Removing and installing leaf spring — VW

Removing and installing leaf spring
Special tools and workshop equipment required
Tensioning strap
T10038
Engine and gearbox jack
V.A.G 1383 A
Removing
Note
Bonded rubber bushes can be twisted only to a limited extent. Therefore, tighten the bolted connections of components with bonded rubber bushes only when the wheel bearing housing has been raised (unladen state)
Chapter
.
Before inserting leaf spring, coat spring bearing with lubricant, e.g. soft soap.
Before installing leaf spring, check that upper spring bearings are attached to subframe.
Remove left and right saddle plates
Chapter
.
Raise vehicle and strap it down
Maintenance
Booklet
10.2
.
WARNING
If the vehicle is not strapped down, it may slip off the lifting platform.
Remove front wheels.
Remove noise insulation
General body repairs, exterior
Rep. gr.
50
Body - front; Noise insulation
.
Detach brake caliper and tie to body with wire
Brake systems
Rep. gr.
46
.
Then attach left saddle plate
A
(with lower spring bearing installed) to subframe with 3 bolts M12 × 1.5, approx. 60 mm long
arrows 1
.
Note
Do not use original bolts again
Do not tighten bolts!
Tighten the 3 bolts until the saddle plate lies on the leaf spring.
Caution
Always make sure that the bolts are screwed far enough into the thread to avoid damaging the thread.
If the thread is damaged (e.g. torn out), the subframe must be renewed.
Only loosen threaded connections
arrows 2
for suspension link
B
to subframe to relieve pre-tension from rubber bushes of suspension link.
Remove left wheel bearing housing
Chapter
.
Unscrew nut
arrow
from spring stop plate
3
for left and right coupling rod on anti-roll bar
1
.
Unscrew left and right spring stop plate bolts
2
from suspension link.
Remove spring stop plates
3
.
Note
Both spring stop plates must be removed because otherwise damage may occur when the leaf spring is refitted.
Remove left suspension link
Chapter
.
Support leaf spring
1
with
engine and gearbox jack
V.A.G 1383 A
.
Remove left saddle plate again, by alternately unscrewing the 3 × M12 × 1.5 bolts of approx. 60 mm in length
Anchor
.
Lower
engine and gearbox jack
V.A.G 1383 A
together with leaf spring.
Remove leaf spring to left from subframe.
Installing
Install in reverse order. Note the following points:
Note
Bonded rubber bushes can be twisted only to a limited extent. Therefore, tighten the bolted connections of components with bonded rubber bushes only when the wheel bearing housing has been raised (unladen state)
Chapter
.
Before inserting leaf spring, coat spring bearing with lubricant, e.g. soft soap.
Before installing leaf spring, check that upper spring bearings are attached to subframe.
When installing, push leaf spring
1
onto right outer spring bearing to stop.
Insert
press tool
V.A.G 1383 A
into
engine and gearbox jack
VW 409
so that the spring is guided on insertion.
Position
engine/gearbox jack
V.A.G 1383 A
under left side of leaf spring. Tension leaf spring by carefully raising the
engine and gearbox jack
V.A.G 1383 A
.
Then attach left saddle plate
A
(with installed lower spring bearing) to subframe with 3 × M12 × 1.5 bolts of approx. 60 mm long
arrows 1
.
Tighten the 3 bolts until the saddle plate lies on the leaf spring.
Install left suspension link
B
Chapter
.
Then install spring stop plates.
Install left wheel bearing housing
Chapter
.
Then remove left saddle plate again, by alternately unscrewing the 3 × M12 × 1.5 bolts of approx. 60 mm long
Anchor
.
Fit left and right brake caliper with brake carrier
Brake systems
Rep. gr.
46
.
Install noise insulation
General body repairs, exterior
Rep. gr.
50
Body - front; Noise insulation
.
Install front wheels.
Install left and right saddle plates
Chapter
.
Specified torques
Chapter
“
Assembly overview - lower suspension link, swivel joint
”
Chapter
“
Assembly overview - wheel bearing assembly
”
Chapter
“
Specified torque for wheel bolts
”