Volkswagen Jetta 2005 Workshop Manual
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Volkswagen Jetta 2005 Workshop Manual

Running gear, axles, steering
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See also: Service Manual , Maintenance Manual
Service
Workshop Manual
Golf Variant 2007 ➤
Jetta 2005 ➤
Running gear, axles, steering
Edition 07.2010
Service Department. Technical Information

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Summary of Contents for Volkswagen Jetta 2005

  • Page 1 Service Workshop Manual Golf Variant 2007 ➤ Jetta 2005 ➤ Running gear, axles, steering Edition 07.2010 Service Department. Technical Information...
  • Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R005420...
  • Page 3 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Contents 00 - Technical data ........... .
  • Page 4 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on) ..109 10.1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint .
  • Page 5 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: shock absorber, coil spring (four-wheel drive) ....218 12.1...
  • Page 6 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 8.13 Basic setting for steering angle sender G85 ........274 8.14...
  • Page 7 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview - electromechanical steering box, right-hand drive vehicle (2nd generation) up to model year 2008 ......... . 327 Removing and installing steering box, left-hand drive vehicle (2nd generation) up to model year 2008 .

  • Page 8: Golf Variant 2007 ➤ , Jetta

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Contents...

  • Page 9: Technical Data

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 00 – Technical data Checklist for evaluating running gear of accident vehicles Damage to running gear may go unnoticed during repairs to load- bearing and suspension parts of accident vehicles. Under certain circumstances, this undiscovered damage could lead to serious consequential damage during later vehicle operation.
  • Page 10 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Entire vehicle Check other vehicle systems as well, for example: ♦ Brake system including ABS ♦ Visual and functional examination of exhaust system and pas‐...

  • Page 11: General Information

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 General information Information concerning wheels, tyres and snow chains can be found in „Wheel and Tyre Guide“ ⇒ Wheels, tyres, wheel align‐ ment; Rep. gr. 44 .

  • Page 12: Front Suspension

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 40 – Front suspension Appraisal of accident vehicles A checklist for evaluating running gear of accident vehicles can be found under ⇒ page 1 Rep. gr.40 - Front suspension...

  • Page 13: Repairing Front Suspension

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Repairing front suspension Overview - front axle Note It is not permitted to carry out welding and straightening operations on load-bearing or wheel-guiding sus‐ ♦...

  • Page 14: Raising Wheel Suspension To Unladen Position

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 The chapter „Removing and installing drive shafts“ can be found ⇒ page 72 The chapter „Repairing drive shaft“ can be found on ⇒ page 87...
  • Page 15 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 To simulate this position on the lifting platform, raise the respec‐ tive wheel suspension with the engine and gearbox jack -V.A.G 1383 A- and support -T10149- .
  • Page 16 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Respective nuts and bolts may be tightened only when dimension -a- between the centre of wheel hub and edge of wheel housing has been attained.

  • Page 17: Subframe, Anti-Roll Bar, Suspension Links

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Subframe, anti-roll bar, suspension links Assembly overview: subframe, anti-roll bar, suspension links Caution ♦ It is not permitted to carry out welding and straightening operations on load-bearing or wheel-guiding suspension components.
  • Page 18 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 8 - Front left vehicle level sender -G78- ❑ Can be checked in guided fault finding of the vehicle diagnostic, testing and information system -VAS 5051B- .
  • Page 19 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ❑ Always renew after removing. 19 - Bolt ❑ M14 x 1.5 x 70 ❑ 100 Nm + 90° further ❑ Do not tighten until pendulum support is bolted to gearbox ❑...
  • Page 20 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Caution From model year 08, HeliCoil inserts are in‐ stalled in the pendulum support connection in gearboxes. Identification ⇒ Rep. gr. 34 . Use a bolt with hardness class 10.9 for this and all...
  • Page 21 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 31 - Nut ❑ 65 Nm ❑ When tightening, counterhold on hexagon socket of joint stub. ❑ Self-locking ❑ Always renew after removing. 32 - Anti-roll bar ❑...

  • Page 22: Assembly Overview: Front Left Vehicle Level Sender G78

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: front left vehicle level sender -G78- Note The front left vehicle level sender -G78/- is only available as a replacement part complete with coupling rod ♦...

  • Page 23: Repairing Thread In Longitudinal Member

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Torque wrench -V.A.G 1410- Removing Note To remove front left vehicle level sender -G78- , steering must be turned to right lock to ensure clearance between suspension link and anti-roll bar.

  • Page 24: Fixing Position Of Subframe And Brackets

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Fixing position of subframe and brack‐ Special tools and workshop equipment required ♦ Locating pins -T10096- ♦ Engine and gearbox jack -V.A.G 1383 A- Installing locating pins -T10096-...

  • Page 25: Lowering Subframe

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Fixing position of mounting bracket – Replace the bracket securing bolts along both sides one after the other with locating pins -T10096- and tighten them to 20 Fixing position of bracket The position of the front axle is now fixed.
  • Page 26 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Locating pins -T10096- ♦ Engine and gearbox jack -V.A.G 1383 A- Removing – Turn steering wheel to straight-ahead position and remove ig‐ nition key so that the steering lock engages.
  • Page 27 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Detach exhaust system bracket from subframe -arrows-. – Disconnect pendulum support from gearbox by removing bolts -14-. – Disconnect coupling rods from anti-roll bar.
  • Page 28 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -4- and -5- and lower subframe a maximum of 10 cm. Note Be sure to observe electrical wires to avoid overstretching them.

  • Page 29: Removing And Installing Subframe Without Steering Box

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Bolt Specified torque M10 x 75 strength class 8.8 40 Nm + 90° further ♦ Use new bolt M10 x 75 strength class 10.9 50 Nm + 90° further ♦...
  • Page 30 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Disconnect pendulum support from gearbox by removing bolts -14-. – Fix position of subframe ⇒ page 16 – Now unscrew bolts for: ♦ steering box -3- and -6- ♦...

  • Page 31: Removing And Installing Subframe With Steering Box

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Torque specifications for pendulum support to gearbox Caution From model year 08, HeliCoil inserts are installed in the pen‐ dulum support connection in the 02Q gearboxes. Identification ⇒...
  • Page 32 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing – Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery . – Disconnect cable -1- from electrics box.
  • Page 33 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolt -1- and pull universal joint -2- off steering box. – Remove front wheels. – Remove lower noise insulation ⇒ General body repairs, ex‐...
  • Page 34 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Disconnect pendulum support from gearbox by removing bolts -14-. – Fix position of subframe with brackets. – Place engine and gearbox jack -V.A.G 1383 A- under sub‐...
  • Page 35 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Secure subframe to engine and gearbox jack -V.A.G 1383 A- with the appropriate strap. Installing Install in reverse order. – Install noise insulation and tighten, torque settings ⇒ General body repairs, exterior;...

  • Page 36: Repairing Subframe (Front-Wheel Drive)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Bolt Specified torque M10 x 35 strength class 8.8 40 Nm + 90° further ♦ Use new bolt M10 x 35 strength class 10.9 50 Nm + 90° further ♦...
  • Page 37 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Press out both bonded rubber bushes at the same time as illustrated. Note Flattened side of thrust piece -3372/1- must face towards in‐ ♦...
  • Page 38 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Press in bonded rubber bushes -1- until dimension -a- is ob‐ tained. Dimension -a- = 2 - 3 mm. Note There are two different types of bonded rubber bushes for ♦...

  • Page 39: Repairing Subframe (Four-Wheel Drive)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 V-type bonded rubber bush – Align tube -T10214/2- with pressed-in bonded rubber bushes on subframe. Note The corners of the inner core of the bonded rubber bush ♦...
  • Page 40 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Assembly tool -T10214- ♦ Assembly tool -T10244- Pressing out bonded rubber bush – Remove subframe ⇒ page 21 – Press out both bonded rubber bushes at the same time as illustrated.
  • Page 41 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Bolt bonded rubber bushes together using original bolt, mak‐ ing sure that both notches -arrows- line up precisely. – Insert assembled bonded rubber bushes with bolt head down‐...
  • Page 42 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Note There are two different types of bonded rubber bushes for ♦ pendulum supports: the T version -I- and the V version -II-. They are allocated by means of the ⇒ Electronic parts cata‐...

  • Page 43: Checking Swivel Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Position subframe against smaller internal diameter of tube -T10244/3-. – Press in bushes to stop and until a force of 20 kN is attained.

  • Page 44: Removing And Installing Swivel Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Press lower part of wheel forcefully inwards and outwards in -direction of arrow-. Note There should be no palpable or visible „play“ during both tests.
  • Page 45 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Caution When bolt is loosened or tightened, vehicle must not be stand‐ ing on its wheels. The wheel bearing can be damaged by the weight of the vehi‐...

  • Page 46: Removing And Installing Suspension Link With Mounting Bracket

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Tighten nuts -arrows-. Note Ensure that bellows are not damaged or twisted. – Fit wheel and tighten, torque setting ⇒ page 241 – Tighten drive shaft bolt at wheel hub: ♦...
  • Page 47 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Locating pins -T10096- Removing – Remove wheel. – Remove lower noise insulation ⇒ General body repairs, ex‐ terior; Rep. gr. 50 ; Assembly overview - noise insulation .
  • Page 48 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -1-. Installing – Insert suspension link with mounting bracket into subframe. – Position items -10- and -17- but do not yet tighten.
  • Page 49 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Bolt suspension link to bracket -10- and -17- in unladen state. Continue installation in reverse order. Note Ensure that bellows are not damaged or twisted.
  • Page 50 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Locating pins -T10096- ♦ Engine and gearbox jack -V.A.G 1383 A- Removing – Remove front left wheel. – Remove noise insulation (bottom). ⇒ General body repairs, exterior;...
  • Page 51 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Disconnect pendulum support from gearbox by removing bolts -14-. – If present, detach coupling rod of front left vehicle level sender -G78- from suspension link.
  • Page 52 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Position engine and gearbox jack -V.A.G 1383 A- under sub‐ frame. – Place, for example, a wooden block -1- between engine and gearbox jack -V.A.G 1383 A- and subframe.
  • Page 53 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Component Specified torque Steering box to subframe 50 Nm + 90° ♦ Use new bolts Exhaust system bracket to subframe ⇒ Engine; Rep. gr. 26...

  • Page 54: Renewing Bonded Rubber Bush For Suspension Link

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 3.15 Renewing bonded rubber bush for suspension link Special tools and workshop equipment required ♦ Tube -T10219/1- ♦ Drift -T10219/2- ♦ Thrust plate -VW 402- ♦...
  • Page 55 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Apply bonded rubber bush at an angle (towards suspension link). Lip -arrow- must slide into hole as shown. Drift -T10219/2- Tube -T10219/1- Thrust plate -VW 402- –...

  • Page 56: Renewing Mounting Bracket With Suspension Link Bush

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 3.16 Renewing mounting bracket with suspension link bush Special tools and workshop equipment required ♦ Guide -VW 439- ♦ Thrust plate -VW 401- ♦ Thrust plate -VW 402- ♦...
  • Page 57 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Note Hold suspension link when pressing off. Thrust plate -VW 401- Guide -VW 439- Thrust plate -VW 402- Pressing in mounting bracket with bush onto suspension link –...

  • Page 58: Removing And Installing Anti-Roll Bar

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 3.17 Removing and installing anti-roll bar Special tools and workshop equipment required ♦ Locating pins -T10096- ♦ Torque wrench -V.A.G 1332- ♦ Engine and gearbox jack - V.A.G 1383 A-...
  • Page 59 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolt -1- and pull universal joint -2- off steering box. – Remove lower noise insulation ⇒ General body repairs, ex‐ terior; Rep. gr. 50 ; Assembly overview - noise insulation .
  • Page 60 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Position engine and gearbox jack -V.A.G 1383 A- under sub‐ frame. – Place, for example, a wooden block -1- between engine and gearbox jack -V.A.G 1383 A- and subframe.
  • Page 61 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Component Specified torque Bracket to body 70 Nm + 90° ♦ Use new bolts Mounting bracket to body 70 Nm + 90° ♦ Use new bolts Subframe to bracket 70 Nm + 90°...
  • Page 62 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Bolt Specified torque M10 x 75 strength class 10.9 50 Nm + 90° further ♦ Use new bolt – After installing, perform basic settings for steering angle send‐...

  • Page 63: Assembly Overview: Wheel Bearing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: wheel bearing 1 - Suspension strut 2 - Track rod ball joint 3 - Multi-point socket head bolt ❑ Tip of bolt must point in...

  • Page 64: Removing And Installing Wheel Bearing Unit

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ❑ With bolted-on brake carrier. ❑ If wheel bearing housing is renewed, wheels must be aligned ⇒ page 261 ❑ Allocation ⇒ Electronic parts catalogue „ETKA“...
  • Page 65 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -arrows-. – Take wheel bearing unit out of wheel bearing housing. Continuation for all vehicles – Remove nuts -arrows-. – Pull swivel joint out of suspension link.

  • Page 66: Removing And Installing Wheel Bearing Housing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Component Specified torque Swivel joint to sheet steel or forged aluminium suspension 100 Nm link ♦ Use new nuts Wheel hub with wheel bearing to wheel bearing housing 70 Nm + 90°...
  • Page 67 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Spreader -3424- Removing – Loosen drive shaft bolt at wheel hub: ♦ Hexagon bolt ⇒ page 70 ♦ Twelve-point bolt ⇒ page 71 Note During this step, vehicle must not be standing on its wheels or wheel bearing will be damaged.
  • Page 68 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove threaded connection between wheel bearing housing and suspension strut -arrow-. – Insert spreader -3424- in slot in wheel bearing housing. – Turn ratchet handle through 90° and detach from spreader -3424- .
  • Page 69 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Specified torques Component Specified torque Suspension strut to wheel bearing housing 70 Nm + 90° ♦ Use new nut Swivel joint to cast steel suspension link 60 Nm ♦...

  • Page 70: Assembly Overview: Suspension Strut

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: suspension strut 1 - Shock absorber ❑ Can be renewed sepa‐ rately ❑ Allocation ⇒ Electronic parts catalogue „ETKA“ 2 - Bump stop...

  • Page 71: Removing And Installing Suspension Strut

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and installing suspension strut Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1332- ♦ Spreader -3424- ♦ Engine and gearbox jack - V.A.G 1383 A-...
  • Page 72 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Unscrew hexagon nut for coupling rod -arrow- from suspen‐ sion strut. – Unhook speed sensor wiring from suspension strut. – Remove nuts -arrows-. – Pull wheel bearing housing with swivel joint out of suspension link.
  • Page 73 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Insert spreader -3424- in slot in wheel bearing housing. – Turn ratchet handle through 90° and detach from spreader -3424- . – Press brake disc towards suspension strut by hand.
  • Page 74 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Tighten hexagon bolts -arrows- for upper shock absorber mount‐ ing. – Install plenum chamber cover. – Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wiper system;...
  • Page 75 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove nuts -arrows-. – Fit drive shaft in wheel hub. – Fit wheel bearing housing with swivel joint in suspension link. – Bolt swivel joint to suspension link.

  • Page 76: Repairing Suspension Strut

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Repairing suspension strut Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1332- ♦ Spring compressor -V.A.G 1752/1- ♦ Strut support clamp -V.A.G 1752/20- ♦...
  • Page 77 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing coil spring – Clamp suspension strut support clamp -V.A.G 1752/20- -4- in a vice. – Clamp suspension strut in suspension strut support clamp - V.A.G 1752/20- -4-.

  • Page 78: Removing And Installing Drive Shafts

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and installing drive shafts Removing and installing drive shaft with constant velocity joint ⇒ page 72 Removing and installing left drive shaft with (push-on) constant velocity slip joint ⇒...

  • Page 79: Loosening And Tightening 12-Point Flange Bolt Securing Drive Shaft

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove hexagon bolt -arrow-. Tightening hexagon bolt – Renew hexagon bolt. Note The wheels must not be in contact with the ground when the drive shaft bolt is tightened;...

  • Page 80: Removing And Installing Drive Shaft With Constant Velocity Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Tighten outer joint to 120 Nm. Loosening 12-point bolt – To avoid damage to wheel bearing, do not loosen 12-point bolt using 24 mm socket -T10361- further than 90° with vehicle still standing on its wheels.
  • Page 81 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Caution When removing and installing drive shafts, do not allow them to hang free and stop against joints due to over bending. Removing – Loosen drive shaft bolt at wheel hub: ♦...

  • Page 82: Removing And Installing Left Drive Shaft With (Push-On) Constant Velocity Slip Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Bolt swivel joint to suspension link -arrows-. Note Ensure that bellows are not damaged or twisted. – Place inner joint of drive shaft in position and tighten bolts di‐...
  • Page 83 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Multi-purpose tool -VW 771- ♦ Drive shaft puller -T10382- ♦ Torque wrench -V.A.G 1332- Removing – Loosen drive shaft bolt at wheel hub ⇒ page 71 Caution During this step, vehicle must not be standing on its wheels.
  • Page 84 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove nuts -arrows-. – Pull wheel bearing housing with swivel joint out of suspension link. – Push drive shaft outer joint out of wheel hub by hand.
  • Page 85 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Install spindles -T10382/2- and traverse -T10382/3- on puller plate -T10382/1- . – Install multi-purpose tool -VW 771- on traverse -T10382/ 3- . – Pull out drive shaft with a couple of strikes of multi-purpose tool -VW 771- .

  • Page 86: Removing And Installing Right Drive Shaft With (Push-On) Constant Velocity Slip Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Specified torques Component Specified torque Swivel joint to cast steel suspension link 60 Nm ♦ Use new nuts Swivel joint to sheet steel or forged aluminium suspension...
  • Page 87 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Caution During this step, vehicle must not be standing on its wheels. The wheel bearing can be damaged by the weight of the vehi‐ cle if the bolt is loosened.
  • Page 88 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Set up drive shaft puller -T10382- and pull out drive shaft. – Remove drive shaft from vehicle. Installing Remove any paint residue and/or corrosion on thread and splines of outer joint.

  • Page 89: Removing And Installing Drive Shafts With Triple Roller Joint Aar2600I

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Component Specified torque Swivel joint to sheet steel or forged aluminium suspension 100 Nm link ♦ Use new nuts Drive shaft to wheel hub „12-point bolt“...
  • Page 90 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove nuts -arrows-. – Pull wheel bearing housing with swivel joint out of suspension link. – Pull drive shaft out of wheel hub and tie up to body.

  • Page 91: Removing And Installing Drive Shafts With Triple Roller Joint Aar3300I

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Bolt swivel joint to suspension link -arrows-. Note Ensure that bellows are not damaged or twisted. – Tighten drive shaft bolt at wheel hub: ♦...
  • Page 92 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove wheel. – Remove lower noise insulation ⇒ General body repairs, ex‐ terior; Rep. gr. 50 ; Assembly overview - noise insulation . – Unbolt drive shaft from gearbox flange shaft.

  • Page 93: Removing And Installing Intermediate Shaft

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Component Specified torque Drive shaft to flange shaft on gearbox „M8 multi-point sock‐ 40 Nm et“ ♦ Initially tighten diagonally to 10 Nm ♦ Use new bolts Drive shaft to flange shaft on gearbox „M10 multi-point...
  • Page 94 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Now push intermediate shaft onto stub shaft of gearbox until bearing -2- contacts bearing bracket -1- without »gap« -arrow-. – Tighten bolts -arrows- to specified torque.

  • Page 95: Repairing Drive Shaft - Overview Of Drive Shafts

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Repairing drive shaft - overview of drive shafts I - Assembly overview: drive shaft with VL90 or VL100 con‐ stant velocity joint ⇒ page 90 II - Assembly overview: drive shaft with VL107 constant ve‐...
  • Page 96 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 IV - Assembly overview: drive shaft with triple roller joint AAR2600i ⇒ page 114 V - Assembly overview: drive shaft with triple roller joint AAR3300i ⇒...

  • Page 97: Heat Shields For Drive Shafts

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Heat shields for drive shafts Front-wheel drive: Component Specified torque Hexagon bolt -1- 25 Nm Four-wheel drive: Component Specified torque Nuts -1- 20 Nm ♦ Initially tighten all nuts to...

  • Page 98: Assembly Overview: Drive Shaft With Vl90 Or Vl100 Constant Velocity Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint 1 - Outer constant velocity joint ❑ Renew only as com‐ plete unit ❑ Removing ⇒...
  • Page 99 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 11 - Clamp ❑ Always renew after removing. ❑ Tightening ⇒ page 96 12 - Left drive shaft 13 - Locking plate ❑ Always renew after removing.

  • Page 100: Dismantling And Assembling Drive Shaft With Vl90 Or Vl100 Constant Velocity Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Dismantling and assembling drive shaft with VL90 or VL100 constant ve‐ locity joint Special tools and workshop equipment required ♦ Thrust plate -VW 401- ♦ Thrust plate -VW 402- ♦...
  • Page 101 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Circlip pliers -VW 161 A- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Special pliers -V.A.G 1682- ♦ Assembly tool -T10065- ♦...
  • Page 102 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Puller -T10382- Removing outer constant velocity joint – Clamp drive shaft in vice using protective jaw covers. – Fold back boot. – Set puller -T10382- up so that smooth side of puller plate - T10382/1- points to spindles -T10382/2- .
  • Page 103 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Pressing off inner constant velocity joint Assembling Installation position of dished spring at inner joint Dished spring Pressing on inner constant velocity joint Note Chamfer on internal circumference of ball hub (splines) must face contact shoulder on drive shaft.

  • Page 104: Checking Outer Constant Velocity Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Tighten clamp on outer joint – Position clamp tensioner -V.A.G 1682- as shown in diagram. Ensure jaws of tensioner lie in corners -arrows B- of ears on O-type clip.

  • Page 105: Checking Inner Constant Velocity Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Turn cage until the two rectangular windows -arrow- align with joint body. – Take out cage with hub. – Swing segment of hub into square cage window.
  • Page 106 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Tip ball hub out of ball cage via ball track -arrows-. – Check joint body, ball hub, ball cage and balls for pitting and traces of seizing.
  • Page 107 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Swivel in hub with balls by applying firm pressure to cage -arrow-. Checking function of constant velocity joint The constant velocity joint is correctly assembled if the ball hub can be moved by hand backwards and forwards over its entire range of axial movement.

  • Page 108: Assembly Overview: Drive Shaft With Vl107 Constant Velocity Joint (Bolt-On)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on) 1 - Outer constant velocity joint ❑ Renew only as com‐ plete unit ❑ Removing ⇒...
  • Page 109 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 11 - Clamp ❑ Always renew after removing. ❑ Tightening ⇒ page 106 12 - Drive shaft 13 - Intermediate shaft ❑ Right side of vehicle: ❑...

  • Page 110: Dismantling And Assembling Drive Shaft With Vl107 Constant Velocity Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Dismantling and assembling drive shaft with VL107 constant velocity joint Special tools and workshop equipment required ♦ Thrust plate -VW 401- ♦ Thrust plate -VW 402- ♦...

  • Page 111: Golf Variant 2007 ➤ , Jetta

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Multi-purpose tool -VW 771- ♦ Puller -T10382- Removing outer constant velocity joint – Clamp drive shaft in vice using protective jaw covers. – Fold back boot.
  • Page 112 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Installation position of dished spring and thrust washer on outer joint Dished spring Thrust washer – Install new retaining ring. – If necessary, push new joint boot onto drive shaft.
  • Page 113 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Pressing on inner constant velocity joint – Press joint on to stop. – Install retaining ring. – Coat sealing surface of cover with -D 454 300 A2- .
  • Page 114 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Tighten clamp on outer joint – Apply special pliers -V.A.G 1682- as shown in diagram. En‐ sure jaws of tool contact corners -arrows B- of clamp.

  • Page 115: Repairing Intermediate Shaft

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Repairing intermediate shaft Special tools and workshop equipment required ♦ Thrust plate -VW 401- ♦ Thrust plate -VW 402- ♦ Thrust piece -T10032- ♦ Thrust piece -3118- ♦...
  • Page 116 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Pressing on bearing – Press bearing to stop on intermediate shaft as shown in figure. Thrust piece -T10032- Intermediate shaft Mounting Thrust piece -3118- Thrust plate -VW 401-...

  • Page 117: Assembly Overview: Drive Shaft With Vl107 Constant Velocity Slip Joint (Push-On)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on) 1 - Outer constant velocity joint ❑ Renew only as com‐ plete unit ❑ Removing ⇒...

  • Page 118: 10.1 Dismantling And Assembling Drive Shaft With Vl107 (Push-On) Constant Velocity Slip Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ❑ Insert in groove in shaft 13 - Clamp ❑ Always renew after removing. ❑ Tightening ⇒ page 112 14 - Constant velocity slip joint ❑...
  • Page 119 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Pull constant velocity joint from drive shaft with puller -T10382- and multi-purpose tool -VW 771- . Puller plate -T10382/1- Spindles -T10382/2- Driving on outer constant velocity joint...

  • Page 120: Checking Outer Constant Velocity Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Tighten clamp on outer joint – Apply special pliers -V.A.G 1682- as shown in diagram. En‐ sure jaws of tool contact corners -arrows B- of clamp.
  • Page 121 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Turn cage until the two rectangular windows -arrow- align with joint body. – Take out cage with hub. – Swing segment of hub into square cage window.

  • Page 122: Assembly Overview: Drive Shaft With Triple Roller Joint Aar2600I

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: drive shaft with triple roller joint AAR2600i 1 - Outer constant velocity joint ❑ Renew only as com‐ plete unit ❑ Removing ⇒ page 103 ❑...

  • Page 123: Dismantling And Assembling Drive Shaft With Triple Roller Joint Aar2600I

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 13 - Clamp ❑ Always renew after removing. ❑ Tighten clamp with hose clip pliers -V.A.G 1275- 14 - Retaining ring ❑ Always renew after removing.
  • Page 124 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Hose clip pliers -V.A.G 1275- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Special pliers -V.A.G 1682- ♦ Assembly tool -T10065- ♦...
  • Page 125 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Puller -T10382- Removing outer constant velocity joint – Clamp drive shaft in vice using protective jaw covers. – Fold back boot. – Set puller -T10382- up so that smooth side of puller plate - T10382/1- points to spindles -T10382/2- .
  • Page 126 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove retaining ring. 1 - Pliers (commercial type) or -VW 161 A- – Set drive shaft into press. – Press triple roller star off drive shaft.
  • Page 127 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Fit triple roller star onto shaft and press on to stop. – Ensure that pressure does not exceed 3.0 t. – If necessary, coat splines of drive shafts and triple roller star with lubricating paste -G 052 142 A2- .

  • Page 128: Assembly Overview: Drive Shaft With Triple Roller Joint Aar3300I

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: drive shaft with triple roller joint AAR3300i 1 - Outer constant velocity joint ❑ Renew only as com‐ plete unit ❑ Removing ⇒ page 94 ❑...
  • Page 129 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ❑ Tighten clamp with hose clip pliers -V.A.G 1275- 12 - Boot for triple roller joint ❑ Check for splits and chafing 13 - Clamp ❑...

  • Page 130: Dismantling And Assembling Drive Shaft With Triple Roller Joint Aar3300I

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 12.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i Special tools and workshop equipment required ♦ Thrust plate -VW 401- ♦ Thrust plate -VW 402- ♦...
  • Page 131 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Hose clip pliers -V.A.G 1275- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Special pliers -V.A.G 1682- ♦ Assembly tool -T10065- ♦...
  • Page 132 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Puller -T10382- Removing outer constant velocity joint – Clamp drive shaft in vice using protective jaw covers. – Fold back boot. – Set puller -T10382- up so that smooth side of puller plate - T10382/1- points to spindles -T10382/2- .
  • Page 133 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove retaining ring. 1 - Pliers (commercial type) or -VW 161 A- – Set drive shaft into press. – Press triple roller star off drive shaft.
  • Page 134 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Fit triple roller star onto shaft and press on to stop. – Ensure that pressure does not exceed 3.0 t. – If necessary, coat splines of drive shafts and triple roller star with lubricating paste -G 052 142 A2- .

  • Page 135: Appraisal Of Accident Vehicles

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 42 – Rear suspension Appraisal of accident vehicles A checklist for evaluating running gear of accident vehicles can be found under ⇒ page 1 1. Appraisal of accident vehicles...

  • Page 136: Repairing Rear Suspension (Front-Wheel Drive)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Repairing rear suspension (front- wheel drive) Overview - rear axle I - Assembly overview: sub‐ frame, transverse link, track rod (front-wheel drive) ⇒ page 132...

  • Page 137: Rear Axle In Unladen Position

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Rear axle in unladen position Special tools and workshop equipment required ♦ Engine and gearbox jack - V.A.G 1383 A- ♦ Tensioning strap -T10038- ♦ Support -T10149-...
  • Page 138 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Before the axle on one side is raised, the vehicle must be strapped to the lifting platform arms using tensioning strap -T10038- . WARNING If the vehicle is not strapped down, there is a danger that the vehicle will slip off the lifting platform! –...
  • Page 139 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Respective nuts and bolts may be tightened only when dimension -a- between the centre of wheel hub and edge of wheel housing has been attained.

  • Page 140: Assembly Overview: Subframe, Transverse Link, Track Rod (Front-Wheel Drive)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: subframe, transverse link, track rod (front-wheel drive) 1 - Eccentric bolt ❑ For camber adjustment ❑ Check wheel alignment whenever this compo‐ nent is loosened ⇒...
  • Page 141 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ❑ Self-locking ❑ Always renew after removing. ❑ Always tighten threaded connections in unladen position ⇒ page 129 12 - Bolt ❑ Always renew after removing.

  • Page 142: Removing And Installing Rear Axle

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and installing rear axle Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1332- ♦ Engine and gearbox jack - V.A.G 1383/A - ♦...
  • Page 143 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolt -arrow-. – Lever off spring clip -1- for handbrake cable. – Push lever -2- in -direction of arrow- and unhook brake cable -3-.
  • Page 144 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Unclip speed sensor wire from retainer -1- -arrows-. – Pull out hose retainer -1- on both sides of vehicle. – Mark installation position of bearing bracket on body.
  • Page 145 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Position engine and gearbox jack -V.A.G 1383 A- under sub‐ frame using universal gearbox mounting -V.A.G 1359/2- and secure with tensioning strap. – Unscrew bolt -1- or -2- on both sides.
  • Page 146 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Specified torques Component Specified torque Subframe to body 90 Nm + 90° ♦ Use new bolts Shock absorber to wheel bearing housing 180 Nm Mounting bracket to body 50 Nm + 45°...

  • Page 147: Vehicle Level Sender For Vehicles With Automatic Headlight Range Control

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Vehicle level sender for vehicles with automatic headlight range control Note The vehicle level sender is available as a replacement part only complete with coupling rod and upper and ♦...

  • Page 148: Removing And Installing Upper Transverse Link

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Torque wrench -V.A.G 1410- Removing – Separate connection -1-. – Remove bolts -2- from lower transverse link. – Remove bolts -arrows- from subframe. – Remove rear left vehicle level sender -G76- .
  • Page 149 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Unhook speed sensor line -arrow A- from upper transverse link. – Remove bolt -1-. – Mark position of eccentric bolt -arrow- relative to subframe us‐...

  • Page 150: Removing And Installing Lower Transverse Link

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Specified torques Component Specified torque Upper transverse link to wheel bearing housing 130 Nm + 90° ♦ Use new nuts and bolts ♦ Tighten threaded connections only when vehicle is in...

  • Page 151: Removing And Installing Track Rod

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -1- from lower transverse link. Continuation for all vehicles – Mark position of eccentric bolt -arrow- relative to subframe us‐ ing e.g. a felt tip pen.
  • Page 152 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- Removing – Remove wheel. – Remove coil spring ⇒ page 165 – Remove nut -1- and pull coupling rod -2- out of anti-roll bar.
  • Page 153 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove nut -arrow- and remove bolt towards rear. – Remove track rod. Installing – Install track rod on vehicle and tighten bolts hand tight.
  • Page 154 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Specified torques Component Specified torque Track rod to wheel bearing housing 130 Nm + 90° ♦ Use new nuts and bolts ♦ Tighten threaded connections only when vehicle is in...

  • Page 155: Assembly Overview: Wheel Bearing Housing, Trailing Arm (Front-Wheel Drive)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 1 - Bolt ❑ 50 Nm + 45° further ❑ Always renew after re‐ moving. 2 - Mounting bracket 3 - Bolt ❑...

  • Page 156: Removing And Installing Wheel Bearing Housing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 A proper seal can be achieved only by installing a new grease cap. 15 - Bolt ❑ M16 x 1.5 x 70 ❑ 180 Nm + 180° further ❑...
  • Page 157 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolt -arrow-. – Remove bolt for track rod -1-, upper transverse link -2- and lower transverse link -3- from wheel bearing housing -4-.
  • Page 158 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Threaded connection for trailing arm and wheel bearing housing may be tightened only after all other components (particularly the spring and shock absorber) of respective wheel suspension have been installed.
  • Page 159 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Tighten bolt -1- for upper transverse link. Note Washer -2- must be installed so that there is a gap -arrow B- be‐ tween washer and splash plate -3-.

  • Page 160: Renewing Bonded Rubber Bush For Wheel Bearing Housing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Renewing bonded rubber bush for wheel bearing housing Special tools and workshop equipment required ♦ Press tool -30 - 506 B- ♦ Drift sleeve -41-501- ♦...
  • Page 161 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove cover plate. – Remove bolt -arrow- for lower transverse link -1-. Pressing out bonded rubber bush – Apply special tools as shown in illustration.
  • Page 162 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Tighten bolt -arrow- for lower transverse link -1-. – Install coil spring ⇒ page 164 – Install brake disc. – Attach brake carrier with brake caliper ⇒ Brake systems; Rep.

  • Page 163: Removing And Installing Wheel Bearing/Wheel Hub Unit

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and installing wheel bearing/wheel hub unit Special tools and workshop equipment required ♦ Hub grease cap puller -VW 637/2- ♦ Fitting sleeve -3241- ♦ Torque wrench -V.A.G 1332- ♦...
  • Page 164 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Loosen grease cap from seat by tapping lightly on the claw of the hub grease cap puller -VW 637/2- . – Lever off grease cap.

  • Page 165: Removing And Installing Trailing Arm With Mounting Bracket

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Drive dust cap on with fitting sleeve -3241/4- . Note Always renew removed grease caps. ♦ Damaged grease caps may allow moisture to enter the bear‐...
  • Page 166 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolt -arrow- securing handbrake cable -1- to trailing arm -2-. Vehicles with retainer for hand brake cable – Remove retainer -1- by pushing out inner pin of rivet -arrow-.
  • Page 167 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Dimension -a- is 34 ± 1 mm. Mounting bracket Trailing arm – Tighten bolt when dimension -a- is set. Installing Threaded connection for trailing arm and wheel bearing housing...
  • Page 168 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Tighten bolts -2- for trailing arm to specified torque setting, observing required positions of parts ⇒ page 159 – Bolt coupling rod -1- to wheel bearing housing and anti-roll bar.

  • Page 169: Repairing Trailing Arm

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Component Specified torque Mounting bracket to body 50 Nm + 45° ♦ Use new bolts Coupling rod to trailing arm. 45 Nm ♦ Use new nut Handbrake cable to trailing arm ⇒...
  • Page 170 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Set up tools as shown in figure. Tube -T10230/3- Thrust piece -T10230/10- Removal tool -3372- Thrust plate -VW 401- Thrust plate -VW 402- – Press out bonded rubber bush.
  • Page 171 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Set up special tools as shown in figure. Tube -T10230/5- Thrust plate -T10230/12- (chamfer must face bonded rubber bush) Bonded rubber bush Removal tool -3372- Thrust plate -VW 402- –...

  • Page 172: Assembly Overview: Shock Absorber, Coil Spring

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: shock absorber, coil spring 1 - Upper spring seat 2 - Coil spring ❑ Note various versions of running gear ⇒ page 275 ❑...
  • Page 173 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Spring retainer -V.A.G 1752/3A- ♦ Adapter -V.A.G 1752/9- , not illustrated Removing – Remove wheel. – Insert spring compressor -3-. WARNING Ensure that coil spring is correctly seated in spring retainers - V.A.G 1752/3A- -2- (accident risk).

  • Page 174: Removing And Installing Shock Absorbers

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Insert this pin in holes in lower transverse link -arrow-. – Then insert top spring seat into upper end of spring. – Release tension on spring while locating upper spring seat on lug on body.
  • Page 175 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolt -arrow-. – Remove shock absorber. Installing Install in reverse order. Note the following points: – Bring rear axle into unladen position ⇒ page 129 The transverse link may be bolted only when dimension „a“...

  • Page 176: Repairing Shock Absorber

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Repairing shock absorber 1 - Shock absorber ❑ Removing and installing ⇒ page 166 ❑ Note different running gear versions ⇒ page 275 , vehicle data sticker.
  • Page 177 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Torque wrench -V.A.G 1332- ♦ Shock absorber set -T10001- Dismantling and assembling Loosening and tightening threaded connection for shock absorb‐ er mounting Commercially available ratchet handle...

  • Page 178: Assembly Overview: Anti-Roll Bar

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: anti-roll bar The -arrow- points forwards. 1 - Anti-roll bar ❑ Note different running gear versions ⇒ page 275 ❑ Removing and installing ⇒...
  • Page 179 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Torque wrench -V.A.G 1331- Removing Note The following procedure is for the left side of the vehicle. The procedure for the right side of the vehicle is identical.
  • Page 180 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Connect coupling rod -2- to anti-roll bar and tighten nut -1-. Specified torques Component Specified torque Anti-roll bar to subframe 25 Nm + 45°...

  • Page 181: Bluemotion (Front-Wheel Drive)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: attachments parts for subframe Jetta BlueMotion, Golf Variant BlueMotion (front-wheel drive) 1 - Subframe 2 - Bolt 3 - Bracket ❑ With pop rivet bolt 4 - Nut ❑...

  • Page 182: Removing And Installing Shield

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and installing shield Removing – Remove nuts -1-. – Pull shield -2- downwards off the subframe and detach above at the same time -arrow-.
  • Page 183 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Tighten nuts -1-. Note After installing shield check again whether the shield lug has en‐ gaged properly in subframe -arrow-. Specified torques Component Shield to subframe 2 Nm 7.

  • Page 184: Repairing Rear Suspension (Four-Wheel Drive)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Repairing rear suspension (four- wheel drive) Overview - rear axle Note It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.
  • Page 185 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 III - Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) ⇒ page 204 IV - Assembly overview: shock absorber, coil spring (four- wheel drive) ⇒...

  • Page 186: Rear Axle In Unladen Position

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Rear axle in unladen position Special tools and workshop equipment required ♦ Engine and gearbox jack - V.A.G 1383 A- ♦ Tensioning strap -T10038- ♦ Support -T10149-...
  • Page 187 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Before the axle on one side is raised, both sides of the vehicle must be strapped to the lifting platform arms with tensioning straps -T10038- .

  • Page 188: Assembly Overview: Subframe, Final Drive (Four-Wheel Drive)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: subframe, final drive (four-wheel drive) -Arrow- indicates direction of travel. 1 - Subframe 2 - Rear bonded rubber bush ❑ Renewing ⇒ page 186 3 - Front bonded rubber bush ❑...
  • Page 189 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Engine and gearbox jack -V.A.G 1383 A- Removing subframe with attachments Note Note that subsequent assembly work in which the twelve-point bolt of the drive shaft has to be loosened has to be carried out with the vehicle standing on its wheels.
  • Page 190 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove retainer -1- by pushing out inner pin of rivet -arrow-. – Mark installation position of mounting bracket on body. – Remove bolts -arrows-.
  • Page 191 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Unscrew centre bearing bolts -arrows- two turns. – Support propshaft -A- on tunnel support -1- using a wooden block. – Push rear propshaft tube towards gearbox as far as possible.
  • Page 192 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 To fix position of subframe, locating pins -T10096- must be screwed in successively at positions -1- and -2- on both sides of vehicle. – Unscrew one hexagon bolt -1- or -2- on both sides.
  • Page 193 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Unclip brake line from clips -arrows- above drive shaft flange on gearbox -1-. Note The clips will be destroyed and must be renewed. – Carefully lower subframe with attachments.

  • Page 194: Repairing Subframe

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Repairing subframe Special tools and workshop equipment required ♦ Tensioning strap -T10038- ♦ Locating pins -T10096- ♦ Assembly tool -T10263- ♦ Engine and gearbox jack - V.A.G 1383 A-...
  • Page 195 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove clip -1-. Note Do not open brake line. – Now strap vehicle to lifting platform arms on both sides of ve‐ hicle using tensioning straps -T10038- .
  • Page 196 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Fix position of subframe using 2 locating pins -T10096- and tighten to 20 Nm. Note The locating pins -T10096- may be tightened only to a maximum of 20 Nm;...
  • Page 197 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Distinguishing features of bonded rubber bushes I - Front bonded rubber bush II - Rear bonded rubber bush The front bonded rubber bushes have two notches on the upper side -arrows- and differ to the rear slightly in height ⇒...
  • Page 198 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove clip -1-. Note Do not open brake line. – Now strap vehicle to lifting platform arms on both sides of ve‐ hicle using tensioning straps -T10038- .
  • Page 199 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Fix position of subframe using locating pins -T10096- . Note The locating pins -T10096- may be tightened only to a maximum of 20 Nm; otherwise the threads of the locating pins may be dam‐...
  • Page 200 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Distinguishing features of bonded rubber bushes I - Front bonded rubber bush II - Rear bonded rubber bush The front bonded rubber bushes have two notches on the upper side -arrows- and differ to the rear slightly in height ⇒...

  • Page 201: Assembly Overview: Transverse Link, Track Rod (Four-Wheel Drive)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: transverse link, track rod (four-wheel drive) -Arrow- indicates direction of travel. 1 - Eccentric bolt ❑ Check wheel alignment whenever this compo‐ nent is loosened ⇒...
  • Page 202 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ❑ Always renew after removing. 9 - Lower transverse link ❑ Removing and installing ⇒ page 199 10 - Nut ❑ 90 Nm + 90° further ❑...
  • Page 203 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 26 - Track rod ❑ Various versions ♦ Forwards closed (left and right track rods differ) ♦ Downwards open (left and right track rods identical) ❑...

  • Page 204: Overview - Rear Left Vehicle Level Sender G76

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 10.1 Overview - rear left vehicle level sender -G76- Note ♦ The vehicle level sender is available as a replacement part only complete with coupling rod and upper and lower retaining plates.

  • Page 205: Removing And Installing Upper Transverse Link

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Torque wrench -V.A.G 1410- Removing – Separate connection -1-. – Remove bolts -2- from lower transverse link. – Remove bolts -arrows- from subframe. – Remove rear left vehicle level sender -G76- .
  • Page 206 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Unhook speed sensor line -arrow A- from upper transverse link. – Remove bolt -1-. – Mark position of eccentric bolt -arrow- relative to subframe us‐...

  • Page 207: Removing And Installing Lower Transverse Link

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Component Specified torque Upper transverse link to subframe 95 Nm ♦ Use new nut ♦ To tighten nuts, set torque wrench -V.A.G 1332- to 80 Nm.
  • Page 208 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -1- from lower transverse link. Continuation for all vehicles – Mark position of eccentric bolt -arrow- relative to subframe us‐ ing e.g. a felt tip pen.

  • Page 209: Removing And Installing Track Rod

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 10.5 Removing and installing track rod Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- Removing – Remove wheel.
  • Page 210 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Now strap vehicle to lifting platform arms on both sides of ve‐ hicle using tensioning straps -T10038- . WARNING If the vehicle is not strapped down, there is a great danger that the vehicle will slip off the lifting platform! –...
  • Page 211 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Tighten bolts -arrows- for anti-roll bar clamp. For the right side of the vehicle only (depending on equipment) – Lower wheel suspension again using engine and gearbox jack -V.A.G 1383 A- and remove support -T10149- from wheel hub.

  • Page 212: Assembly Overview: Wheel Bearing Housing, Trailing Arm (Four-Wheel Drive)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) -Arrow- indicates direction of travel. 1 - Mounting bracket 2 - Cover 3 - Bolt ❑ M12 x 1.5 x 80 ❑...

  • Page 213: Removing And Installing Wheel Bearing Housing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ❑ Self-locking ❑ Always renew after removing. 14 - Bolt ❑ M10 x 35 ❑ 50 Nm + 45° further ❑ Always renew after removing.
  • Page 214 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove wheel. – Remove brake carrier with brake caliper and tie to body with wire ⇒ Rep. gr. 46 . – Remove ABS speed sensor from wheel bearing housing.
  • Page 215 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Position: threaded connection between trailing arm and wheel bearing housing Threaded connection for trailing arm and wheel bearing housing may be tightened only after all other components (particularly the spring and shock absorber) of respective wheel suspension have been installed.

  • Page 216: Renewing Bonded Rubber Bush For Wheel Bearing Housing

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Component Specified torque Drive shaft to hub 70 Nm + 90° further ♦ Use new bolt 11.2 Renewing bonded rubber bush for wheel bearing housing...
  • Page 217 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing – Remove wheel. – Remove coil spring ⇒ page 218 – Remove brake carrier with brake caliper and tie to body with wire ⇒ Rep. gr. 46 .

  • Page 218: Removing And Installing Wheel Bearing/Wheel Hub Unit

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Attach tools as shown in figure. 1 - -3346/3- 2 - -3301- 3 - -30-506 B- 4 - Bonded rubber bush 5 - -3160-...

  • Page 219: Removing And Installing Trailing Arm With Mounting Bracket

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Torque wrench -V.A.G 1410- Removing – Remove coil spring ⇒ page 218 – Remove drive shaft ⇒ page 230 – Remove brake carrier with brake caliper and tie to body with wire ⇒...
  • Page 220 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Torque wrench -V.A.G 1332- Removing – Remove wheel. – Remove coil spring ⇒ page 218 – Remove retainer -1- by pushing out inner pin of rivet -arrow-.
  • Page 221 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Determining position of mounting bracket in relation to trailing arm Dimension -a- is 34 mm. 1 - Mounting bracket 2 - Trailing arm – Tighten bolt when dimension -a- is set.
  • Page 222 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Tighten bolts -2- for trailing arm to specified torque setting, observing required positions of parts ⇒ page 213 – Bolt coupling rod -1- to wheel bearing housing and anti-roll bar.

  • Page 223: Repairing Trailing Arm

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 11.5 Repairing trailing arm Special tools and workshop equipment required ♦ Assembly tool -T10230- ♦ Removal tool -3372- ♦ Thrust plate -VW 401- ♦ Thrust plate -VW 402- Pressing out bonded rubber bush –...
  • Page 224 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Set up tools as shown in figure. Tube -T10230/3- Thrust piece -T10230/10- Removal tool -3372- Thrust plate -VW 401- Thrust plate -VW 402- – Press out bonded rubber bush.
  • Page 225 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Set up tools as shown in figure. Tube -T10230/5- Thrust plate -T10230/12- (chamfer must face bonded rubber bush) Bonded rubber bush Removal tool -3372- Thrust plate -VW 402- –...

  • Page 226: Assembly Overview: Shock Absorber, Coil Spring (Four-Wheel Drive)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: shock absorber, coil spring (four-wheel drive) 1 - Lower spring seat ❑ End of coil spring turned to stop 2 - Assembly aid ❑...
  • Page 227 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Suspension strut clamp -V.A.G 1752- ♦ Spring retainer -V.A.G 1752/4- ♦ Adapter -V.A.G 1752/9- , not illustrated Removing – Remove wheel. – Insert spring compressor -3-.

  • Page 228: Removing And Installing Shock Absorbers

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 End of spring -arrow- must lie against stop on bottom spring seat. – Install spring together with spring seat. – The bottom spring seat has a pin.
  • Page 229 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -arrows-. – Remove bolt -arrow-. – Remove shock absorber. Installing Install in reverse order. Note the following points: The shock absorber may be bolted to the wheel bearing housing only when dimension „a“...

  • Page 230: Repairing Shock Absorber

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 12.3 Repairing shock absorber Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1332- ♦ Shock absorber set -T10001- Rep. gr.42 - Rear suspension...
  • Page 231 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 1 - Shock absorber ❑ Removing and installing ⇒ page 220 ❑ Note different running gear versions ⇒ page 275 , vehicle data sticker. 2 - Protective cap...
  • Page 232 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Loosening and tightening threaded connection for shock absorb‐ er mounting 1 - Commercially available ratchet handle 2 - Socket -T10001/9- 3 - Ratchet handle -T10001/11- 4 - Socket -T10001/1- Rep.

  • Page 233: Assembly Overview: Anti-Roll Bar (Four-Wheel Drive)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: anti-roll bar (four-wheel drive) -Arrow- indicates direction of travel. 1 - Anti-roll bar ❑ Note different running gear versions ⇒ page 275 , vehicle data sticker.
  • Page 234 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing – Remove rear wheels. Note The following procedure is for the left side of the vehicle. The procedure for the right side of the vehicle is identical.
  • Page 235 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Evenly tighten bolts -arrows- for anti-roll bar clamp. For the right side of the vehicle only (depending on equipment) – Lower wheel suspension again using engine and gearbox jack -V.A.G 1383 A- and remove support -T10149- from wheel hub.

  • Page 236: Assembly Overview: Drive Shaft

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: drive shaft 1 - Outer constant velocity joint ❑ Renew only as com‐ plete unit ❑ Removing ⇒ page 234 ❑ Installing: drive onto...

  • Page 237: Loosening And Tightening 12-Point Flange Bolt Securing Drive Shaft

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 11 - Locking plate 12 - Multi-point socket head bolt ❑ M8 x 48 ❑ Initially tighten diagonally to 10 Nm and then tighten diagonally to specified torque ❑...

  • Page 238: Removing And Installing Drive Shaft

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Wheel bearings must not be subjected to load after bolt securing drive shaft to wheel hub has been loosened. If wheel bearings are loaded with weight of vehicle, bearing will be damaged.
  • Page 239 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolt -arrow-. – Loosen drive shaft at gearbox flange. – Swing wheel bearing housing out and pull drive shaft out of inner splines.

  • Page 240: Dismantling And Assembling Drive Shaft

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 14.3 Dismantling and assembling drive shaft Special tools and workshop equipment required ♦ Thrust plate -VW 401- ♦ Thrust plate -VW 402- ♦ Press tool -VW 408 A- ♦...
  • Page 241 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Circlip pliers -VW 161 A- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Special pliers -V.A.G 1682- ♦ Assembly tool -T10065- ♦...
  • Page 242 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Puller -T10382- Removing outer constant velocity joint – Clamp drive shaft in vice using protective jaw covers. – Fold back boot. – Set puller -T10382- up so that smooth side of puller plate - T10382/1- points to spindles -T10382/2- .
  • Page 243 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Pressing off inner constant velocity joint – Drive joint protective boot off joint using a drift. – Remove retaining ring. – Remove both clamps and slide boot towards outer joint.

  • Page 244: Checking Outer Constant Velocity Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Tighten clamp on outer joint – Position clamp tensioner -V.A.G 1682- as shown in diagram. Ensure jaws of tool contact corners -arrows B- of clamp.

  • Page 245: Checking Inner Constant Velocity Joint

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Turn cage until the two rectangular windows -arrow- align with joint body. – Take out cage with hub. – Swing segment of hub into square cage window.
  • Page 246 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Tip ball hub out of ball cage via ball track -arrows-. – Check joint body, ball hub, ball cage and balls for pitting and traces of seizing.
  • Page 247 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Swivel in hub with balls by applying firm pressure to cage -arrow-. – Checking function of constant velocity joint The constant velocity joint is correctly assembled if the ball hub can be moved by hand backwards and forwards over its entire range of axial movement.

  • Page 248: Appraisal Of Accident Vehicles

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 44 – Wheels, tyres, vehicle geometry Appraisal of accident vehicles A checklist for evaluating running gear of accident vehicles can be found under ⇒ page 1...

  • Page 249: Torque Settings For Wheels

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Torque settings for wheels Wheel bolt to wheel hub for all vehicles Torque setting: 120 Nm. 2. Torque settings for wheels...

  • Page 250: Fitting Wheel And Tyre

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Fitting wheel and tyre General information New wheels with a modified contour have been introduced for all vehicles as of model year 2005. The tyre fitting unit must be fitted with the tyre fitting head de‐...
  • Page 251 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 indicates that the tyre is intensively absorbing heat from its environment through the process of water vapour in the air condensing out on the tyre surface.

  • Page 252: Removing And Fitting Tyres (Wheels With Tyre Pressure Monitoring)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and fitting tyres (wheels with tyre pressure monitoring) Notes on safety and conditions for re‐ moving and fitting tyres (wheels with tyre pressure monitoring) •...

  • Page 253: Pressing Tyre Off Wheel Rim

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Tyre sets with other specified tyre inflation pressures If a vehicle is fitted with tyres requiring nominal tyre inflation pres‐ sures other than those specified on the tank flap sticker, these tyres (second wheel set) can also be monitored with the TPM system.

  • Page 254: Removing Tyre From Wheel

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing tyre from wheel Caution ♦ Comply with the notes on safety and conditions ⇒ page 244 ♦ The assembly head must never be within area -a- of tyre valve/tyre pressure sensor, or the assembly head will damage the tyre pressure sensor .
  • Page 255 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Turn wheel on tyre fitting unit so that tyre valve with tyre pres‐ sure sensor -arrow- is directly opposite assembly head. – Press tyre into drop centre in -direction of arrow- between tyre valve with tyre pressure sensor and assembly head.

  • Page 256: Removing And Fitting Tyres With Run-Flat Properties To Wheel Rims

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and fitting tyres with run- flat properties to wheel rims Notes on safety • Only specially trained mechanics may remove or install tyres with run-flat properties.
  • Page 257 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 WARNING The minimum installation temperature of a tyre must neither be less than 15°C nor exceed 30°C in the core of the tyre. • To install tyres without damage, it is especially important to warm the upper part of the sidewall and the inside of the upper bead to at least 15 °C.

  • Page 258: Pressing Tyre Off Wheel Rim

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Pressing tyre off wheel rim Caution ♦ Observe the safety instructions ⇒ page 248 – Deflate tyre by unscrewing nickel-plated valve core. – When pressing off a tyre using tyre fitting equipment with a press-off plate, always ensure that the tyre valve/ tyre pres‐...
  • Page 259 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Turn wheel on tyre fitting unit so that tyre valve with tyre pres‐ sure sensor -2- is directly in front of assembly head -1-.

  • Page 260: Fitting Tyre To Wheel Rim

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Hold bead over wheel rim flange from outside using plastic assembly lever -1- and run tyre fitting machine clockwise until tyre is pulled completely off wheel rim.
  • Page 261 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Turn wheel rim on tyre fitting unit so that tyre valve/ tyre pres‐ sure sensor -1- is directly opposite assembly head -2-. – Fit depressor -3- on wheel rim.

  • Page 262: Tyre Pressure Monitor Display

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Tyre pressure monitor display General The tyre pressure monitor system is part of the software in the ABS control unit -J104- . The system is used to detect slow tyre pressure loss from a wheel.

  • Page 263: System Fault In The Abs System

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 System fault in the ABS system System fault in the ABS system If a fault in the ABS is displayed by the ESP and TCS warning...
  • Page 264 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Vehicles as of model year 2010 – Push button in glove compartment until an audible signal sounds. The audible signal confirms basic setting. Rep. gr.44 - Wheels, tyres, vehicle geometry...

  • Page 265: Tyre Pressure Monitor

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Tyre pressure monitor For detailed information on the tyre pressure monitor (TPM), refer to ⇒ Self-study programme No. 347 ; Tyre Pressure Monitoring Systems .
  • Page 266 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Time for which the button is pressed Up to 2 seconds 3-7 seconds 8-10 seconds 11-15 seconds State or action Actual state Switch Confirm Deactivation...

  • Page 267: Assembly Overview: Tyre Pressure Sensor

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: tyre pressure sensor 1 - Tyre pressure sensor ❑ Supplied complete as spare part. ❑ Removing and installing ⇒ page 259 ❑ Replace complete tyre...
  • Page 268 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Install tyre pressure sensor -2- along with a new seal and sealing washer and push it into wheel rim at the points marked by -arrows-.

  • Page 269: Wheel Alignment

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Wheel alignment Special tools and workshop equipment required ♦ Wheel alignment computer -V.A.G 1813- or VW/Audi- approved wheel alignment computer ♦ Brake pedal depressor - V.A.G 1869/2-...
  • Page 270 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐ ware; Wheel alignment; John Bean Note Wheel alignment should not be checked before the vehicle has ♦...

  • Page 271: Test Prerequisites

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Prerequisite: the positions of the subframe and brackets were fixed before the parts were removed ⇒ page 16 Test prerequisites • Check suspension, wheel bearing, steering and steering link‐...

  • Page 272: Specifications For Wheel Alignment Jetta From 2006, Golf Variant From 2008

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Apply brake pedal depressor -V.A.G 1869/2- . – Use brake pedal depressor to depress brake pedal. Specifications for wheel alignment Jetta from 2006, Golf Variant from 2008 •...

  • Page 273: Sportwagen From 2009 (North America)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Front axle Heavy-duty running BlueMotion BlueMotion gear Jetta from 2006 Golf Variant from 2008 PR numbers G13, 2UC G14, 2UC 1°38′ ± 20′ 1°40′ ± 20′...

  • Page 274: Specifications For Wheel Alignment Bora From 2006 (Mexico)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Explanation of PR Nos. can be found here ⇒ page 275 The ride height shown in the table refers to dimension -a-. Front axle...

  • Page 275: Specifications For Wheel Alignment, Jetta From 2006 (India)

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 • Specifications for wheel alignment, Jetta from 2006 (India) ⇒ page 267 ♦ Explanation of PR Nos. can be found here ⇒ page 275 The ride height shown in the table refers to dimension -a-.

  • Page 276: Overview - Wheel Alignment Procedure

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Explanation of PR Nos. can be found here ⇒ page 275 The ride height shown in the table refers to dimension -a-. Front axle...
  • Page 277 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Alignment procedure → → Start Carry out wheel runout com‐ Bounce springs. pensation. ↓ ← ← Turn steering wheel to Measure vehicle height. Fit brake pedal depressor -V.A.G...

  • Page 278: Correcting Front Axle Camber

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Correcting front axle camber Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1332- Note Camber correction is necessary only after body repairs. The ♦...

  • Page 279: Adjusting Camber On Rear Axle

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 There must be a clearance of 5 mm all round between universal joint -2- and recess in bulkhead. Specified torques Component Specified torque Subframe to body 70 Nm + 90°...
  • Page 280 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Loosen upper transverse link nut -A- on subframe. – Adjust camber by turning eccentric bolt -B- with 18 mm socket -T10001- -1-. Note The maximum adjustment range is 90° to the left or right of centre.

  • Page 281: Adjusting Toe At Rear Axle

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Component Specified torque Upper transverse link to subframe (vehicles with front- 95 Nm wheel drive) ♦ To tighten nuts, set torque wrench -V.A.G ♦ Use new nut 1332- to 80 Nm ♦...

  • Page 282: Basic Setting For Steering Angle Sender G85

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Torque wrench -V.A.G 1332- ♦ Tool insert 24 mm -V.A.G 1332/11- – Loosen lock nut -arrow 3- counterholding on track rod ball joint -arrow 2-.

  • Page 283: Vehicle Data Sticker

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 8.14 Vehicle data sticker Explanation of „PR numbers“ on vehicle data sticker Various types of running gear are installed depending on engine and equipment level. These are identified by the PR numbers.

  • Page 284: Wheels, Tyres

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Wheels, tyres Models with breakdown set These vehicles are equipped with either a spare wheel or a break‐ down set. The breakdown set is located in the luggage compartment where normally the spare wheel would sit.

  • Page 285: Fitting A New Tyre

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Use a suitable drill or mill to carefully drill a hole in shoulder area of tyre. – Hold wheel over a suitable container and drain sealant.
  • Page 286 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 usual rubber valves. Metal valves must be renewed completely each time a tyre is changed. 1 - Wheel rim 2 - Valve cap 3 - Hexagon nut ❑...

  • Page 287: Instructions For Changing Or Fitting Wheels

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Instructions for changing or fitting wheels WARNING Perform the checks and follow the instructions listed below. This is important to ensure that the wheel bolts and the wheels are properly secured.

  • Page 288: Fitting Wheels

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Check whether the wheel bolts can be easily screwed in by hand. The thread of the wheel bolts must not come into contact with the bore in the brake disc -arrow-.

  • Page 289: Protecting Wheel Centring Seat Against Corrosion

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Protecting wheel centring seat against corrosion Applies to alloy and steel wheels When a wheel is installed, wheel centring seat should be waxed with Wax spray -D 322 000 A2- to prevent corrosion between the wheel centring seat and the wheel rim.

  • Page 290: Rough Running Due To Wheels/Tyres - Causes And Rectification

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Rough running due to wheels/tyres - causes and rectification Causes of rough running ⇒ page 282 Balancing wheels ⇒ page 282 Conducting a road test before balancing wheels ⇒...

  • Page 291: Balancing Wheels On Stationary Wheel Balancing Machine

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ This will give you information about the nature of the rough running. ♦ You will be able to determine in which speed range the rough running occurs.
  • Page 292 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Note To clamp the wheel, use e.g. centring system for wheel bal‐ ♦ ancing machines -VAS 5271- . This ensures that the wheel is 100% centred and that the ♦...

  • Page 293: Vibration Control System Vas 6230

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 If you detect vibration during the road test, it may be due to tol‐ erance in the wheel centring. In unfavourable circumstances, the component tolerances of wheels and hubs could cumulate.

  • Page 294: Radial And Lateral Runout Of Wheels And Tyres

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Note The imbalance should always be less than 20 grams before you change the balance weight. – If necessary, remove the wheel bolts again. – Rotate the wheel relative to the hub once more, turning it one or two wheel bolt holes further.

  • Page 295: Checking Radial And Lateral Runout On Wheel Rim

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Set tyre gauge against sidewall of tyre. – Slowly rotate the wheel. – Note the smallest and the largest dial readings. Note If the difference is greater than 1.3 mm, the lateral runout is too great.

  • Page 296: Matching

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Wheel rim Radial runout (mm) Lateral runout (mm) Alloy wheel Note If the measured value exceeds the specification, acceptably smooth running cannot be attained. 12.10...

  • Page 297: Flat Spots Caused By Storage Or Handling

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 If the radial and/or lateral runouts are still not within the specifi‐ cations, check the radial and/or lateral runouts of the wheel: ⇒ page 287...
  • Page 298 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Traffic and road conditions permitting, drive a 20 to 30 km stretch at a speed of 120 to 150 km/h. WARNING ♦ Do not endanger yourself or other road users during this road test.

  • Page 299: Appraisal Of Accident Vehicles

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 48 – Steering Appraisal of accident vehicles A checklist for evaluating running gear of accident vehicles can be found under ⇒ page 1 1. Appraisal of accident vehicles...

  • Page 300: General Repair Instructions

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 General repair instructions To achieve the desired results when performing repairs on the steering box it is important to work with the greatest possible care and cleanliness, and to use proper tools in good condition.

  • Page 301: Electrical Components

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Electrical components At some point, you have probably received an electric shock when touching a metal object. This is due to the electrostatic charge accumulated by the human body. This charge can cause mal‐...

  • Page 302: Steering Wheel, Steering Column

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Steering wheel, steering column Removing and installing steering wheel Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1332- Removing – Remove airbag in steering wheel ⇒ General body repairs, in‐...
  • Page 303 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Centre steering wheel (wheels in straight-ahead position). – Remove bolt -3- and pull steering wheel from steering column. Installing – Set steering wheel onto steering column.
  • Page 304 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Guide connector for steering angle sender -G85- into intended opening in the base of steering wheel. – Join connector -1- with the connector -2- of the steering angle sender -G85- .

  • Page 305: Year 2008

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview - steering column, Golf Variant up to model year 2009, Jetta up to model year 2008 Note It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.
  • Page 306 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- Removing Only the complete steering column is supplied as a replacement part. Repair is not possible.
  • Page 307 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove left trim on driver side ⇒ General body repairs, inte‐ rior; Rep. gr. 68 ; Compartments, covers and trims; Removing and installing left driver side trim .
  • Page 308 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove earth cable -arrow- and cable -1- from steering col‐ umn. – Remove bolts -2-. Vehicles with crash bars – Remove earth cable -arrow- and cable -1- from steering col‐...
  • Page 309 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Tighten steering column bolts -2-. – Attach earth wire -arrow- and wire -1- to steering column. Vehicles with crash bars – Tighten steering column bolts -2-.
  • Page 310 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Fit universal joint -2- onto steering box pinion and tighten bolt -1-. – Install footwell trim -1- and secure with nuts -arrows-. – Install cable duct -1- below steering column.

  • Page 311: Assembly Overview - Steering Column, Left-Hand Drive, Jetta As Of Model Year 2009

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Specified torques Component Specified torque Universal joint to steering box 30 Nm ♦ Use new bolt Steering column to mounting bracket 20 Nm Assembly overview - steering column, left-hand drive, Jetta as of model year...

  • Page 312: Removing And Installing Steering Column, Left-Hand Drive, Jetta As Of Model Year 2009

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and installing steering col‐ umn, left-hand drive, Jetta as of model year 2009 Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦...
  • Page 313 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove airbag in steering wheel ⇒ General body repairs, in‐ terior; Rep. gr. 69 ; Airbag; Removing and installing driver side airbag unit .
  • Page 314 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolt -1- and pull universal joint -2- off steering box. Vehicles with manual gearboxes – Remove left bolt -1- and remove crash bar for clutch pedal -2-.
  • Page 315 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -1- and firmly hold steering column. – Lower steering column -1- slightly and carefully pull column out of guides on mounting bracket -arrow-.
  • Page 316 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Fit crash bar for brake pedal -1- and bolt -2- on. Vehicles with dual clutch gearbox or automatic gearbox – Fit bolt -1-. Vehicles with manual gearboxes –...
  • Page 317 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Install cable duct -1- below steering column. The lugs -arrow- must engage in the guide on both sides. – Reconnect earth cable to steering column .
  • Page 318 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Plug in connector -1-. – Install steering column switch ⇒ Electrical system; Rep. gr. 94 ; Steering column switch; Removing and installing steering column switch .

  • Page 319: Assembly Overview - Steering Column, Right-Hand Drive, Jetta As Of Model Year 2009

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview - steering column, right-hand drive, Jetta as of model year 2009 Note ♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.
  • Page 320 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- Removing Only the complete steering column is supplied as a replacement part. Repair is not possible.
  • Page 321 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove steering column switch ⇒ Electrical system; Rep. gr. 94 ; Steering column switch; Removing and installing steering column switch . – Separate connection -1-.
  • Page 322 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolt -1- for universal joint and pull universal joint -2- off steering box. Vehicles with manual gearboxes – Remove left bolt -1- and remove crash bar for clutch pedal -2-.
  • Page 323 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -1- and firmly hold steering column. – Lower steering column -1- slightly and carefully pull column out of guides on mounting bracket -arrow-.
  • Page 324 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Fit crash bar for brake pedal -1- and bolt -2- on. Vehicles with dual clutch gearbox or automatic gearbox – Fit bolt -1-. Vehicles with manual gearboxes –...
  • Page 325 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Install cable duct -1- below steering column. The lugs -arrow- must engage in the guide on both sides. – Reconnect earth cable to steering column .

  • Page 326: Following Repair Work

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Plug in connector -1-. – Install steering column switch ⇒ Electrical system; Rep. gr. 94 ; Steering column switch; Removing and installing steering column switch .
  • Page 327 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Proper steering column handling and transport ♦ Use both hands to transport steering column. ♦ Hold steering column upper jacket tube and in area of upper universal joint.

  • Page 328: Handling And Transporting Steering Column, Jetta As Of Model Year 2009

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 3.10 Handling and transporting steering col‐ umn, Jetta as of model year 2009 WARNING ♦ Adherence to proper steering column handling is essen‐ tial. ♦ Improper handling of steering column may damage the steering column, leading to safety risks.

  • Page 329: Checking Steering Column For Damage

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Improper handling of steering column with safety risks Following methods of handling will damage universal joint bushes and lower steering column bearing: ♦ Transporting steering column with one hand on jointed shaft.
  • Page 330 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -arrows- under bracket. – Push connector -1- in -direction of arrow- and remove from support in mounting bracket. – Unscrew bolt -arrow A-.
  • Page 331 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Install bolts -arrows B-. Note Bolts -arrows B- are screwed in from cross member. – Screw in bolt -arrow A-. – Insert connector -1- into support in mounting bracket and push to stop opposite -direction of arrow-.
  • Page 332 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolt -arrow- in plenum chamber. – Remove steering column ⇒ page 297 – Remove bolts -1-. – Remove bolt -2- and remove strut -3-.

  • Page 333: Electromechanical Steering Box Up To Model Year 2008

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Electromechanical steering box up to model year 2008 Assembly overview - electromechanical steering box, left-hand drive vehi‐ cle (2nd generation) up to model year 2008 Note There are no 2nd generation steering boxes available as spare parts.
  • Page 334 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ❑ Always renew clamp for steering box ❑ Always renew after removing. 9 - Shield 10 - Torx bolt ❑ 6 Nm ❑ Self-locking Rep. gr.48 - Steering...

  • Page 335: Generation) Up To Model Year 2008

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview - electromechanical steering box, right-hand drive ve‐ hicle (2nd generation) up to model year 2008 Note There are no 2nd generation steering boxes available as spare parts.

  • Page 336: Year 2008

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ❑ Self-locking ❑ Always renew after removing. 12 - Subframe 13 - Bolt ❑ M10 x 70 ❑ 50 Nm + 90° further ❑ Always renew after removing.
  • Page 337 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing steering box Note There are no 2nd generation steering boxes available as spare ♦ parts. If the steering box has to be replaced, a new 3rd generation ♦...
  • Page 338 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Press track rod ball joint off wheel bearing housing using ball joint puller -3287A- and now remove nut. – Remove lower noise insulation ⇒ General body repairs, ex‐...
  • Page 339 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Now remove bolts -3-, -6-, -11- and -16- for steering box and anti-roll bar. – Fix subframe and brackets in place ⇒ page 16 –...
  • Page 340 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove heat shield -1- over steering box. – Remove bolts -arrows-. – Remove cable guide from subframe -arrow-. – Unclip all remaining cable clips on steering box.
  • Page 341 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Set steering box down as illustrated. This prevents damage to the control unit -1-. Installing steering box Install in reverse order. Threaded sleeves of steering box must seat in holes in brackets.
  • Page 342 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Note If parking aid 2 is fitted in the vehicle, the power steering con‐ ♦ trol unit -J500- must be recoded following the installation of a new steering box⇒...
  • Page 343 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Torque specifications for pendulum support to gearbox Caution From model year 08, HeliCoil inserts are installed in the pen‐ dulum support connection in the 02Q gearboxes. Identification ⇒...

  • Page 344: Year 2008

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and installing steering box, right-hand drive vehicle (2nd gener‐ ation) up to model year 2008 Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦...
  • Page 345 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing Note There are no 2nd generation steering boxes available as spare ♦ parts. If the steering box has to be replaced, a new 3rd generation ♦...
  • Page 346 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Press track rod ball joint off wheel bearing housing using ball joint puller -3287A- and now remove nut. – Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly overview - noise insulation .
  • Page 347 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -arrows- from heat shield. – Remove heat shield from subframe. – Remove bolts -5- and -6- for steering box. – Remove bolts -7- and -8- for anti-roll bar.
  • Page 348 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Position engine and gearbox jack -V.A.G 1383 A- under subframe. – Place, for example, a wooden block -1- between engine and gearbox jack -V.A.G 1383 A- and subframe.
  • Page 349 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Now lift anti-roll bar -1- forwards over subframe -2- and down while turning anti-roll bar slightly. – Unbolt steering box from subframe. 4. Electromechanical steering box up to model year 2008...
  • Page 350 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Set steering box down as illustrated. This prevents damage to the control unit -1-. Installing Install in reverse order. Threaded sleeve of steering box must be located in subframe hole.
  • Page 351 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Note If parking aid 2 is fitted in the vehicle, the power steering control unit -J500- must be recoded ⇒ Vehicle diagnostic, testing and information system VAS 5051.
  • Page 352 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Bolt Specified torque M10 x 35 strength class 8.8 40 Nm + 90° further ♦ Use new bolt M10 x 35 strength class 10.9 50 Nm + 90° further ♦...

  • Page 353: Electromechanical Steering Box From Model Year 2009

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Electromechanical steering box from model year 2009 Assembly overview - electromechanical steering box, left-hand drive vehi‐ cle (3rd generation) from model year 2009 1 - Wiring...

  • Page 354: Generation) From Model Year 2009

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview - electromechanical steering box, right-hand drive ve‐ hicle (3rd generation) from model year 2009 1 - Universal joint 2 - Bolt ❑ M8 x 35 ❑...

  • Page 355: Year 2009

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and installing steering box, left-hand drive vehicle (3rd genera‐ tion) from model year 2009 Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦...
  • Page 356 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolt -1- and pull universal joint -2- off steering box. – Remove front wheels. – Loosen nut on track rod ball joint but do not remove complete‐...
  • Page 357 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -3- and -5- for steering box. – Remove bolts -11- and -16- for anti-roll bar. – Fix subframe and brackets in place ⇒...
  • Page 358 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -4 and 5- and lower subframe with brackets slightly, observing electrical wires. – Remove heat shield -1- over steering box. – Remove bolts -arrows-.
  • Page 359 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Set steering box down as illustrated. This prevents damage to the control unit -1-. Installing steering box Install in reverse order. Threaded sleeves of steering box must seat in holes in left brack‐...
  • Page 360 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Adapting electromechanical steering Specified torques Component Specified torque Subframe to body 70 Nm + 90° ♦ Use new bolts Anti-roll bar to subframe 20 Nm + 90°...

  • Page 361: Year 2009

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and installing steering box, right-hand drive vehicle (3rd gener‐ ation) from model year 2009 Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦...
  • Page 362 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolt -1- for universal joint and pull universal joint -2- off steering box. – Remove front wheels. – Loosen nut on track rod ball joint but do not remove complete‐...
  • Page 363 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Detach exhaust system bracket from subframe -arrows-. Vehicles with front-wheel drive – Remove bolts -arrows- from heat shield. – Remove heat shield from subframe.
  • Page 364 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -11- and -16- for anti-roll bar. – Fix position of subframe ⇒ page 16 – Separate connector for extended service intervals on oil sump.
  • Page 365 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove heat shield -1- over steering box. – Remove bolts -arrows-. – Remove cable guide from subframe -arrow-. – Unclip all remaining cable clips on steering box.
  • Page 366 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Set steering box down as illustrated. This prevents damage to the control unit -1-. Installing Install in reverse order. Threaded sleeve of steering box must be located in subframe hole.
  • Page 367 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Note If parking aid 2 is fitted in the vehicle, the power steering control unit -J500- must be recoded ⇒ Vehicle diagnostic, testing and information system VAS 5051.

  • Page 368: Differentiating Between 2Nd And 3Rd Generation Steering Boxes

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Differentiating between 2nd and 3rd generation steering boxes From model year 2009, a new, 3rd generation, steering box is being used. It replaces the 2nd generation steering box.

  • Page 369: Repairing Electromechanical 2Nd And 3Rd Generation Steering Boxes

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Repairing electromechanical 2nd and 3rd generation steering boxes At present, there is no provision for performing repairs on the 2nd and 3rd generation steering boxes.
  • Page 370 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 No dirt must be allowed to enter the steering box through a de‐ fective rubber boot during this operation. – Mark position of nut -3- on steering rack.

  • Page 371: Removing And Installing Track Rod

    Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Install new clamp, as shown in figure, with locking pliers for Phaeton steering box -VAS 6199- . Continue installation in reverse order. Specified torque for wheel bolts ⇒...
  • Page 372 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing track rod – Turn steering wheel to straight-ahead position. – Clean outside of steering box in vicinity of boots. – Loosen nut -3-, counterholding on track rod ball joint -2-.
  • Page 373 Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Screw track rod into track rod ball joint until dimension -a- is attained. Dimension -a- = 371 ± 1 mm – Turn track rod into steering rack and tighten to specified tor‐...

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Golf variant 2007

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