400619 Removing and installing front-axle carrier
WM 400619 Removing and installing front-axle carrier
Tools
Preliminary work
1. Raise the vehicle. -> 4X00IN Lifting the vehicle Service and Repair
2. Remove front wheels. -> 440519 Removing and installing wheel
3. Remove front wheel housing liner at the left and right. -> 505619 Removing and installing front wheel housing liner Service and Repair
4. Remove underbody panelling. -> 519219 Removing and installing cover for front underbody 519219 Removing and installing Cover For Front Underbody
5. Remove front support -1-.
Front support
5.1. Unscrew fastening screws -2-.
5.2. Remove front support -1-.
6. Remove fastening screws on engine mounting.
7. Loosen lower torque support.
7.1. Remove outer threaded joint (take out screw).
7.2. Loosen inner threaded joint (leave screw in place).
8. On all-wheel-drive vehicles, remove the drive shafts at the transmission side and set them down carefully. Use a protective tube (shop-made) if necessary so as not to damage the drive shaft.
9. Remove heat protection panel -1- between the universal joint for the steering gear and the primary catalytic converter.
Heat protection panel
9.1. Remove fastening screws -2-.
9.2. Remove heat protection panel -1-.
Information
- Fix steering wheel with wheels in straight-ahead position (engage steering column lock or clamp steering wheel in centre position with steering wheel holder). If this is not done, the airbag contact unit will have to be put in the centre position after installation of the steering gear -> 945019 Removing and installing steering column switch
- Before loosening the pressure and return lines, place a suitable container underneath to collect steering fluid.
- Wear protective goggles and gloves.
10. Remove universal joint -1-.
Removing universal joint (example)
10.1. On vehicles with Servotronic: Pull off connector -3-.
10.2. Loosen holder on Servotronic connector cable and set the cable aside.
10.3. Loosen clamping screw -2- (accessible from the wheel housing).
10.4. Slide universal joint -1- and lower part of steering column upwards.
11. Remove connecting link on the spring strut -arrow- at both sides. -> 407819 Removing and installing front connecting link (suspension/stabilizer)
Fastening nut on connecting link
12. Remove air guides on the two lower trailing arms.
13. Loosen fastening nuts -1- on the lower control arm at both sides (do not remove the bolts yet!).
Fastening nuts on lower control arms
14. Remove transverse control arm cover.
-> 852219 Removing and installing plenum panel cover 852219 Removing and installing plenum panel cover
15. Support the engine on the body. -> 1001IN Supporting engine on the body (engine safety device)
Tools and materials
Removing and installing front-axle tools
Master Gear unit elevating platform WE 1206
Only the supports marked with single digits (e.g. P1, P2, P3) are used for mounting the front axle!
Overview of assembly drivers
Legend for assembly drivers and supports
Ball joint puller T40010
Spring tensioner VW 552
Removing
WARNING
Wheel bearing housing raised incorrectly
- Risk of squashing
- Risk of damage to components
-> Wear personal protective gear.
-> Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
NOTICE
Aggressive fluids
- Risk of damage to components and surfaces
-> Do not spill fluids.
-> If a component comes into contact with the fluid, wash the component or surface with water.
-> Replace components that are already damaged.
Front-axle carrier, component
1. Secure upper trailing arm using the spring tensioner VW 552 -arrow-. This involves tensioning the trailing arm slightly because otherwise the top ball joint can become damaged.
Spring tensioner VW 552 -arrow- must be secured at the top.
Securing spring tensioner on front axle, top
Spring tensioner VW 552 -arrow- must be secured at the bottom.
Securing spring tensioner on front axle, bottom
2. Release and disconnect plug connection for rpm sensor at the wheel carrier on both sides -direction arrow-.
Connector for rpm sensor
3. Disconnect plug connection for brake pad wear indicator at the wheel bearing housing.
4. Loosen the brake caliper (do not unscrew screws fully!).
5. Unclip PDCC line at the front supporting frame (grille) from the four brackets.
6. Mark the position of the supporting frame on the longitudinal member -arrows- (using a felt-tip pen, for example; to facilitate assembly).
6.1. This marking must be applied to at least two corners of the supporting frame. This gives a rough idea of the correct position for reinstallation.
Marking on supporting frame
7. Remove transverse struts.
Removing transverse struts (right side with wheel housing liner)
7.1. Right side, rear wheel housing: Remove transverse strut -2- between the sheetmetal cross member (support, cross strut) and door sill.
7.2. Left side, rear wheel housing: Remove transverse strut between the sheetmetal cross member (support, cross strut) and door sill.
Information
Collect power-steering fluid.
- Before loosening the pressure and return lines (also PDCC), place a suitable container underneath to collect power-steering fluid.
- Wear protective goggles and gloves.
8. Disconnect pressure and return lines for the steering at the steering gear.
Remove the two mounting elements for the pressure line at the supporting frame.
8.1. Left centre wheel housing: Remove fastening nut on power-steering pressure line holder and detach the retaining eyelet. (The holder is located in front of the rear attachment point for the supporting frame.) => Fastening nut on holder.
Fastening nut on holder
8.2. Front left wheel housing: Disconnect the lower connection at the servo oil cooler (open the clamp on the power-steering return line and pull off the hose). The return line remains on the supporting frame during removal.
Information
Working with steel flexi-pipes
- Steel flexi-pipes are particularly prone to kinking and pinching.
- Be particularly careful with steel flexi-pipes during removal, storage and reinstallation.
- Mark the installation position of the pipe with a paint marker during removal.
- Steel flexi-pipes must never be installed twisted.
9. Rear left wheel housing: Disconnect steel flexi-pipes on the PDCC valve block at the front and place a suitable container underneath to collect power-steering fluid.
9.1. Mark the installation position of the steel flexi-pipes -2- on the steel flexi-pipes themselves and on the valve block using a suitable paint marker -3-.
Steel flexi-pipes
9.2. Unscrew cap screws on steel flexi-pipes -1-.
10. Loosen the fastening nuts on the upper control arms (do not remove fully!).
10.1. Loosen fastening nuts -1-.
Fastening nuts on upper control arms (example)
10.2. Press off the ball joint using the ball joint puller T40010. When doing this, leave the fastening nut flush on the ball pin so as not to damage the thread.
Pressing off trailing arm for upper control arm
11. Place elevating platform Master Gear unit elevating platform WE 1206 under the vehicle and move all assembly drivers -A, B, C, D, E, F- to the same height at the correct position.
Overview of assembly drivers
Carefully guide in the elevating platform and remove the spring tensioner VW 552 on both sides -arrow-.
Spring tensioner fitted
Information
- Before moving the lifting platform, mark the position of the wheels on the workshop floor with a piece of chalk. This makes it easier to position the platform again for re-installation.
12. Remove brake caliper at the left/right, but do not remove the brake line (Do not open the brake system!).
Fastening screws on brake caliper
Get another worker to remove the fastening nut from the upper control arm and tilt the wheel bearing housing out slightly. Guide the brake caliper through between the spring strut and wheel bearing housing and hang it at a suitable position in the wheel housing.
-> 473919 Removing and installing front brake caliper
-> 473919 Removing and installing front brake caliper (PCCB)
13. Fit the wheel hub holder -1- at the left and right using assembly aids (threaded bolts for mounting wheels) -2- on the wheel hub.
Wheel hub holder (shown here on steel brake disc)
14. Remove bolts on lower control arms.
14.1. Raise the elevating platform slightly in order to relieve the pressure on the bolts on the lower control arms.
14.2. Pull out bolt on the lower control arm at the left and right -direction arrow-.
Bolts on lower control arms
15. Detach front-axle carrier.
Marking and fastening screw on front-axle carrier
15.1. Remove fastening screws securing front-axle carrier to the longitudinal member.
16. Remove fastening screws on the sheetmetal cross member (support, cross strut) -position arrows-.
Mounting point for sheetmetal cross member (support, cross strut) to body
17. Carefully guide out the elevating platform under the vehicle with the axle without hitting against adjacent components.
17.1. Remove the front holder for the power-steering pressure line.
Information
If you are replacing the supporting frame, the accessories must also be converted as required following a visual inspection.
Replace supporting frame
Install at the correct position and check that all accessories are installed. Document installation by taking photos if necessary (installation aid!).
- Remove sheetmetal cross member (support, cross strut) and anti-roll bar (be careful of the lines on anti-roll bars with PDCC!)
- Remove mounting element for anti-roll bar (crash element, anti-roll-bar mount)
- Remove steering
- Remove lower trailing arm with wheel bearing housing and drive shaft
- Remove bulkhead plate (heat protection panel) at the left/right
- Remove steering return line
Installing
WARNING
Wheel bearing housing raised incorrectly
- Risk of squashing
- Risk of damage to components
-> Wear personal protective gear.
-> Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).
NOTICE
Aggressive fluids
- Risk of damage to components and surfaces
-> Do not spill fluids.
-> If a component comes into contact with the fluid, wash the component or surface with water.
-> Replace components that are already damaged.
Information
Working with steel flexi-pipes
- Steel flexi-pipes are particularly prone to kinking and pinching.
- Be particularly careful with steel flexi-pipes during removal, storage and reinstallation.
- Mark the installation position of the pipe with a paint marker during removal.
- Steel flexi-pipes must never be installed twisted.
Installation is performed in reverse order.
Fit mounting element for front power-steering pressure line holder while carefully guiding the elevating platform into position.
Secure the upper trailing arms using the spring tensioner VW 552 before removing the elevating platform.
Subsequent work
1. Remove engine safety device. -> 1001IN Supporting engine on the body (engine safety device)
2. Fit transverse control arm cover.
-> 852219 Removing and installing plenum panel cover 852219 Removing and installing plenum panel cover
3. Fit air guides on the two lower trailing arms.
4. Fit connecting link on the spring strut -arrow- at both sides. -> 407819 Removing and installing front connecting link (suspension/stabilizer)
Fastening nut on connecting link
5. Fit universal joint.
5.1. On vehicles with Servotronic: Plug in connectors -3-.
6. Fit heat protection panel -1- between the universal joint for the steering gear and the primary catalytic converter.
Heat protection panel
7. Fit fastening screws on engine mounting.
8. On all-wheel-drive vehicles, fit inner drive shafts.
9. Fit front support -1-.
Front support
10. Bleed the steering system. -> 4890IN Test and assembly work on power steering
11. Bleed the PDCC system on vehicles with PDCC. -> 430307 Bleeding Porsche Dynamic Chassis Control (PDCC)
12. Fit front wheel housing liner at the left and right. -> 505619 Removing and installing front wheel housing liner Service and Repair
13. Fit underbody panelling. -> 519219 Removing and installing cover for front underbody 519219 Removing and installing Cover For Front Underbody
14. Fit front wheels. -> 440519 Removing and installing wheel
15. Press the brake pedal if necessary in order to position the pads.
16. Read out and erase the fault memory using PIWIS Tester II 9818.
17. Perform suspension alignment. -> 449503 Suspension alignment, complete