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SUSPENSION - REAR

Volkswagen Technical Site - http://volkswagen.msk.ru

ARTICLE BEGINNING

1997-98 SUSPENSIONVolkswagen - Rear

1997-98: Cabrio, Golf, GTI, Jetta, Passat1998: Beetle

DESCRIPTION

Suspension uses control arms and axle beam for stabilization.Control arms and axle beam are combined as one unit. Brake drums ordiscs rotate on stub axles bolted to control arms. See Fig. 1.

Fig. 1: Rear Suspension Assembly (Typical)Courtesy of Volkswagen United States, Inc.

ADJUSTMENTS & INSPECTION

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

NOTE: See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES article inWHEEL ALIGNMENT section.

WHEEL BEARING

NOTE: Wheel bearing and wheel hub for Beetle and 1998 Passat are

installed together in a housing. Wheel bearing/wheel hubassembly is maintenance and adjustment free.

While rotating brake disc or drum by hand, insert tip ofscrewdriver between thrust washer and hub. Adjustment is correct whenlight finger pressure against screwdriver moves thrust washer. Turnhub nut to adjust. Install castellated nut and NEW cotter pin.

REMOVAL & INSTALLATION

AXLE BEAM & SUSPENSION ASSEMBLY

CAUTION: When removing suspension assembly, add weight to rear ofvehicle to prevent tipping due to change in center ofgravity.

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Removal1) With vehicle on floor, remove plastic cap covering upper

strut nuts. Remove strut nuts. Raise and support vehicle. Disconnectparking brake at bracket near axle mount.

2) Disconnect and plug brakelines. Leave flex hose attachedto suspension. Separate brake pressure regulator spring from axle

beam. Remove axle beam-to-body nuts.

NOTE: DO NOT install bolts and nuts fouled with undercoating. Withwaxy coating on threads, true tightening torque cannot bemeasured. Clean or replace bolts and nuts.

Installation

1) If axle beam mounting has been removed, adjust mountingpad. See step 2) under INSTALLATION underAXLE BEAM BONDED RUBBER MOUNTING. If pad is not correctly aligned,torsional preload of mounting bushings will be incorrect.

2) Position rear suspension assembly on body. Install axlebeam-to-body nuts. Raise wheel. Guide upper end of strut into bodymount.

3) Connect parking brake cables. Connect brakelines. Lowervehicle. Tighten upper strut nuts. Tighten all bolts and nuts tospecification. See TORQUE SPECIFICATIONS. Bleed brake system.

AXLE BEAM BONDED RUBBER MOUNTING OR BUSHING

Removal (Beetle)1) On vehicles without ABS remove bolts fastening brake

pressure regulator. Unclip parking brake cable from retainer on rearaxle beam and unhook from retainers.

2) Position Engine/Transmission Jack (VGA1383A) with ragunder brake line. Disconnect brake line from rear axle. Remove rearaxle mounting bracket bolts on both sides.

3) Position a wooden block between rear axle beam and body.Install Slide Hammer (VW771) and pull out bonded rubber bushing.

InstallationMarkings on face of bonded rubber bushing must align withedge of trailing arm. Mark position of marks on bonded rubber bushing.

Assemble Installer Set (3416/2, 3346 & 3416/1) and bonded rubberbushing onto rear axle. Ensure mark aligns with edge of turningspindle. Check position of bonded rubber bushing after installing.Complete installation by reversing removal procedures.

Removal (Except Beetle & 1998 Passat)Raise and support vehicle. With no pressure on beam, remove

axle beam-to-body nuts. Using Remover/Installer (VW 3111), press outrubber mounting. Press new rubber mounting into place.

Installation1) Loosely install mounting pad onto axle beam. Using

remover/installer, install bushing. Using Mounting Bracket Aligner(3021), align mount until aligner reads 12.5-14.5 on Passat, and 10-14degrees for all others. See Fig. 2.

2) Install all mounting bolts but do not tighten. Alignright-hand mounting bracket so that bolts are in center of elongatedholes. On left-hand side press mounting bracket against axle beam

pushing with a lever until gap on inside is minimal. Tighten bolts tospecification.

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Fig. 2: Aligning Axle Beam Mounting Pad (Except Beetle & 1998 Passat)Courtesy of Volkswagen United States, Inc.

Removal (1998 Passat)1) Remove axle beam, rubber mountings can only be removed and

installed with axle beam lowered. See AXLE BEAM & SUSPENSION ASSEMBLY.Except for stabilizer bar no other part needs to be removed from axle

beam.2) Mark position of bonded rubber mounting on axle beam, to

ensure new bonded rubber mounting is installed in correct position.3) Pry aluminum washer off bonded rubber mounting using a

screwdriver. Mark position of semi-circular cut-out on axle beam. Pullout bonded rubber mounting using Removal Bolt (3291), Removal Plate(VW-402) and Removal Sleeve (3291/4). See fig.3.

Fig. 3: Removing Bonded Rubber Mounting (1998 Passat)Courtesy of Volkswagen United States, Inc.

Installation

1) Front and rear bounded rubber mountings are different.Place bounded rubber mounting with cut-out facing markings. Eccentrichole in mounting must point forward. Mounting must be guided by asecond technician during installation.

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NOTE: Install correct bonded rubber mounting. There is 2 types ofbonded rubber mounting parts. Part 8E0-505-545-C has aheight of 2.84" (72.2 mm) and an aluminum washer with adiameter of 4.09" (104 mm). Part 8E0-505-545-D has a heightof 2.77" (70.5 mm) and an aluminum washer with a diameter of3.7" (94 mm).

2) Install bounded rubber mounting into Installer Set(3346/3, 3346/1, 3291/3 & 3354/1). Use Lubricant (G-294-421-A1), when

pressing in bonded rubber mounting.

CAUTION: DO NOT tilt bonded rubber mounting when pulling in or

aluminum washer can be damaged.

3) Pull in bonded rubber mounting until chamfer is positionedat edge of mounting hole. Ensure chamfer is positioned evenly allaround.

STRUT ASSEMBLY

Removal1) With vehicle on floor, remove plastic cap covering upper

strut nuts. Remove strut upper nuts. Slowly raise vehicle until weightis off spring. Remove strut-to-axle beam bolt. Raise vehicle until

strut can be removed. It may be necessary to turn top of strut untillugs are over cutouts in body. Place strut assembly in vise.

2) Hold piston rod. Remove piston rod nut and relatedcomponents. See Fig. 1. Remove slotted nut (some models). Removespacer and coil spring. If coil spring is to be replaced, ensure paintstripe color on replacement spring matches original spring colorstripe.

Installation1) Install protective cap and tube onto shock absorber.

Install rubber bumper with small end downward. Install snap ring and

washer. Place spring into lower seat. Install upper retainer withspacer sleeve.2) Tighten piston rod nut. Install upper mounting hardware.

Tighten piston rod. To complete installation, reverse removalprocedure. Tighten bolts and nuts to specification. SeeTORQUE SPECIFICATIONS.

WHEEL BEARING

Removal (Beetle)1) Raise and support vehicle. Remove wheel. Remove dust cap.

On models with rear disc brakes, remove brake caliper and support it

aside. Remove brake disc.2) On models with rear drum brakes, remove brake drum. On all

models, remove wheel bearing/hub unit using Kukko Puller (20/2). Pullbearing inner race off stub axle using Leg Clamp Puller Kukko(204-2).

Installation1) Install wheel bearing/hub unit as far as possible onto

stub axle. Attach Assembler (3420) and pull wheel bearing/hub unitfully on up to stop. Remove installer.

2) Install new 12 point nut and tighten to specifications.See TORQUE SPECIFICATIONS. To complete installation, reverse removal

procedure.

Removal Disc Brakes (Except Beetle & 1998 Passat)Raise and support vehicle. Remove wheel. Remove caliper

assembly and support it aside. Remove dust cap, cotter pin, hub nut,

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and thrust washer. Remove brake disc. Using a long drift, tapbearings, races, and grease seal from disc hub.

Installation1) Clean hub cavity thoroughly. Using Bearing Race Installer

(VW 411 and VW 432), press inner and outer bearing races into bore.Lubricate and install inner bearing. Using Seal Installer (VW 295 and3074), tap grease seal into bore.

2) Install brake disc, outer bearing, thrust washer, and hubnut. Reverse removal procedure to complete installation. Adjust wheel

bearing. See WHEEL BEARING under ADJUSTMENTS & INSPECTION. Install NEWcotter pin.

RemovalDrum Brakes (Except Beetle & 1998 Passat)Raise and support vehicle. Remove wheel. Remove dust cap,

cotter pin, hub nut, and thrust washer. Remove brake drum. Using along drift, tap bearings, races, and grease seal from hub.

Installation1) Clean hub cavity thoroughly. Using Bearing Race Installer

(VW 411 and VW 432), press outer bearing race into bore. Using samebearing race installer, press inner bearing race into bore. Lubricateand install inner bearing. Using Seal Installer (VW 295 and 3074), tapgrease seal into bore.

2) Install brake drum, outer bearing, thrust washer, and hubnut. Reverse removal procedure to complete installation. Adjust wheel

bearing. See WHEEL BEARING under ADJUSTMENTS & INSPECTION. Install NEWcotter pin.

Removal (1998 Passat)1) Raise and support vehicle. Remove wheel. Remove bolt for

drive axle.

CAUTION: Drive axle bolt must be loosened or tightened only withvehicle standing on its wheels.

2) Remove brake caliper and support it aside. Remove brakedisc. Remove Splash shield.

3) Pull ABS wheel speed sensor out of wheel bearing housing.Remove connecting link. Remove track rod. Mark installed position ofeccentric washer for bolt. Remove bolt.

4) Remove bolt for control arm. Pull wheel bearing housingoff drive axle.

InstallationTo install, reverse removal procedure.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application Ft. Lbs. (N.m)

Brake Backing Plate Bolt ................................... 44 (60)Brake Caliper Bracket BoltBeetle & Passat .......................................... 48 (65)Except Beetle & Passat ................................... 41 (56)

Brake Pressure Regulator Mounting Bracket Bolt

Beetle ................................................... 55 (75)Except Beetle & 1998 Passat .............................. 52 (70)1998 Passat ............................................. 81 (110)

Brake Splash Shield

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Except 1998 Passat ....................................... 44 (60)1998 Passat ............................................... 7 (10)

Coil Spring Retainer-To-Piston Rod NutExcept 1998 Passat ....................................... 11 (15)1998 Passat .............................................. 20 (27)

Rear Axle Beam Pivot Bushing Bolt ......................... 60 (80)Rear Axle Mounting Pad-To-Body BoltExcept 1998 Passat ....................................... 52 (70)1998 Passat .............................................. 55 (75)

Strut-To-Axle Beam NutBeetle ................................................... 44 (60)Except Beetle ............................................ 52 (70)

Strut-To-Body Bolt

Beetle ................................................... 55 (75)Except Beetle & 1998 Passat .............................. 18 (25)1998 Passat .............................................. 33 (45)

Stub Axle-To-Control Arm Bolt ............................. 44 (60)Wheel Lug Bolt

Beetle & 1998 Passat .................................... 89 (120)Except Beetle & 1998 Passat ............................. 81 (110)

END OF ARTICLE