and V10
drivetrain

Catalog "ETKA"
Subframe, removing and installing
Стр. 3 из 8
Special tools, testers and auxiliary items
required

Engine/transmission jack V.A.G
1383 A

Tightening strap T10038

Torque wrench V.A.G 1332
Removing
- Brake pedal loading device V.A.G 1869/2 .
- Remove rear wheels.
- Remove rear cover on rear bumper
Стр. 4 из 8
Repair Manual, Body Exterior, Repair Group 63, Bumper
cover, removing and installing
.
- Disconnect all electrical wires from body to rear axle.
Note:

Secure vehicle to hoist to continue procedure.
- Remove plugs (2 per vehicle side).
- Secure vehicle to hoist lifting arm with Tensioning Strap
T10038 .
- Remove rear section of exhaust system
Repair Manual, Engine Mechanical, Fuel Injection
Ignition, Repair Group 26, Exhaust system parts, removing
and installing
- Disconnect brake lines.
- Remove brake cable from rear axle
Repair Manual, Brake System, Repair Group 46, Rear
brake cable, removing and installing
.
Стр. 5 из 8
- Remove heat shield - 1 - from spare wheel well - arrows .
- Remove drive shaft from rear final drive and tie up to body
Repair Manual, Automatic Transmission, Repair Group
39, Drive shaft, removing and installing
.
- Place engine/transmission jack V.A.G 1383 A with
Support 1359/2 below final drive.
- Remove nut - 1 - , remove bolt - 2 - and press air spring
strut - 3 - to center of vehicle.
- Remove subframe from body.
- Slowly lower rear axle.
Installing
Installation is in reverse order of removal, note the
following:
- Tighten subframe with bolts originally installed. Replace
these with new bolts after vehicle alignment.
- Tighten bolts originally installed to specified torque
Стр. 6 из 8
Стр. 7 из 8
without additional tightening.
- Tighten drive shaft to rear final drive
Repair Manual, Automatic Transmission, Repair Group
39, Drive shaft, removing and installing
.
- Attach brake caliper to brake carrier
brakes, servicing; Disc brakes
.
- Adjust parking brake
brakes, servicing; Disc brakes; Parking brake, adjusting
.
- Bleed brake system
Repair Manual, Brake System, Repair Group 47, Brake
system, bleeding
.
- Install wheels and tighten
- Perform vehicle alignment
44-2, Wheel mounting .
44-3, Wheel alignment .
Tightening torque
Bumper to body
Repair Manual, Body Exterior, Repair Group 63, Bumper cover,
removing and installing
Exhaust system to
body
Repair Manual, Engine Mechanical, Fuel Injection Ignition, Repair
Group 26, Exhaust system components, removing and installing
Drive shaft to body
and final drive
Стр. 8 из 8
Repair Manual, Automatic Transmission, Repair Group 39, Drive
shaft, removing and installing
Air spring damper to
lower link
80 Nm plus an additional 1 / 4 turn (90
1)
2)
Subframe to body
1)
1) Always
use new nuts and bolts
2) Tighten
bolts and nuts in curb weight position
)
II - Link, tie rod, air spring strut, assembly overview
Стр. 1 из 31
42 - 4
Note :

If components with bonded rubber bushings were
replaced or bolts/nuts on these components were
loosened, corresponding wheel suspension must be
lifted into curb weight position 40-2, Wheel
bearing, lifting to curb weight position .

Welding and straightening work on supporting or
wheel carrying components of the suspension is not
permitted.

Always replace self-locking nuts.

Always replaced corroded bolts and nuts.

Wheel bearing housing

42-5, Wheel bearing housing,

Wheel bearing unit, removing
and installing
42-5, Wheel
bearing unit, removing and
installing

Eccentric washer

Hex nut

95 Nm

Self-locking

Always replace
Coupling rod

For tie rod to lower link

42-4, Tie rod to lower link
connecting links, removing
and installing

Washer

Hex nut

95 Nm

Self-locking

Always replace
Hex nut

80 Nm plus an additional 1 / 4
turn (90

)

Self-locking

Always replace
Hex nut

Стр. 2 из 31
turn (90

Self-locking

Always replace
Hex head bolt

Lift the wheel bearing housing
before fastening

Always replace
Lower link

42-4, Lower link, removing
and installing

Bracket

Hex nut

turn (90

)
)

Self-locking

Always replace

Lift wheel bearing housing
before fastening
Hex nut

Self-locking

Always replace
Hex head bolt

turn (90

Always replace

before fastening
Hex head bolt
Стр. 3 из 31

turn (90

Always replace

before fastening

Bracket

Hex bolt

before fastening

replace after every removal
Hex bolt

Self-locking

Always replace
Connecting link for vehicle level
sensor
Do not pull connecting link
from ball joint!
Hex bolt

Always replace
Hex nut

10 Nm
10 Nm
Coupling rod

For stabilizer bar to lower link

42-4, Stabilizer bar to lower
link connecting links,
Стр. 4 из 31

25 Nm

Stabilizer bar clamp

Stabilizer bar

42-4, Stabilizer bar, removing
and installing
Hex bolt

turn (90

Always replace

Cable channel

Hex bolt

turn (90

)
Always replace
Upper link

)
42-4, Upper link, removing
and installing
Hex nut

Self-locking

Always replace
Eccentric bolt

For toe adjustment

Bolt

Tie rod
Стр. 5 из 31

42-4, Tie rod, removing and
installing

Eccentric washer

Hex nut

95 Nm

Self-locking

Always replace

before fastening
Air spring strut

The air spring damper
protective boot must not
sustain any indentations!

42-4, Air spring strut,
Hex bolt

turn (90

Always replace
Hex nut

Self-locking

Always replace
Eccentric bolt

For camber adjustment
Air spring strut, removing and installing
Special tools, testers and auxiliary items required
Стр. 6 из 31

Removing
During assembly work, make sure that no indentations
form on boot of air spring strut!
- Remove level control system sensor bolt - 2 - from lower
link.
- Remove wheel housing liner
Стр. 7 из 31
Repair Manual, Body Exterior, Repair Group 66, Wheel
housing liner, removing and installing; Rear wheel housing
liner
.
Left rear
- Remove air line (yellow) from reservoir. Seal off both air
connections after air is released.
- Remove reservoir - A - by removing air line - 1 - and hex
nuts - arrows - .
- Disconnect damper adjustment switching valve electrical
connector.
Right rear
- Remove hex screw - 1 - and move tank - B - as far down
as possible.
- Disconnect damper adjustment switching valve electrical
connector.
- Remove air line from air spring strut and seal off both
connectors.
Continued for all vehicles
The wheel bearing housing must be pulled down slightly so
Стр. 8 из 31
Стр. 9 из 31
that the strut can be removed.
If air spring strut is to be replaced, first read the following
42-4, Air spring strut, filling .
Installing
Installation is in reverse order of removal, note the
following:
During assembly work, make sure that no indentations
form on boot of air spring shock absorber!
- Insert air spring strut and tighten.
- Attach air spring strut to link.
- Raise wheel bearing housing to tighten.
- Check basic setting of level control system Vehicle
Diagnosis, Testing and Information System VAS 5051 .
Tightening torque
Connecting link from vehicle
level sensor to lower link
10 Nm
Air spring strut to lower link
1)
)
2)
Wheelhouse liner to body
Repair Manual, Body Exterior, Repair Group 66,
Wheelhouse liner, removing and installing; Rear wheelhouse
liner
Air line to air spring strut
5 Nm
Reservoir to body
9 Nm
Air spring strut to body
30 Nm
1) Always
2) Tighten
Air spring strut, filling

Adapter T10157

Air suspension strut charger VAS 6231 , not
illustrated

Steel gas cylinder filled with Argon or Corgon, not
depicted
Note:

Air spring struts are supplied as replacement parts
with a minimum pressure. By sitting in storage for
extended periods this minimum pressure can
diminish (just like a tire). Before the air spring strut is
removed from its packaging, this minimum pressure
must be controlled and restored by "refilling" . Without
this necessary refilling, folds can form in the underfilled air spring boot. These folds cause damage
which can lead to premature failure.
- Remove cover from packaging.
- Remove union bolt - arrow - from residual pressure
retaining valve. Illustration shows front air spring strut.
- Close steel gas bottle pressure valve.
Стр. 10 из 31
Стр. 11 из 31
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
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- Become familiar with relevant rules for prevention of
accidents for pressurized containers and technical gases.
- Connect air spring filler unit VAS 6231 and adapter
T10157 as shown in illustration.

Air spring strut in packaging
Steel gas bottle for argon, corgon with gauges
Air spring filler unit VAS 6231
Adapter T10157
- Set flow rate limiter gauge to 2.0 L/min - arrow - .
- Fill gas into air spring strut using several individual
pressure bursts.
The display only shows a correct gas pressure if the
"oscillatory pressure" of the residual pressure retaining
valve is overcome. The "oscillatory pressure" is at approx.
3.5 bar. When the display reaches 3.5 to 4.5 bar, air spring
damper is sufficiently filled with gas.
- Make sure gas pressure does not exceed 4.5 bar when
filling.
- Disconnect air spring filler unit VAS 6231 from adapter
T10157 . This dissipates the gas above an internal
pressure of 3.5 bar.
Minimum pressure is reproduced, air spring strut can be
removed from packaging.
- After installation, first drive the vehicle at high ride height
and then at normal ride height. Repeat this sequence once
more.
By moving the ride height settings twice, the majority of the
gas is exchanged with filtered air from the air supply motor.
- Install air spring strut
42-4, Installing .
Stabilizer bar, removing and installing

Стр. 12 из 31

Removing
- Remove wheels.
- Remove heat shield - 1 - from spare wheel well - arrows .
- Remove stabilizer bar - 1 - from left and right connecting
links - arrow - .
- Remove tie rod
42-4, Removing .
Стр. 13 из 31
- Remove bolts - arrows - evenly on both sides.
- Turn stabilizer bar so that clamps - 1 - can be guided out
of notches on subframe.
- Remove clamps - 1 - from stabilizer bar brackets.
- Turn stabilizer bar so that connecting link mounts face
downward.
- Guide stabilizer bar out toward left.
Installing
- Guide in stabilizer bar from left over exhaust system.
- Place clamps on stabilizer bar bracket. Make sure longer
clamp tab faces opposite to direction of travel.
Стр. 14 из 31
- Turn stabilizer bar in subframe so that clamps - 1 - project
into subframe notches.
- Install bolts - arrows - hand-tight evenly on both sides
and tighten to specified torque.
- Move air spring strut - 3 - outward on link bracket and
upward.
- Insert bolt - 2 - and tighten nut - 1 - to specified torque.
- Install tie rod
42-4, Installing .
- Tighten stabilizer bar - 1 - at left and right connecting links
- arrow - .
Стр. 15 из 31
Стр. 16 из 31
- Attach heat shield - 1 - to spare wheel well - arrows - .
- Install wheels and tighten
Tightening torque
Air spring strut to upper link
1)
)
)
2)
Connecting link to stabilizer bar
1)
2)
Stabilizer bar to body
1) Always
2) Tighten
Upper link, removing and installing

Removing
25 Nm
- Remove wheel.
- Remove brake caliper with brake carrier and brake disc
caliper, removing and installing
.
- Remove bolts - 1 - and remove cover plate - 2 - from
wheel bearing housing.
- Remove cable channel - 1 - from upper link - 2 - .
Стр. 17 из 31
- Mark position of eccentric washer - 3 - to wheel bearing
housing, e.g. using a felt tip pen.
- Remove nut - 4 - and remove bolt - 5 - from wheel bearing
housing.
- Remove nut from bolt - 1 - for securing upper link - 2 - to
subframe.
- Remove bolt - 1 - until it comes in contact with fuel tank 4 - - arrow - .
- Lightly press bolt - 1 - in direction of - arrow - downward
toward subframe while moving it slightly toward upper link.
- Remove bolt - 1 - .
- Move upper link toward wheel bearing housing until it
comes out of subframe.
- Remove upper link behind lower link.
Installing
- Insert upper link in subframe.
Стр. 18 из 31
- Insert bolt - 1 - at a slight angle in upper link and then
push in direction of - arrow - toward fuel tank - 4 - .
- Insert bolt - 1 - straight into upper link and secure with a
new nut.
- Install bolt - 5 - together with an eccentric washer - 3 - and
nut - 4 - .
- Install cable channel - 1 - to upper link - 2 - .
- Install eccentric washer - 3 - to marking applied to wheel
bearing housing and tighten nut - 4 - to specified torque.
Стр. 19 из 31
Стр. 20 из 31
upward.
- Install bolt - 2 - and tighten nut - 1 - to specified torque.
- Tighten upper link and subframe bolted connection to
specified torque.
- Place cover plate - 2 - on wheel bearing housing and
secure with screws - 1 - .
- Install brake disc and brake caliper with brake carrier
.
- Install wheel and tighten
Tightening torque
Upper link to subframe
1)
2)
Upper link to wheel bearing housing
95 Nm
)
Стр. 21 из 31
1)
2)
Air spring strut to upper link
1)
2)
Cover plate to wheel bearing housing
1) Always
2) Tighten
Tie rod, removing and installing

Removing
- Remove wheel.
- Mark location of eccentric washer to subframe, e.g. with a
felt-tip pen.
- Remove nut - 2 - , remove eccentric washer and eccentric
bolt.
- Pivot tie rod - 3 - down.
10 Nm
)
Стр. 22 из 31
- Remove nut - 1 - from tie rod.
- Lightly press brake caliper upward and at the same time,
remove tie rod from connecting link/wheel bearing housing
mount.
Installing
- Lightly press brake caliper upward and place tie rod in
connecting link/wheel bearing housing mount.
- Pivot tie rod - 3 - upward in subframe.
- Insert eccentric bolt and eccentric washer.
- Turn eccentric bolt to marking applied to subframe and
tighten nut - 2 - to specified torque.
- Install nut - 1 - to tie rod and tighten to specified torque,
counter holding at tie rod hex head, if necessary.
Tightening torque
Tie rod to subframe
1)
95 Nm
2)
Tie rod to wheel bearing housing
1)
2)
1) Use
new nut
2) Tighten
Stabilizer bar to lower link connecting links, removing
and installing
95 Nm

Removing
- Remove wheel.
- Remove bolt - 1 - .
- Disconnect connecting link/lower link bolted connection 2-.
- To remove bolt from connecting link, push wheel bearing
housing downward.
- Remove connecting link - 3 - .
Installing
Стр. 23 из 31
Стр. 24 из 31
- Attach connecting link - 3 - to lower link.
- Insert a new bolt - 2 - for this and at the same time, attach
brake line bracket - 4 - .
- Hand-tighten new nut.
- Screw connecting link to stabilizer bar with a new bolt - 1 .
- Tighten connecting link/stabilizer bar bolt - 1 - to specified
torque.
- Tighten connecting link/lower link nut to specified torque.
Tightening torque
Coupling rod to stabilizer
1)
)
)
2)
Connecting link to lower link
2)
3)
1) Use
new bolt
3) Use
new bolt and nut
2) Tighten
bolts in curb weight position
Tie rod to lower link connecting links, removing and
installing

Removing
Стр. 25 из 31
- Remove wheel.
42-4, Removing .
- Remove tie rod
- Remove nut - 1 - .
- Remove bolt - 2 - from lower link/connecting link.
- Remove connecting link - 3 - from lower link.
Installing
- Insert connecting link - 3 - in lower link.
- Insert bolt - 2 - and hand-tighten nut - 3 - .
- Install tie rod
42-4, Installing .
- Tighten bolt - 2 - to specified torque.
Tightening torque
Connecting link to lower link
1)
2)
1) Use
new bolt and nut
2) Tighten
)
Lower link, removing and installing

Removing
- Remove wheel.
housing downward.
Стр. 26 из 31
- Remove bolt from - 2 - level control system sensor.
- Remove brake line bracket bolt - 4 - .
.
Стр. 27 из 31
- Remove bolted connection nuts - 1 to 4 - from lower link 6-.
- Remove screw - 5 - .
- First remove bolt - 3 - and then bolt - 4 - .
- Remove lower link from notches on subframe and swing
downward.
- Remove bolt - 1 - and disengage lower link - 2 - from
connecting link - 3 - .
Installing
- Engage lower link - 2 - in wheel bearing housing and
control link - 3 - .
- Insert bolt - 1 - and secure with a new nut.
- Pivot lower link - 2 - upward and press into notches in
subframe.
Стр. 28 из 31
- First insert bolt - 3 - and then bolt - 4 - .
Note:

To insert bolt, holes in bracket must be aligned with
subframe.
- Move tie rod downward and place bolt - 5 - in lower link
and connecting link.
Note:

To insert bolt, trapezoidal link holes must be aligned
with connecting link.
upward.
- Install brake line bracket bolt - 4 - .
Стр. 29 из 31
- Tighten bolted connection nuts - 1 to 4 - .
secure with bolts - 1 - .
.
- Connect connecting link/lower link bolted connection - 1 and tighten to specified torque.
- Install bolt in - 2 - level control system sensor.
Стр. 30 из 31
Стр. 31 из 31
Tightening torque
Lower link to subframe
1)
)
2)
Lower link to wheel bearing housing
1)
)
2)
Level control system sensor connecting link to lower
link
1)
10 Nm
)
2)
Stabilizer bar connecting link to lower link
1)
)
2)
Tie rod connecting link to lower link
1)
)
2)
1) Use
new bolt and nut
2) Tighten
10 Nm
Стр. 1 из 16
42 - 5

Wheel bearing housing

42-5, Wheel bearing housing,

Servicing 42-5, Wheel
bearing housing bonded
rubber bushings, replacing
Wheel bearing

Replacing 42-5, Wheel
bearing, replacing
Slide washer

Always replaced together with
wheel bearing Item - 2 - or
wheel hub Item - 4

Wheel hub

Replacing 42-5, Slide
washer, prying out
Replacing 42-5, Wheel
bearing, replacing
Wheel bearing unit

Consists of wheel bearing
Item - 2 - , slide washer
Item - 3 - and wheel hub
Item - 4 -

42-5, Wheel bearing unit,

Shield plate

Bolt, 10 Nm

Hex socket head collar bolt

200 Nm plus an additional
180 ( 1 / 2 turn)

Always replace

before fastening

Bolt, 23 Nm

Cover

Drive axle

42-6, Drive axle, removing
and installing

Servicing
servicing

Catalog "ETKA"
Bolt, 70 Nm
42-6, Drive axle,
Стр. 2 из 16

First pre-tighten to 10 Nm
then tighten diagonally to
specified torque

Backing plate

Stub axle

Bonded rubber bushing

Bearing with large contact
surface

Replace with bonded rubber
bushing Item - 16 -

Installing 42-5, Wheel
Bonded rubber bushing

Bearing with small contact
surface

Replace with bonded rubber
bushing Item - 15 -

Installing 42-5, Wheel
Cap bolts

Follow tightening sequence:

turn

Rotate bolt back 360

( 1 / 4 turn)

Always replace
Wheel bearing housing, removing and installing
Стр. 3 из 16

Стр. 4 из 16
Removing
- Remove hex socket head collar bolt from drive axle
6, Drive axle, removing and installing .
42-
- Remove bolt - 1 - from speed sensor - 2 - .
- Pull speed sensor out from wheel bearing housing.
.
- Remove tie rod - 2 -
42-4, Removing .
- Mark location of bolted connection eccentric bolt - 1 - to
wheel bearing housing - 4 - , e.g. with a felt-tip pen.
- Remove bolt - 1 - from upper link.
Стр. 5 из 16
- Remove bolt - 3 - from lower link.
- Remove wheel bearing housing - 4 - from drive axle and
out of suspension.
- If wheel bearing unit should be removed, then clamp
wheel bearing housing in vise with protective covers.
- To remove wheel bearing unit, remove bolts - arrows - .
Installing
- Place wheel bearing housing - 4 - on drive axle.
- Insert wheel bearing housing - 4 - on upper link and in
lower link.
- Install new bolts - 1 - and - 3 - and secure with new nuts
- Install tie rod - 2 -
42-4, Installing .
- Turn bolted connection eccentric washer - 1 - to mark
placed on wheel bearing housing and tighten nut to
specified torque.
Note:

Do not turn eccentric bolt more than 90 left or right
(that is smallest to largest possible adjustment).
Стр. 6 из 16
- Tighten bolt - 3 - to specified torque.
secure with bolts - 1 - .
upward.
.
Стр. 7 из 16
Стр. 8 из 16
- Insert speed sensor - 2 - in wheel bearing housing and
tighten bolt - 1 - .
- Tighten drive axle hex socket head collar bolt
6.
Topic 42-
Tightening torque
Lower link to wheel bearing housing
1)
( 1 / 4 turn)
2)
Upper link to wheel bearing housing
95 Nm
1)
2)
1)
2)
1) Use
10 Nm
new bolt and nut
2) Tighten
Wheel bearing unit, removing and installing

Removing
- Remove axle pins or drive axle
removing and installing .
42-6, Drive axle,
( 1 / 4 turn)
Стр. 9 из 16
.
- Remove bolts - 1 - .
- Remove wheel bearing unit from wheel bearing housing.
Installing
- Insert wheel bearing unit in wheel bearing housing and
tighten bolts - 1 - .
.
- Install axle pins or drive shaft
Topic 42-6 .
Tightening torque
Wheel bearing unit to wheel bearing housing
1)
Follow tightening sequence:
1st, 80 Nm plus an additional 135
Стр. 10 из 16
2nd, turn bolt back 360
3rd, 80 Nm plus an additional 90
1) Use
new botls
Wheel bearing, replacing
required

Thrust plate VW 401

Thrust plate VW 402

Punch VW 407

Punch VW 412

Thrust pad VW 511
( 1 / 4 turn)

Press tube 30-100

KUKKO separating tool 17/2 Abbildung 3

Assembly tool T40089/2
Pressing out hub
Стр. 11 из 16
- Press out wheel hub.
- Insert separating tool in bearing inner race ring groove arrow - and pretension threaded spindle.
Note:

Use a commercially-available separating tool , for
example Kukko 17/2 .
This deforms slide washer and it must be replaced.
- Press bearing inner race of wheel hub.
Стр. 12 из 16
Pressing off bearing inner ring
Slide washer, prying out
- Carefully pry out old slide washer - 1 - with a screwdriver.
Wheel hub, pressing in
- Position new slide washer on wheel hub.
Стр. 13 из 16
- Install special tools as shown in illustration.

Press piece VW 473
Assembly tool T40089/2
Slide washer
Wheel hub
Thrust plate VW 401
Note:

Slide washer must be pressed on up to wheel bearing
hub radius.
- Press wheel hub into wheel bearing to stop.
Wheel bearing housing bonded rubber bushings,
replacing
Стр. 14 из 16

Assembly tool 3292

Press piece 3292/3
Observe installation position:
Bonded rubber bushing - 1 - with larger contact surface
faces toward wheel bearing housing side - arrow - .
Bonded rubber bushing - 2 - with smaller contact surface
faces away from wheel bearing housing.
- Insert new bearing into wheel bearing housing with thrust
pieces 3292/3 and threaded spindle 3292 .
Note:
Стр. 15 из 16

Do not use lubricant!

Carefully insert bearing so that it does not tilt.
- Screw thrust pieces together to stop.
Outer sleeve collar on both bearings must contact
Стр. 16 из 16
IV - Drive axle, assembly overview
Стр. 1 из 24
42 - 6

Hex socket head collar bolt

200 Nm plus an additional
180 ( 1 / 2 turn)

Vehicle must be standing on
the ground when
loosening/tightening

Always replace
Outer constant velocity joint

Replace only as a unit

Checking 42-6, Outer
constant velocity (CV) joint,
checking

Driving off 42-6, Outer
constant velocity joint,
servicing

Installing: Drive onto shaft
using plastic hammer until
compressed circlip seats.

Circlip must lie in joint
chamfer when guiding in,
guide with pliers if necessary.
Clamp

Always replace

Tensioning 42-6, Clamp
large clamping sleeve to outer
joint
Outer constant velocity
protective joint boot

Check for tears and chafing,
replace if necessary
Circlip

Always replace

Insert in shaft groove

Axle shaft

Clamp

Always replace

small clamping sleeve to inner
joint
Protective boot for inner
constant velocity joint

Check for tears and chafing,
replace if necessary

Axle shaft must be cleaned
before new protective joint
boot is installed

Lightly lubricate axle shaft
Стр. 2 из 24
profile before installing
protective joint boot

Clamp

Always replace

large clamping sleeve to outer
joint
Cover

Carefully drive off using drift

Before installing on constant
velocity joint, coat sealing
surface with D-3

Adhesive surface must be
free of oil and grease

Pre-tighten to 10 Nm in
diagonal sequence

Tighten to 70 Nm

Always replace

Backing plate

Inner constant velocity joint

Replace only as a unit

Checking 42-6, Inner
constant velocity (CV) joint,
checking

Pressing off 42-6, Inner CV
joint, servicing

Pressing on
Circlip

Topic 42-6
Always replace
Gasket

Replacing. Pull off protective
Стр. 3 из 24
foil and stick into joint.

Cover

Pry out with screwdriver
42-6, Inner CV joint, servicing

Always replace

Replace seal before attaching
to CV joint Item - 15 -

Pressing on
Topic 42-6
Drive axle, removing and installing

engine/transmission jack V.A.G 1383 A

Removing
Стр. 4 из 24
- Only loosen hex socket head bolt - arrow - 90
otherwise wheel bearing is damaged.
Стр. 5 из 24
,
Warning!
When loosening collar bolt, vehicle must stand on
wheels -risk of accident-.
- Remove wheel.
- Install all 4 wheel bolts hand-tight.
- Activate parking brake.
- Remove collar bolt.
If collar bolt is loose or removed, wheel bearings must
not be loaded.
If bearings are loaded by the vehicles own weight the
wheel bearing will be damaged. The wheel bearings
will be stressed and the life expectancy reduced.
If a vehicle that has a drive axle removed is to be moved,
an outer CV joint must be installed in place of the drive axle
and be tightened to 200 Nm. Otherwise, wheel bearing will
be damaged.
Стр. 6 из 24
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru
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- Remove bolts - 2 - and cover.
- Remove bolts - 1 - .
- Loosen parking brake.
housing downward.
- Remove bolt from - 2 - level control system sensor.
- Remove brake line bracket bolt - 4 - .
- Loosen bolted connection nuts - 1 and 2 - from lower link
-6-.
- Remove bolted connection bolts - 3 and 4 - .
- Remove lower link from notches on subframe and swing
downward.
- Loosen double clamp and retainers on exhaust system
center muffler and lower this as much as possible
and installing
.
- Push wheel bearing housing towards outside in order to
remove drive axle from flange on transmission rear axle.
- Move drive axle inward until it can be removed from wheel
hub.
- Remove drive axle from vehicle behind lowered lower link.
Стр. 7 из 24
Installing
- Insert drive axle in vehicle behind lowered link.
- Insert drive axle in wheel hub to stop.
- Push wheel bearing housing towards outside in order to
insert drive axle in flange on transmission rear axle.
- Pivot lower link upward into notches on subframe and
secure with new bolts and nuts - 1 and 2 - .
- Attach brackets on exhaust system center muffler to
vehicle underbody and fasten double clamp to designated
position
and installing
.
- Align drive axle holes and flange shaft/transmission to
Стр. 8 из 24
each other.
- Install bolts - 1 - and tighten to specified torque.
- Insert cover and combi-bolts - 2 - and tighten to specified
torque.
upward.
- Install brake line bracket bolt - 4 - .
- Tighten bolted connection nuts - 1 to 4 - to specified
torque.
- Connect connecting link/lower link bolted connection - 1 -
Стр. 9 из 24
tighten to specified torque without additional tightening.
- Install bolt - 2 - in level control system sensor.
- Activate parking brake.
- Tighten drive axle collar bolt to 200 Nm.
- Tighten collar bolt to specified additional torque angle of
180 .
Warning!
When tightening collar bolt to additional torque angle,
vehicle must be standing on wheels -risk of accident-.
Drive axle, servicing
required

Thrust plate VW 401
Стр. 10 из 24

Thrust plate VW 402

Punch V 409

Punch VW 412

Support sleeve VW 522

Clamp 40-204 A

Assembly tool T10065 can also be
used instead of clamp 40-204 A .
required

Bracket 2036/1
Стр. 11 из 24

Sleeve 3144

CV joint boot clamp tool V.A.G
1275

CV joint boot clamp tool V.A.G
1682

Assembly tool T10065

Sealant D 454 300 A2

Circlip pliers (commerciallyavailable)
Inner CV joint, servicing
Inner CV joint, removing
- Secure drive axle with protective covers in vise.
- Pry off cap, e.g. with a screwdriver.
Стр. 12 из 24
- Remove sealing ring - arrow - .
- Drive protective joint boot cap under with a brass or
copper drift.
Note:

Clamping sleeves must not be loosened.
- Remove circlip.
- Press inner CV joint off of drive axle with special tool
shown in illustration.
- Open small clamping sleeve on drive axle and remove
protective joint boot from drive axle.
Inner CV joint, installing
Стр. 13 из 24
- Apply sealant - hatched surface - to clean surface on
inner side of protective joint boot cover. Sealant bead:
unbroken, diameter 2 to 3 mm, skirting area around inner
holes - arrow - .
- Use sealant D 454 300 A2 for this.
- Slide protective joint boot with small clamping sleeve on
drive axle.
Shaft, protective joint boot and cap contact surfaces must
be free of grease.
- Press on joint until stop.
Chamfer on inner diameter of ball hub (splines) must face
contact shoulder of drive axle.
Use special tool shown in illustration.
You can also use assembly tool T10065 instead of clamp
40-204 A .
Clamp 40-204 A or assembly tool T10065 and clamping
surfaces on drive axle must be free of grease.
Circlip must be replaced.
Стр. 14 из 24
- Install circlip.
- Check circlip for correct seating.
- Before installing cover, apply 60 grams of drive axle
grease in CV joint through ball paths.
Make sure you do not damage sealant bead.
- Align cover with bolts - arrows - to bolt holes.
It must be aligned exactly because it cannot be aligned
after driving on.
- Drive cover on with a plastic hammer.
- Wipe away any sealant leaking out.
- Apply 60 grams of joint grease to CV joint through ball
paths.
- Lubricate contact surfaces for sealing ring.
Стр. 15 из 24
- Remove adhesive foil from seal and adhere to CV joint.
- Align new cover - A - to bolt holes.
It must be aligned exactly because it cannot be aligned
after pressing on.
- Press cover - A - on with special tool shown in illustration.
Flat steel in an appropriate size can be used instead of
bracket 2036/1 .
- Position protective joint boot in outer groove - arrow 2 - .
Inner groove - arrow 1 - must remain visible "identifying
groove" (for correct installation of protective joint boot).
Стр. 16 из 24
Clamp large clamping sleeve to outer joint
- Use CV joint boot clamp tool V.A.G 1682 as shown in
illustration. Make sure that the jaws of the tension clamp
seat in the corners - arrows B - of hose clip.
- Tighten hose tie by turning spindle using a torque wrench
(do not bend tensioning clamp).
Note:

A stainless steel clamp must be used due to the
hardness of the CV boot material (compared to
rubber). This clamp can only be tensioned using the
CV joint boot clamp tool V.A.G 1682 .

Torque specification: 25 Nm

Use torque wrench - C - with a range of 5 to 50 Nm
(e.g. V.A.G 1331 ).

Be sure thread of spindle - A - of clamp tool moves
freely. Grease with grease MOS 2 if necessary.

If does not move freely, e.g. due to dirt in thread,
required clamp tension will not be achieved at
specified torque.
Стр. 17 из 24
Clamp small clamping sleeve to inner joint
Inner constant velocity (CV) joint, checking
In order to replace grease in case of strong soiling, joint
must be disassembled and if journal surfaces and balls
must be checked for wear and damage.
Disassembling
Note:

Ball hub and joint are paired and should be identified
before removal. Do not interchange cage allocation.
- Pivot ball hub and ball cage.
- Press out ball joint housing in direction of - arrow - .
- Press balls out of cage.
Стр. 18 из 24
- Flip out ball hub from ball cage via running path of ball arrows - .
- Check joint housing, ball hub, ball cage and balls for
indentations (pitting) and signs of seizure.
Note:

Excessive circumferential backlash in joint makes
itself noticed via tip-in shock. In such cases the joint
must be replaced. Flattening and running marks of
balls are no reason to replace joint.
Assembling
- Insert ball hub into ball cage via two chamfers. The hub
can be installed in any position. Press balls into cage.
- Insert hub with cage and balls at right angle to joint.
Стр. 19 из 24

When inserting make sure that the wide space - a on joint housing is aligned with the narrow space - b on hub after swiveling in.

Chamfer on inner diameter of wheel hub (splines)
must face toward drive axle.
- Install ball hub, whereby the hub must be swiveled out of
cage - arrows - far enough to allow balls to fit into ball
tracks.
Стр. 20 из 24
- Press cage firmly - arrow - until hub swings fully in
position.
Constant velocity joint, checking for function
Constant velocity joint is properly assembled, if ball hub
can be slid back and forth by hand over whole
compensation length.
- Press grease into joint body.
Outer constant velocity joint, servicing
Outer CV joint, removing
- Secure axle shaft with protective covers in vise clamp.
- Open both clamping sleeves and remove protective joint
boot from outer joint.
- Strike a copper or brass drift - A - on CV joint inner race
with a hammer.
- Remove joint and protective joint boot.
Outer CV joint, installing
- Slide joint protective boot onto drive axle.
Стр. 21 из 24
Joints and protective joint boots must be free of grease.
1 - Circlip (snap ring), must be replaced.
- Position protective joint boot between - arrows - .
- Apply 40 grams of joint grease to inside of joint.
- Screw old drive shaft bolt into joint as shown in
illustration.
- Drive joint onto shaft with plastic hammer until circlip
engages.
- Apply 50 grams of joint grease in boot side of joint.
Install clamping sleeve on outer joint and clamp
- Install clamping sleeve on outer joint.
Стр. 22 из 24
- Bleed protective joint boot.
- Tension clamp using pliers V.A.G 1275 .
Outer constant velocity (CV) joint, checking
In order to replace grease in case of strong soiling, joint
must be disassembled or if journal surface of balls must be
checked for wear and damage.
Disassembling
- Before disassembling mark ball hub position in relation to
ball cage and housing using an electric scriber or oil stone.
- Swivel ball hub and ball cage.
- Remove balls one after another.
- Turn cage, until two rectangular windows - arrow contact joint body.
- Lift out cage together with hub.
Стр. 23 из 24
- Swing hub segment with smaller pins into rectangular
window on cage.
- Tilt hub out of cage.
Checking
6 balls for each joint belong to a tolerance group. Check
stub axle, hub, cage and balls for small indentations
(pitting) and signs of seizure. Excessive circumferential
backlash in joint makes itself noticed via tip-in shock, in
such cases joint should be replaced. Flattening and running
marks of balls are no reason to replace joint.
Assembling
- Install cage with hub in the joint housing.
Note:

Cage must be installed laterally correct.
- Press in opposing balls in sequence, during this, previous
position of ball hub to ball cage and to joint body must be
re-established.
- Press grease into joint body.
Стр. 24 из 24

Volkswagen Phaeton - Volkswagen Technical Site

Transcription

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