VW Transporter V 2.5 TDI, 96 KW

VW Transporter V 2.5 TDI, 96 KW
Your system specialist RUVILLE also
offers a broad product range for the
chassis of VW Transporter V (T5) 2.5 TDI,
96 KW which has been practically rounded
off with the introduction of suspension
springs for the front and rear axle.
VW T5 2.5 TDI, 96 KW
CHASSIS
Please always comply with the general and
specific procedures for the respective components when carrying out repairs.
GENERAL INSTRUCTIONS
Basic installation instructions:
When fitting waxed parts, the contact surfaces must be cleaned.
Contact surfaces must be free of wax and grease
No welding or straightening work is permitted to structural or wheel
suspension parts
Vehicles must not be moved without the drive shaft as this would
otherwise damage the wheel bearing
Rubber/metal bearings have a limited swivelling range. Before fixing axle
parts with rubber/metal bearings, they must therefore be brought into a
position corresponding to the driving position (empty weight position)
Always replace self-locking nuts
Always replace corroded bolts/nuts
INSTRUCTIONS FOR specific COMPONENTS
ALL RUVILLE CHASSIS COMPONENTS
FOR THE VW T5 2.5 TDI, 96 KW
Article No.
Description
755438
Bellows set, drive shaft
815406
Dust cap set, shock absorber
825409
Strut mounting
825409S
Repair set, strut mounting
825410
Strut mounting
835422
Buffer mounting, suspension
845404
Cover/bellows, shock absorber
865403
Roller bearing, strut mounting
895456
Chassis spring
895496
Chassis spring
925492
Tie rod
925493
Tie rod
925494
Tie-rod end
Vehicle-specific installation instructions:
925495
Tie-rod end
Specific installation instructions have to be heeded for some chassis components in VW T5 2.5 TDI, 96 KW. These are described in greater detail
below. The corresponding articles are marked in grey in the table.
925496
Axial joint, tie rod
925497
Supporting/guide joint
925498
Supporting/guide joint
925499
Rod/strut, stabiliser
985451
Bearing, steering
985452
Bushing, stabiliser
985456
Bearing, steering
5462
Wheel bearing set
We provide hands-on, PRACTICAL TRAINING
Every new model or series entails new installation specifications for the chassis.
RUVILLE passes on all the latest know-how to the garages. You can find out
more about our training courses at www.ruville.de or directly from our technical
instructor Remo Schönsee on e-mail: [email protected]
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➜ VW T5 2.5 TDI, 96
Know-how in detail
Use the new Ruville detector card for the generations of wheel
bearings with integrated wheel hub and multi-pole code ring:
The detector card has a cut-out for also
checking the wheel bearing with integrated
wheel hub and for diagnosis of the magnetic
multi-pole code ring. Damage to the wheel
revs sensor ring is quickly and easily detected
simply by holding the card in position.
Page 1
VW T5 2.5 TDI, 96 kw
chassis
Article: 5462 | Wheel bearing set
This wheel bearing belongs to the 2.1 generation of wheel bearings. A
special tool must always be used for dismantling and installation. The
wheel bearing can be replaced with a normal press. Please always use the
special tool in this case as otherwise considerable damage will be caused
to the bearing with premature failure as a foregone conclusion. This is
because of the design. The wheel hub and bearing are only connected via
the bearing inner ring through the pre-tension of the orbitally formed
shoulder. If the bearing is fitted without using a special tool, it will be automatically forced against the bearing inner ring which will cause pressure
marks on the raceways and roller bodies.
Caution, damage to the vehicle:
Do not loosen the central bolt of the
drive shaft when the vehicle is
standing on its wheels. When the
bolt is loosened, the vehicle can be
damaged by the dead weight of the
vehicle.
Dismantling and fitting:
Apply the tools as shown in the
picture (Fig. 1): Screw the grips (3)
to the wheel hub (1) with wheel
bolts. The wheel bolts (2) must
not protrude at the back of the
grips as otherwise the wheel
bearing cannot be pressed in
completely.
Apply the tools as shown
in the drawing:
1 Threaded rod
2 Threaded nut
3 Pressure head
4 Hydraulic cylinder
5 Bell
6 Grips
7 Threaded rod
8 Threaded nut
9 Pressure piece
Extract the wheel hub with
wheel bearing, holding the jig
tight
Apply the tools as shown in
the drawing: Use a larger
guide piece (9) for installation
Fasten the bellows (4) to the steering
gear (5) using a new clamp (3). To do
so, please use the gripper for Phaeton
steering gear or hose clip pliers. Make
sure that the bellows are not twisted.
Then screw the tie-rod end (1) to the
steering lever of the wheel bearing
housing using a new nut. Always align
the vehicle.
Article:755438 | Bellows set, drive shaft
815406 | Dust cap set, shock absorber
825409 | Strut mounting
825409S| Repair set, strut mounting
825410 | Strut mounting
835422 | Buffer mountings, suspension
845404 | Cover/bellows, shock absorber
865403 | Roller bearing, strut mounting
895456 | Chassis spring
895496 | Chassis spring
Repairs to the strut
To remove the left strut:
For vehicles with 5-speed manual transmission
Unscrew drive shaft from transmission
For vehicles with 6-speed transmission and vehicles with
4-wheel drive
Press the drive shaft out of the wheel bearing housing
Caution: To prevent stretching the protective collar of the intermediate
steering shaft and the hydraulic lines, unscrew the steering gear from the
unit support and press the left side approx. 40 mm upwards. Place a
wooden wedge or similar under the steering gear.
To remove the right strut:
For vehicles with 5-speed manual transmission
Unscrew the drive shaft from the transmission
For vehicles with 6-speed manual transmission
Unscrew the mounting from the bracket and remove the drive shaft
from the transmission.
For vehicles with 4-wheel drive
Press the drive shaft out of the wheel bearing housing.
The rear fastening bolt of the unit carrier must be unscrewed completely
on both sides of the vehicle. Now screw this bolt in again through 5 turns.
Then loosen the front fastening bolt until the washer is loose. Turn the wheel
hub so that one of the holes of the wheel bolts is at the top. Fit holder
-T10149- to the wheel hub with the wheel bolt. To do so, the wheel bearing
housing must be supported with an engine and transmission hoist.
Unscrew the strut from the wheel bearing housing and spread the wheel
bearing housing (1) open with spreader 3424. Now lower the wheel bearing housing until it is separated from the strut and swivel it in the drive direction. You can then remove and dismantle the strut.
Article: 925492 | Tie rod
925493 | Tie rod
925494 | Tie-rod end
925495 | Tie-rod end
925496 | Axial joint, tie rod
Note: When lowering the wheel bearing housing, always make sure that
the drive shaft has sufficient clearance.
Installation: Caution! The gear rack of the steering gear must be
greased before fitting the tie rod. Please only use the grease specified by
the manufacturer. To distribute the grease, turn the steering alternately to
both sides as far as it will go. Grease the gear rack on the gearing and
pressure piece side. Then turn the steering to straight-on position. Screw
the tie rod (2) into the gear rack of the steering gear (5). Tighten the tie
rod (2) using the open-end wrench (SW 38). There is no need to hold the
gear rack. Comply with the tightening torques of the tie rod!
Know-how in detail
Page 2