Front Suspension

Removing and installing front axle carrier
These removal and installation instructions apply to vehicles with level control and steel springs. The points relating to level control are not relevant for vehicles with steel springs.








Tools

Removal

Caution! Risk of damage to property and personal injury when lowering the front axle carrier. Wear protective gear, e.g. gloves.
Position the mounting frame correctly on the lifting platform and carefully remove the front axle carrier.
Watch out for falling parts during removal on the mounting frame.

1. In vehicles with level control: Switch off level control.
2. Raise the vehicle at the support points provided for this purpose.
3. Open the engine compartment lid and secure with the bonnet stay 9704.
4. Remove engine design covers.

Note!
^ Point 5 is not necessary for a 6-cylinder engine. There is a perforated plate at both the front right and rear left of the engine for transporting and raising to the safety device.





5. Remove -torque support- from the engine. Then re-insert fastening screw .





6. Position the safety device 10-222 A correctly and fit the chain to the fastening bracket -A-. Fit the transport eyebolt 9700 for securing the engine -B- (the bore for the transport eyebolt is located between cylinder 6 and 7 on the left cylinder bank).
7. Remove the front wheels.
8. Remove engine guard.

Note!
^ The spring struts are not removed in order to remove the front axle carrier.
^ The lower control arms are loosened on the front axle carrier and remain with the spring struts in the vehicle. The upper axle strut must first be secured.





9. Fix the upper axle struts with tension jack VW 552. This involves tensioning the axle strut slightly because otherwise the top ball joint can be damaged. When doing this, insert the -tension jack into the top opening of the wheel well (double panel, under the wheel housing cover) and into the axle strut (do not disconnect the air spring connection!).





10. For easier removal of the outer tie rod end, swivel the relevant wheel carrier so that the tie rod extends fully. Remove the -outer tie rod ends- with the press-out tool T10187. When pressing out, screw fastening nut on flush (protects the ball joint thread).





11. The screw in the steering shaft is removed from the wheel well. Release the coolant hoses from the holders on the body. Unscrew the -screw in the steering column (arrow)- from the steering gear.
12. Remove the hydraulic lines from the steering gear (collect hydraulic fluid in a suitable container). Remove the heat shield of the steering, if necessary.
13. Mark the installation position of the cardan shaft and remove it from the front-axle final drive. Make sure that the cardan shaft does not become kinked (tie it up).
14. Remove drive shafts from the front-axle final drive. Make sure that the drive shafts do not become kinked (tie them up).
15. Remove lower control arms from the front axle carrier.
16. Remove stabilizer mount.

Note!
^ The lifting platform with the -mounting frame- must be secured firmly under the front axle carrier at the points provided.
^ The mounting points for the front axle carrier (1 and 3), both right and left, and the two positioning guides (4) that are pushed into the body are required for removing the front axle carrier. The other mounting points can be removed.
^ The mounting points 1/11 (designation on the guide pin) are fitted into -position/ 1-. Double codes (e.g. 11, 22) are also used for mounting the rear axle.
^ A second worker is required in order to avoid damaging adjacent components when lowering the front axle carrier.
^ For installation, it is a good idea to mark the installation position of the front axle carrier diagonally at at least two places on the body. To do this, place the marks vertically with respect to the floor of the body using a felt-tip pen (e.g. mark along the front-axle carrier mount with the pen).





17. Position the -lifting platform- with the correctly positioned mounting frame under the front axle carrier.





18. Mark the installation position of the front axle carrier diagonally at at least two places on the body.





19. The show the mounting points for the mounting frame in the front axle carrier.





20. Position the front axle carrier into the mounting points provided (points 4 in the body).





21. Remove the four fastening screws of the front axle carrier.
22. Lower the front axle carrier with steering, final drive and stabilizer. Be careful not to damage adjacent parts (e.g. cardan shaft, oil pan, body).
23. Remove accessories from the front axle carrier (steering, final drive, stabilizer). Get another worker to help.

Installation
Install in reverse order.

Caution! Risk of damage to property arid personal injury when installing the front axle carrier. Position the mounting frame correctly or/ the lifting platform arid carefully install the front axle carrier.
Danger of injury and material damage if the wheel carrier is raised incorrectly.
^ Do not raise the wheel suspension higher than the Formal vehicle position/ (vehicle resting or/wheels). When raising the suspension, use a suitable intermediate layer (hard rubber).
^ Do not damage the brake cover plate.
^ The steering angle sensor must be calibrated following repairs.
^ Watch out for falling parts during installation on the mounting frame.

Note!
^ Before installing the front axle carrier, check the parts visually.
^ Note previously applied markings on the front axle carrier and on the cardan shaft.
^ A second worker is required in order to avoid damaging adjacent components when fitting the front axle carrier.
^ When fitting the ball joints, ensure that the bevel pinions are clean! Remove dirt or grease on bevel pinions, e.g. with a lint-free cloth. Do not use cleaning agent/solvent.
^ Replace all fastening nuts and all expansion screws (screws which are fitted with torque angle tightening procedure).





^ The entire threaded parts of the axle must be tightened in vehicle position. Vehicle position means: vehicle standing on the wheels, or the wheel suspension is raised using a universal vehicle lift. -Dimension X-, from lower edge of wing to middle of axle 502 mm ± 10 mm corresponds to vehicle position.





^ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels). When raising the suspension, use a suitable -intermediate layer (hard rubber)-. Do not damage the brake cover plate.
^ Bleed power-assisted steering.
^ Use correct tightening torques.
^ Perform suspension alignment.





^ Calibrate the steering angle sensor with the Porsche System Tester.
^ Perform a function test.

1. Position the front axle carrier on the mounting frame.
2. Pre-fit the accessories on the front axle carrier (steering, final drive, stabilizer). Get another worker to help.
3. Position the front axle carrier back in the original, marked installation position and be careful not to damage adjacent parts.
4. Tighten the four fastening screws to the prescribed tightening torque.
5. Remove the -lifting platform- with the mounting frame and secure the water hose holders.
6. Fit the steering gear to the steering column and connect the hydraulic lines.
7. Attach the cardan shaft at the positions marked.
8. Install the drive shafts.
9. Fit the tie rod ends. The tightening torque for the fastening nut for attaching the tie rod end is 70 Nm (52 ft. lbs.).
10. Install engine guard.
11. Remove the safety device 10-222 A. To do this, remove the transport eyebolt 9700 -B- and the chain -A-, which is used to secure the engine.





12. Fit the -torque support-.
13. Bleed power-assisted steering.
14. Fit engine design covers and radiator tank cover.
15. Switch on level control.
16. Perform suspension alignment.