b6 42 Eng

Volkswagen Passat B6 2005 - Rear suspension, servicing (front wheel drive) Стр.
1 из 5
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info
42 - 2
Rear suspension, servicing (front wheel drive)

Rear axle, overview
Note :
Welding and straightening operations are not

permitted on load-bearing or wheel-controlling
components.
Always replace self-locking nuts.
Always replaced corroded bolts/nuts.
Bonded rubber bushings have a limited torsional

range. Therefore, the threaded connections of the
components with bonded rubber bushings should
only be tightened when the wheel bearing housing is
lifted (curb weight position) 42-2, Rear axle in
curb weight position .
Always replace bonded rubber bushings on both

sides of vehicle.
Rear suspension, servicing (front wheel drive) Стр. 2 из 5
I - Subframe, transverse link, tie rod

42-4, Subframe, transverse link, tie rod
- Front Wheel Drive (FWD), assembly
overview
II - Wheel bearing housing, trailing

arm 42-5, Wheel bearing housing,
trailing arm - Front Wheel Drive (FWD),
assembly overview
III - Shock absorber, coil spring 42-

6, Shock absorber, coil spring - Front
Wheel Drive (FWD), assembly
overview
IV - Stabilizer bar 42-7, Stabilizer

bar - Front Wheel Drive (FWD),
assembly overview
Rear axle in curb weight position

Special tools, testers and auxiliary items

required
Engine/transmission jack V.A.G

1383 A
Tensioning Strap T10038
Wheel Hub Support T10149
Note:
All chassis component bolts with bonded rubber

bushings must be tightened with the suspension in
the curb weight position (unladen).
Bonded rubber bushings have a limited torsional range.

Before axle components with bonded rubber bushings are

tightened, they have to be brought to a position which
matches the position when vehicle is being operated (curb
weight position).
Otherwise the bonded rubber bushing will be distorted,

resulting in reduced service life.
By raising axle on one side using engine/transmission jack

V.A.G 1383 A and wheel hub support T10149 , this
position can be simulated on hoist.
Before individual suspension is raised on one side, the

vehicle must be secured on both sides to lifting arms
on hoist using tensioning strap T10038 .
Warning!
If the vehicle is not secured, there is a risk that it may

slip off the hoist.
- Turn wheel hub until one of the holes for wheel bolts is at
12 o'clock position.
- Install wheel hub support T10149 with a wheel bolt.
The bolts may only be tightened if dimension - a - is

attained between wheel hub center and lower edge of
wheel housing.
Measurement - a - measured
Dimension - a - is dependent on ride height of the installed

suspension:
Suspension 1) Ride height - a - in mm

Basic suspension 383 10 mm
Basic suspension with Nivomat 383 10 mm
Heavy duty suspension 393 10 mm
Sport suspension except 18" wheels 368 10 mm
Sport suspension with 18" wheels 368 10 mm
1) The suspension that the vehicle is equipped with is

indicated on the vehicle data plate. The suspension is
indicated by a PR number. To determine which PR number
represents which suspension, refer to 44-7,
Specifications for wheel alignment .
- Raise wheel bearing housing using engine/transmission

jack V.A.G 1383 A until dimension - a - is reached.
Caution!
Do not raise or lower vehicle while

engine/transmission jack V.A.G 1383 A is under
vehicle.
Do not leave engine and transmission lift under

the vehicle longer than necessary.
- Tighten respective bolts/nuts.
- Lower steering knuckle.
- Move engine/transmission jack V.A.G 1383 A away from

under vehicle.
- Remove wheel hub support T10149 .

Volkswagen Passat B6 2005 - Rear axle, torque specifications (front wheel drive) Стр. 1 из 3
42 - 3
Rear axle, torque specifications (front wheel drive)

Subframe
Threaded fasteners Thread Torque specification (Nm)

To lower transverse link M12 x 1.5 95 1)
Item - 2 -
To upper transverse link M12 x 1.5 95 1) 2)
Item - 6 -
To body M12 x 1.5 x 90 90 plus an additional 90 turn 3)
Item - 9 - and Item - 28 -
To tie rod M12 x 1.5 x 90 90 plus an additional 90 turn 3)
Item - 30 -
3) Replace each time it is removed

2) Torque specification applies only in conjunction with
insert tool 18 mm T10179
1) Fastenin curb weight position 42-2, Rear axle in curb
weight position
Left Rear Level Control System Sensor G76

To subframe M5 x 20 5
Item - 3 -
To lower transverse link M5 x 20 5
Item - 3 -
Wheel bearing housing

To lower transverse link M12 x 1.5 x 75 90 plus an additional 90 turn 1) 2)
Item - 11 -
To upper transverse link M14 x 1.5 x 115 130 plus an additional 90 turn 1) 2)
Item - 23 -
To tie rod M14 x 1.5 x 115 130 plus an additional 90 turn 1) 2)
Item - 17 -
To wheel hub with wheel bearing M16 x 1.5 x 70 200 plus an additional 180 turn 1)
Item - 15 -
To speed sensor M6 x 16 8
Item - 6 -
To cover plate M6 x 10 12
Rear axle, torque specifications (front wheel drive) Стр. 2 из 3
Item - 17 -

weight position
Trailing arm

To wheel bearing housing M12 x 1.5 x 40 90 plus an additional 45 turn 1) 2)
Item - 4 -
To mounting bracket M12 x 1.5 x 80 90 plus an additional 90 turn 1)
Item - 19 -
Mounting bracket to body M10 x 35 50 plus an additional 45 turn 1)
Item - 21 -

2) Be aware of this chapter 42-5, Installing for
tightening
Lower transverse link

Stone impact protection to control arm
M6 x 12 8 Nm
Item - 16 -
Shock absorber

To wheel bearing housing M14 x 1.5 x 85 150 plus an additional 90 turn 1)
Item - 5 -
To shock absorber mounting M10 x 1.0 25
Item - 7 -
To body M10 x 35 50 plus an additional 45 turn 1)
Item - 6 -
Stabilizer bar

To subframe M8 x 30 25 plus an additional 45 turn 1) 2)
Item - 4 -
To connecting link M10 40
Item - 6 -
Rear axle, torque specifications (front wheel drive) Стр. 3 из 3
Connecting link to wheel bearing housing M10 40 1)

Item - 11 -

weight position
Volkswagen Passat B6 2005 - Subframe, transverse link, tie rod - Front Wheel Drive (FWD) .
42 - 4
Subframe, transverse link, tie rod - Front Wheel

Drive (FWD), assembly overview
Eccentric bolt
For camber adjustment
After loosening, perform

vehicle alignment 44-7,
Wheel alignment
Nut
Torque specifications 42-

3, Rear axle, torque
specifications (front wheel
drive)
Self-locking
Subframe, transverse link, tie rod - Front Wheel Drive (FWD), assembly overview Стр. 2 из 16
Replace each time it is

removed
Only tighten threaded

connections when vehicle is
in curb weight position 42-
2, Rear axle in curb weight
position
Eccentric washer
Inner bore with tab
Eccentric bolt
For toe adjustment

Wheel alignment
Eccentric washer
Inner bore with tab
Nut
Torque specification Topic

42-3
Self-locking

removed

position
Subframe
Bracket for rear muffler
Bolt

42-3

removed
Removing and installing

42-4, Lower transverse link,
removing and installing
Nut

42-3
Self-locking

removed

position
Bolt

removed
Threaded rivet
M6
Expanding rivet
Stone protection plate
Application Electronic
Parts Catalog "ETKA"
Hex head bolt

42-3
Nut

42-3
Self-locking

removed
Washer
Bolt

removed

position
Washer
Upper transverse link

42-4, Upper transverse link,
Washer
Nut

42-3
Self-locking

removed

position

42-5, Wheel bearing
housing, removing and
installing
Washer
Bolt

removed

position
Tie rod
Locked in direction of travel
Bolt

42-3

removed
Bolt

removed
Nut

42-3
Self-locking

removed

position
Level control system sensors for vehicles with automatic

headlight range control
Level control system sensor, overview
Note :
The level control system sensor is only available as

a replacement part together with the connecting link
and upper and lower mounting plates.
Replace with subframe installed.
Headlamp Range Control Module J431
Subframe
Bolt

42-3
Left Rear Level Control System

Sensor G76
Complete with attachments
Lever - arrow - must face

toward outside of vehicle
Replace in vehicle
After replacing, perform

Basic setting of headlights
Perform Basic setting of

headlights using Vehicle
Diagnosis, Testing and
Information System VAS 5051 .
Level control system sensor, replacing in vehicle
Special tools, testers and auxiliary items required
Torque wrench V.A.G 1331
Removing
- Disconnect connector - 1 - .
- Remove bolts - 2 - and - 3 - .
- Remove sensor.
Installing
Further installation is in reverse order of removal. Note the

following:
The lever of sensor must face toward outside in direction of

travel.
- After replacing, perform Basic setting of headlights.
Torque specifications Topic 42-3
Upper transverse link, removing and installing
Removing
- Remove wheel.
- Remove coil spring 42-6, Coil spring, removing and

installing .
- Unhook speed sensor wiring - arrow A - from upper

transverse link.
- Remove bolt - 1 - .
- Mark position of eccentric bolt - arrow - to subframe,

e.g. with a felt tip pen.
- Remove bolt - arrow - .
- Remove upper transverse link.
Installing
- Set upper transverse link into vehicle and hand-tighten

bolts.
The bolted connections of transverse link must only be

fastened when dimension "a" is achieved! 42-2,
Measurement
- Fasten upper transverse link to subframe and tighten

new nut.
- Observe applied marking for eccentric bolt - arrow - to

subframe.
- Tighten bolt - 1 - for upper transverse link.
Note:
Make sure that a washer is installed between the

bolt and wheel bearing housing.
- Hook speed sensor wiring - arrow A - in at upper

transverse link.
- Install coil spring 42-6, Coil spring, removing and

installing .
- Install and fasten wheel 44-2, Torque specification for

mounting wheels .
Torque specifications 42-3, Rear axle, torque

specifications (front wheel drive)
- Perform vehicle alignment 44-7, Wheel alignment .
Lower transverse link, removing and installing

Removing
- Measure dimension from center of wheel to lower edge of

wheel housing.
- Remove wheel.

installing .
- Remove bolt - arrow - for lower transverse link - 1 - .
Vehicles with automatic headlight range control

- Remove connecting link - arrow A - of Left Rear Level

Control System Sensor G76 .
Continued for all vehicles
- Mark position of eccentric bolt - arrow B - to subframe,

e.g. with a felt tip pen.
- Unhook rear exhaust system and lower.
- Remove bolt - arrow B - .
- Remove lower transverse link.
Installing
- Set lower transverse link into vehicle and hand-tighten

bolts.
The bolted connections of transverse link must only be

fastened when dimension "a" is achieved 42-2,
Measurement !
- Fasten upper transverse link to subframe and tighten

new nut to torque specification.
- Observe applied marking for eccentric bolt - arrow B - to

subframe.
- Attach rear exhaust system.

Vehicles with automatic headlight range control
- Install connecting link - arrow A - of Left Rear Level

- Install bolt - arrow - for lower transverse link - 1 - .
- Install coil spring 42-6, Installing .


mounting wheels .
Tie rod, removing and installing

Removing
- Remove wheel.
- Remove coil spring 42-6, Removing .
- Remove nut - 1 - and pull connecting link - 2 - out from

stabilizer bar.
- Remove bolt - arrow - for tie rod - 3 - .

- Remove bolts - arrows - for stabilizer bar clamp.
- Remove nut - arrow - and remove bolt toward rear.
- Remove tie rod - 1 - .
Installing
- Set tie rod into vehicle and hand-tighten bolts.
The bolted connections of tie rod must only be

fastened when dimension "a" is achieved 42-2,
Measurement !
- Fasten tie rod - 1 - to subframe and tighten new nut -

arrow - .
- Fasten bolts - arrows - for stabilizer bar clamp.
- Fasten bolt - arrow - for tie rod - 3 - .
Note:
Make sure that a washer is installed between the nut

and the wheel bearing housing.
- Set connecting link - 2 - into stabilizer bar and fasten nut

- 1- .


mounting wheels .

Volkswagen Passat B6 2005 - Wheel bearing housing, trailing arm - Front Wheel Drive (FWD)
42 - 5
Wheel bearing housing, trailing arm - Front Wheel

Drive (FWD), assembly overview
Cover
Mounting bracket
Connecting Link
Connects stabilizer bar with

trailing arm/wheel bearing
housing
Bolt
Observe tightening
sequence 42-5, Installing

Wheel bearing housing, trailing arm - Front Wheel Drive (FWD), assembly overview Стр. 2 из 24
42-3

removed
Trailing arm

42-5, Trailing arm with
mounting bracket, removing
and installing
Servicing 42-5, Trailing

arm, servicing
Bolt

42-3
Right rear ABS wheel speed

sensor G44 / Left rear ABS
wheel speed sensor G46
Can be tested in Guided

Fault Finding using Vehicle
diagnosis, testing and
information system VAS
5051
Before inserting sensor,

clean inner surface of
mounting hole and coat with
Polycarbamide grease G
000 650

42-5, Wheel bearing
installing
Bonded rubber bushing
Replacing 42-5, Bonded

rubber bushing for wheel
bearing housing, replacing
Washer
Nut

42-3
Brake disc
Bolt
4 Nm
Dust cap

removed
Pressing out and driving in

42-5, Wheel
bearing/wheel hub, removing
and installing
A perfect seal is only achieved

using a new dust cap.
Bolt
Loosen and tighten with bit

XZN 18 T10162

42-3

removed
Wheel hub with wheel bearing
The ABS sensor ring is

installed in wheel hub

42-5, Wheel bearing/wheel
hub, removing and
installing
The wheel bearing and wheel

hub are installed together.
This wheel bearing/hub unit is

maintenance and adjustment
free. Adjusting and servicing is
not possible!
Bolt

42-3
Protective plate
Bolt

42-3

removed
Replacing 42-5, Trailing

arm, servicing
Bolt

42-3

removed
Wheel bearing housing, removing and installing
Removing
- Remove wheel.

installing .
- Remove wheel bearing/wheel hub unit 42-5, Wheel

bearing/wheel hub, removing and installing .
- Remove shield.
- Remove ABS speed sensor from wheel bearing housing.
- Remove bolt for tie rod - 1 - , upper transverse link - 2 -

and lower transverse link - 3 - from wheel bearing housing
- 4- .
- Remove connecting link - arrow - from wheel bearing

housing.
- Hold wheel bearing housing tightly and remove bolts -

arrows - .
- Pull connecting link - 1 - out from trailing arm.
Installing
The bolted connection of trailing arm/wheel bearing

housing may only be tightened if all other components
(especially spring and shock absorber) of the relevant
suspension are installed. To fasten, suspension must be in
an upward deflection condition. Only then will the trailing
arm and wheel bearing housing move to necessary
position - arrows - .
Observe exact sequence of the following work steps!

- Install bolt for tie rod - 1 - , upper transverse link - 2 -

and lower transverse link - 3 - , but do not tighten.
- Hand-tighten connecting link - arrow - to wheel bearing

housing - 4 - .
- Install bolts - arrows - and insert tie rod - 1 - into trailing

arm.
- Tighten bolt - arrow - for shock absorber.
The bolted connections on wheel bearing housing

must only be fastened when dimension "a" is achieved
42-2, Measurement !

- Tighten bolt for tie rod - 1 - , upper transverse link - 2 -

and lower transverse link - 3 - .
- Tighten nut for connecting link - arrow - .
- Tighten bolts - arrows - .
- Install shield.
- Install wheel bearing/wheel hub unit.
- Install ABS speed sensor into wheel bearing housing.
- Install brake disc.

- Install brake carrier with brake caliper
Repair Manual, Brake System, Repair Group 46,

brakes, servicing

mounting wheels .
Bonded rubber bushing for wheel bearing housing,

replacing

required
Support Arm Bearing Inst. Tool

3346
Carrier Bearing Inst. Tool 3350
Fitting sleeve 3378
Tappet 3390
Removing
- Remove wheel.

installing .
- Remove wheel bearing/wheel hub unit 42-5, Wheel

bearing/wheel hub, removing and installing .
- Remove shield.
Pressing out bonded rubber mounting
- Install tools as shown in illustration.
Nut 3346/3
Tappet 3390
Nut, commercially available
Spindle 3346/2
- Pull out bonded rubber bushing by tightening spindle.
Installing
Pulling in bonded rubber bushing

Nut 3346/3
Support Arm Bearing Inst. Tool 3346
Fitting sleeve 3378
Spindle 3346/2
- Press in bonded rubber bushing by turning spindle.
Note:
Do not use lubricants!
Carefully set bushing in place to prevent it from

distorting.
- Install shield.
The bolted connections on wheel bearing housing

must only be fastened when dimension "a" is achieved
42-2, Measurement !
- Install bolt - arrow - for lower transverse link - 1 - .


installing .


brakes, servicing

mounting wheels .
Wheel bearing/wheel hub, removing and installing


required
Grease Cap Puller VW 637/2
Fitting sleeve 3241
Bit Xzn 18 T10162
Removing
- Raise vehicle.
- Remove wheel.
Loosen dust cap from its seat by tapping lightly on claws of

grease cap puller VW 637/2 .
- Pull off dust cap.
- Remove brake carrier and brake caliper and tie to body

with wire
Repair Manual, Brake system, Repair Group 46, Brake

caliper, removing and installing
Note:
Suspend brake caliper from body.
- Remove brake disc screw and take out brake disc.
- Remove multi-point socket head bolt with bit XZN 18

T10162 .
- Pull off wheel bearing/wheel hub unit from stub axle.
Installing
- Carefully push wheels hub/wheel bearing unit onto stub

axle.
Make sure that the hubs/wheel bearing unit does not

tilt!
- Install a new multi-point socket head bolt and tighten.
Note:
First tighten the bolt to the given torque specification

using the torque wrench.
For the additional turning angle, use a star key.

- Drive in dust cap using installation sleeve 3241/4 .
Note:
Always replace dust caps.
Damaged dust caps allow ingress of moisture,

always use the tool illustrated. Always use tool
illustrated to reduce chance of damage to dust cap.
Further installation is in reverse order of removal


mounting wheels .
Trailing arm with mounting bracket, removing and

installing

Removing
- Remove wheel.

installing .
- Remove retainer - 1 - , pressing out inner pins of rivets -

arrows A - .
- Remove connecting link - 2 - from trailing arm.
- Remove bolts - arrows B - .
- Unclip electrical wiring at mounting bracket.
- Mark installation position of mounting bracket on body.

- Remove bolts - arrows - .
- Remove trailing arm - 1 - with mounting bracket.
If trailing arm is to be replaced, the mounting bracket must

be removed from trailing arm.
- To do this, tension trailing arm in a vise, so that the

mounting bracket - 1 - rests against vise - arrow - .
The installation position of mounting bracket to trailing arm

must then be adjusted 42-5, Determining installation
position of mounting bracket to trailing arm .
Determining installation position of mounting bracket to trailing

arm
Measure dimension - a - from middle of bolt to outer edge

of mounting bracket.
Dimension - a - is 57.5 1 mm
Mounting bracket
Trailing arm
- When dimension - a - is adjusted, tighten bolt.
Torque specification Topic 42-3
Installing
The bolted connection of trailing arm/wheel bearing

housing may only be tightened if all other components
(especially spring and shock absorber) of relevant
suspension are installed. To fasten, suspension must be in
an upward deflection condition. Only then will the trailing
arm and wheel bearing housing move to necessary
Position: Trailing arm/wheel bearing housing bolts
Observe exact sequence of following work steps!

- Set trailing arm and mounting bracket with bolts - arrows

- in place at wheel bearing housing, but do not tighten.
- Set connecting link - 1 - into trailing arm, but do not

tighten nut.
- Lift suspension using engine/transmission jack V.A.G

1383 A and wheel hub support T10149 until mounting
bracket contacts body.
- Fasten bolts - arrows - on old mark.
- Lower suspension using engine/transmission jack V.A.G

1383 A and remove wheel hub support T10149 from
wheel hub.

installing .
- Fasten bolts - arrows B - for trailing arm to torque

specification, making sure of required positioning of
components 42-5, Position: Trailing arm/wheel bearing
housing bolts
- Tighten nut for connecting link - 2 - to wheel bearing

housing.
- Install retainer - 1 - , pressing in inner pins of rivets -

arrows A - .


mounting wheels .
Trailing arm, servicing


required
Thrust plate VW 401
Thrust plate VW 402
Installation Device 3372
Assembly tool T10230
Pressing out bonded rubber bushing
- Remove trailing arm 42-5, Trailing arm with mounting

bracket, removing and installing .
- Tension trailing arm in a vise, so that the mounting

bracket - 1 - rests against vise - arrow - .
Tube T10230/3
Press piece T10230/10
Thrust plate VW 401
Thrust plate VW 402
- Press out bonded rubber bushing.
Pressing in bonded rubber bushing

- Set trailing arm on a level.
- Place trailing arm on a level so that dimension - A - =

113 mm is achieved.
- Mark a vertical line on trailing arm socket - arrows - .
Position bonded rubber bushing on trailing arm so that the

marked line is positioned between protrusions - 1 - .
Note:
Make absolutely sure that the bonded rubber

bushing is in the correct installation position to the
trailing arm socket.
Tube T10230/5
Thrust plate T10230/12 , chamfer must face toward
bonded rubber bushing.
Thrust plate VW 402
- Press in bonded rubber bushing so that it is flush.
- Install mounting bracket to trailing arm 42-5,

Determining installation position of mounting bracket to
trailing arm .
- Install trailing arm 42-5, Installing .

Shock absorber, coil spring - Front Wheel Drive (FWD), assembly overview Стр. 1 из 11
42 - 6
Shock absorber, coil spring - Front Wheel Drive

(FWD), assembly overview
Lower spring seat
End of spring must be turned

to stop
Assembly aid
Must not be used again after

removal
Coil spring
Be aware of various
suspension versions, 44-
7, Vehicle data sticker

42-6, Coil spring, removing
and installing
Upper spring seat
Bolt

42-3

removed
Bolt
Torque specifications
Topic 42-3

removed
Shock absorber

42-6, Shock absorber,
Be aware of various
Vehicle data sticker.
Washer


42-5, Wheel bearing
installing
Coil spring, removing and installing
Spring compressor V.A.G 1752
Spring holder V.A.G 1752/3A
Adapter V.A.G 1752/9 , without illustration
Removing
- Remove wheel.
- Insert spring holder - 3 - .
Warning!
Make sure the coil spring is properly seated in the

spring holder V.A.G 1752/3A - 2 - (risk of accident).
- Use a wrench or a ratchet for tightening spring

compressor.
- Compress coil spring until it can be removed.
- Remove spring.
Spring holder V.A.G 1752/3A

Adapter V.A.G 1752/9
Spring compressor V.A.G 1752/1
Installing
Observe installation position!
End of spring - arrow - must lie against stop on lower

spring seat.
- Install spring together with spring seat.
- The lower spring seat has a tab.
- Place tab into hole in lower transverse link - arrow - .
- Place upper spring seat into upper end of spring.
- Relieve tension on spring while guiding upper spring seat

onto tab of body.
- Remove spring compressor.

mounting wheels .
Shock absorber, removing and installing
Removing
- Remove wheel.
- Remove wheel housing liner
Repair Manual, Body Exterior, Repair Group 66,

Wheelhousing liner, removing and installing

installing .
- Remove shock absorber.
Installing
Further installation is in reverse order of removal. Note the

following:
The bolted connections of shock absorber to wheel

bearing housing must only be fastened when
dimension "a" is achieved 42-2, Measurement !
- Install shock absorber and fasten bolts - arrows - .
- Tighten bolt - arrow - .


installing .
- Install wheel housing liner

Wheelhousing liner, removing and installing

mounting wheels .
Shock absorber, servicing

Shock absorber

Be aware of various
Protective cap
Protective tube
Support ring
Bump stop
For shock absorbers with

support ring Item - 4 -
Shock absorber mounting
For shock absorbers with

Nut

42-3

removed
Loosening and tightening

42-6, Loosening and
tightening shock absorber
mounting threaded
connection
Cover
For shock absorbers without

Buffer stop
For shock absorbers without

Shock absorber, disassembling and assembling

Shock absorber set T10001
Loosening and tightening shock absorber mounting threaded

connection
Ratchet (commercially available)

Socket T10001/9
Ratchet T10001/11
Socket T10001/1

Volkswagen Passat B6 2005 - Stabilizer bar - Front Wheel Drive
42 - 7
Stabilizer bar - Front Wheel Drive (FWD), assembly

overview
Stabilizer bar
Be aware of various

42-7, Stabilizer bar,
Bushing
Always replace bushings on

both sides of vehicle
Stabilizer bar - Front Wheel Drive (FWD), assembly overview Стр. 2 из 5
Clamp
Bolt

42-3
Tighten evenly

removed
Nut

42-3
Self-locking

removed
When tightening,
counterhold at inner multi-
point fitting of bolt Item - 7
-
Bolt
Connecting Link

housing
Subframe
Stabilizer bar, removing and installing

Removing
- Remove rear wheels.
Note:
The following work steps describe the procedure for

the left side of vehicle. The work steps are the same
for the right side of vehicle.
- Remove nut - 1 - and pull connecting link - 2 - out from

stabilizer bar.
Note:
Do not loosen bolt - arrow - for tie rod - 3 - .

- Remove stabilizer bar.
Installing
- Set stabilizer bar into vehicle.
- Evenly fasten bolts - arrows - for stabilizer bar clamp.
- Set connecting link - 2 - into stabilizer bar and fasten nut

- 1- .

- Install and fasten wheel. 44-2, Torque specification for

mounting wheels
Volkswagen Passat B6 2005 - Rear suspension - All Wheel Drive (AWD), servicing 7
42 - 8
Rear suspension - All Wheel Drive (AWD), servicing

Rear axle, overview
Note :
Welding and straightening work on supporting or

wheel carrying components of suspension are not
permitted.
Always replace self-locking nuts.
Always replaced corroded bolts/nuts.
Bonded rubber bushings have a limited torsional

range. Therefore, only tighten bolts on components
with bonded rubber bushings when wheel bearing
housing is lifted (curb weight position) 42-8, Rear
axle in curb weight position
Always replace bonded rubber bushings on both

sides of vehicle.
Rear suspension - All Wheel Drive (AWD), servicing Стр. 2 из 7
I - Assembly Overview: Subframe,

final drive 42-10, Subframe, final
drive - All Wheel Drive (AWD),
assembly overview
II - Assembly Overview: Transverse

link, tie rod 42-11, Transverse link,
tie rod - All Wheel Drive (AWD),
assembly overview
III - Wheel bearing housing, trailing

arm 42-12, Wheel bearing housing,
trailing arm - All Wheel Drive (AWD),
assembly overview
IV - Shock absorbers, coil spring

42-13, Shock absorber, coil spring -
All Wheel Drive (AWD), assembly
overview
V - Stabilizer bar 42-14, Stabilizer

bar - All Wheel Drive (AWD), assembly
overview
Rear axle in curb weight position


required
Engine/transmission jack
VAG1383A
Note:
All bolts at suspension parts with bonded rubber

bushings must always be tightened in curb weight
position (unladen condition).
Bonded rubber bushings have a limited torsional range.

Parts with bonded rubber bushings must therefore be

brought into a position that corresponds to the position in
driving mode before being tightened (curb weight position)
Otherwise, bonded rubber bushing will be stressed

resulting in a shortened service life.
By raising the axle on one side using the

Engine/transmission jack VAG1383A and the Wheel Hub
Support T10149 , this position can be simulated on the
hoist.
Before lifting the axle on one side, the vehicle must be

secured on both sides to the lift arms of the lift using
Tensioning Strap T10038 .
Warning!
If a vehicle is not secured, there is danger that the

vehicle could slip off the lift!
- Turn the wheel hub until one of the holes for the wheel
bolts is at the 12 o'clock position.
- Install Wheel Hub Support T10149 with wheel bolt.
Threading in must only occur after dimension - a - ,

measured before installation, between wheel hub
center and lower edge of wheel housing has been
attained!
Measure dimension - a -
Dimension - a - is dependent on ride height of installed

suspension:
Suspension 1) Ride height - a - in mm

Basic suspension 383 10 mm
Basic suspension with Nivomat 383 10 mm
Heavy duty suspension 393 10 mm
Sport suspension except 18" wheels 368 10 mm
Sport suspension with 18" wheels 368 10 mm
1) Vehicledata plate carries data of suspension installed in

vehicle. Suspension is represented by PR number. PR
numbers and assigned suspensions can be found here
44-7, Specifications for wheel alignment .
- Using engine/transmission hoist, lift wheel bearing

housing until dimension - a - has been obtained.
Warning!
Do not lift or lower vehicle with

engine/transmission jack below vehicle.
Do not leave engine/transmission jack under the

vehicle longer than necessary.
- Tighten respective bolts/nuts.
- Lower wheel bearing housing.
- Move engine and transmission jack away from under

vehicle.
- Remove Wheel Hub Support T10149 .

Rear axle - All Wheel Drive (AWD), torque specification Стр. 1 из 3
42 - 9
Rear axle - All Wheel Drive (AWD), torque

specification
Subframe
Threaded connection Thread Tightening torque (Nm)

To lower transverse link M12 x 1.5 95 1)
Item - 2 -
To upper transverse link M12 x 1.5 80 1) 2)
Item - 6 -
To body M12 x 1.5 x 125 90 + 90 3)
Item - 8 -
To tie rod M12 x 1.5 x 100 90 + 90 3)
Item - 29 -
To front cross member M10 x 115 50 + 180 3)
Item - 2 -
To final drive M12 x 1.5 x 85 60 + 90 3)
Item - 9 - and Item - 12 -
3) Always replace after removal

2) This tightening torque applies only in conjunction with
Insert Tool 18 mm T10179
weight position
Left Rear Level Control System Sensor G76

To subframe M5 x 20 5
Item - 3 -
To lower transverse link M5 x 20 5
Item - 3 -

To lower transverse link M12 x 1.5 x 75 90 + 90 1) 2)
Item - 10 -
To upper transverse link M14 x 1.5 x 95 130 + 90 1) 2)
Item - 18 -
To tie rod M14 x 1.5 x 95 130 + 90 1) 2)
Item - 25 -
To wheel hub with M12 x 1.5 x 45 70 + 90 1)

wheel bearing
Item - 7 -
To shielding plate M6 x 12 12
Item - 17 -
To speed sensor M6 x 16 8
Item - 10 -

weight position
Trailing arm

To wheel bearing housing M12 x 25 90 + 45 1) 2)
Item - 4 -
To mounting bracket M12 x 1.5 x 80 90 + 90 1) 3)
Item - 19 -
Mounting bracket M10 x 35 50 + 45 1)
to body
Item - 21 -

2) Observeinstallation position 42-12, Position: Trailing
arm/wheel bearing housing bolts
3) To tighten, note this dimension 42-12, Installation
position of mounting bracket to trailing arm, determining

Stone impact protection
to cross member M6 x 12 8
Item - 15 -
Shock absorber

To wheel bearing housing M14 x 1.5 x 70 180
Item - 5 -
To shock absorber mount M10 x 1.0 25
Item - 7 -
To body M10 x 35 50 + 45 1)
Item - 6 -
Stabilizer bar

To subframe M8 x 30 25 + 90 1) 2)
Item - 4 -
To connecting link M10 x 55 40
Item - 6 -
Connecting link to M10 40
wheel bearing housing
Item - 6 -

weight position
Drive axle

To final drive M8 x 48 20 + 90 1)
Item - 13 -
To wheel hub M16 x 1.5 x 80 200 + 180 1) 2)
Item - 2 -

2) When tightening, vehicle must not rest on wheels, see
also 42-15, Connection of drive axle hex bolt, loosening
and tightening
Subframe, final drive - All Wheel Drive (AWD), assembly overview Стр. 1 из 14
42 - 10
Subframe, final drive - All Wheel Drive (AWD),

assembly overview
The - arrow - points in direction of

travel.
Subframe
Nut
Tightening torque Topic

42-9

removed
Spacer sleeve
Between subframe front

bonded rubber bushings and
body
Rear bonded rubber bushing
Replacing 42-10,
Subframe, servicing
Front bonded rubber bushing
Replacing 42-10,
Subframe, servicing
Cross member
Hex head screw
Final drive
Repair Manual, Final Drive, Repair

Group 39, Rear final drive, removing and
installing
Bolt

42-9
Washer
installed between final drive

and subframe
Washer
washer must be placed with

holes on tabs of bonded
rubber bushing
Bolt

42-9
Bracket
Rear axle, removing and installing
Torque Wrench 40-200 Nm VAG 1332
Engine/transmission jack VAG 1383A
Subframe with components, removing
Note:
Be aware that if there is additional work where the

drive axle hex head screw must be loosened, this
must also occur with the vehicle resting on the
wheels. Loosening drive axle hex head screw 42-
15, Connection of drive axle hex bolt, loosening and
tightening .
- Remove wheels.
- Coil springs, removing 42-13, Coil spring, removing

and installing .
- Exhaust system rear muffler, removing
Repair Manual, Engine Mechanical, Repair Group 26,

Exhaust system; Exhaust system parts, removing and
installing
- Disconnect electrical connections between rear axle and

body.
- Disconnect brake lines, items - 1 - and - 2 - .
- Disconnect electrical parking brake connections at brake

caliper.
- Remove retainer - 1 - by pressing out inner pins of rivets

- arrows A - .
- Remove line - 1 - at mounting bracket - arrow A - .
- Mark installation position of mounting bracket - 2 - on

body.
- Remove bolt - arrows B - .
- Disconnect Left Rear Level Control System Sensor G76

connector.
- Check whether there is a marking (colored point) -

arrows - on flexible coupling or final drive flange. If there
is no mark, mark position of flexible coupling and final drive
flange to each other - arrows - .
- Disconnect Right Rear ABS Wheel Speed Sensor G44

and Left Rear ABS Wheel Speed Sensor G46 connectors.
- Remove rear driveshaft tube from rear final drive with

flexible coupling and vibration damper - arrows - .
- Remove center bracket bolts - arrows - two turns.
- Support driveshaft at tunnel support with a piece of

wood.
- Move rear driveshaft tube as far as possible in direction

of transmission.
- Disconnect connector to Haldex clutch above final drive.
- Now secure vehicle on both sides to lifting arms on hoist

using Tensioning Strap T10038 .
Warning!
If vehicle is not secured, it could slide off of hoist.
- Place Engine/transmission jack VAG1383A with

universal transmission support V.A.G 1359/2 below
subframe and secure using strap.
- Remove hex head screw - 1 - or - 2 - on both sides.
Note:
For the sake of a better illustration, only the left side

of the vehicle is shown.
To locate subframe, Locating Pins T10096 must be

screwed in one after the other on both sides of the vehicle
at positions - 1 - and - 2 - .
- Location position of subframe using Locating Pins

T10096 .
Note:
Locating Pins T10096 must only be tightened to

maximum of 20 Nm, otherwise threads of locating
pins may be damaged.
- Replace subframe bolts one after the other on both sides

using Locating Pins T10096 and tighten them to 20 Nm.
Position of subframe is now secured.
- Carefully lower subframe with components.
Note:
Ensure there is enough clearance for brake lines,

electrical wires and driveshaft centering pin when
lowering.
Subframe with components, installing
Further installation is in the reverse sequence to removal.

Observe the following when doing so:
Install driveshaft at rear final drive
Repair Manual, Final Drive, Repair Group 39,

Driveshaft, removing and installing
Tightening torques 42-9, Rear axle - All Wheel Drive

(AWD), torque specification .
- Bleed brake system
Repair Manual, Brake System, Repair Group 47, Brake

system, bleeding
Subframe, servicing

required
Hydraulic Press VAS 6178
Engine/transmission jack VAG

1383A
Assembly Tool T10263
Hollow Piston Cylinder VAS 6179
Locating Pins T10096
Front or rear bonded rubber bushings, pulling out
- Coil springs, removing 42-13, Coil spring, removing

and installing .
- Exhaust system rear muffler, removing
Repair Manual, Engine Mechanical, Repair Group 26,

Exhaust system; Exhaust system parts, removing and
installing
- Disconnect electrical connections between rear axle and

body.
- Remove stabilizer bar 42-14, Stabilizer bar, removing

and installing .
- Remove tie rods.

- Now secure vehicle on both sides to lifting arms on hoist

using Tensioning Strap T10038 .
Warning!
If vehicle is not secured, it could slide off of hoist.
- Place Engine/transmission jack VAG1383A with

universal transmission support V.A.G 1359/2 below
subframe and secure using strap.
- Remove hex head screw - 1 - or - 2 - on both sides.
Note:
For the sake of a better illustration, only the left side

of the vehicle is shown.
To locate subframe, Locating Pins T10096 must be

screwed in one after the other on both sides of the vehicle
at positions - 1 - and - 2 - .
- Locate position of subframe using Locating Pins

T10096 .
Note:
Locating Pins T10096 must only be tightened to

maximum of 20 Nm, otherwise threads of locating
pins may be damaged.
- Replace subframe bolts one after the other on both sides

with Locating Pins T10096 and tighten them to 20 Nm.
Position of subframe is now secured.
- Lower subframe 10 cm using Engine/transmission jack

VAG 1383A .
- Mark installation position of bonded rubber bushing to

subframe, e.g. using a felt-tip pen.
- Install special tools as depicted in the illustration.
1 - Nut T10263/5
2 - Washer , commercially available
3 - Subframe
4 - Tube T10263/1
5 - Hydraulic Press VAS6178 VAS6178
7 - Nut T10263/5
8 - Spindle T10263/4
- Pretension special tool.
- Pull out bonded rubber bushing by operating pump.
Front or rear bonded rubber bushings, pulling in

Observe the following when doing so:
Front and rear bonded rubber bushings have slightly

different construction heights. Make sure allocation is
correct when installing Electronic Parts Catalog
"ETKA" .
Bonded rubber bushing must be installed in the correct

direction, note marking on subframe.
- Insert special tool with bonded rubber bushing in

subframe as shown.
Caution!
Thrust piece T10263/3 must be positioned so that

locking tabs on bonded rubber bushing align with
opening on thrust piece T10263/3 .
1 - Nut T10263/5
3 - Press piece T10263/3
4 - Subframe
5 - Bonded rubber bushing
6 - Press piece T10263/2
7 - Hydraulic Press VAS6178 VAS6178
9 - Nut T10263/5
10 - Spindle T10263/4
- Pretension special tool with bonded rubber bushing.
- Carefully insert bonded rubber bushing by operating

pump until collar lies on subframe "without a gap" .
Torque specifications 42-9, Rear axle - All Wheel Drive

(AWD), torque specification

Transverse link, tie rod - All Wheel Drive (AWD), assembly overview Стр. 1 из 16
42 - 11
Transverse link, tie rod - All Wheel Drive (AWD),

assembly overview

travel.
Eccentric bolt

Wheel alignment
Do not turn more than 90

right or left (that is smallest
to largest possible
adjustment)
Nut
Self-locking

removed

42-9
Always tighten bolts in curb

weight position 42-8, Rear
Eccentric washer
Inner bore with tab
Eccentric bolt

Wheel alignment
Do not turn more than 90

right or left (that is smallest
to largest possible
adjustment)
Eccentric washer
Inner bore with tab
Nut
Self-locking

removed

42-9

Note :
Adjust Torque Wrench 40-200 Nm VAG 1332 to 80

Nm when tightening nut.
This tightening torque applies only in conjunction

with Insert Tool 18 mm T10179
Subframe
Bolt

removed

42-9

Nut
Self-locking

removed

42-9

Bolt

removed
Threaded rivet
M6
Expanding rivet
Stone protection plate
Hex head bolt

42-9
Nut
Self-locking

removed

Washer
Bolt

removed


42-9
Washer
Upper transverse link

42-11, Upper transverse link,
Washer
Nut
Self-locking

removed

42-12, Wheel bearing
installing
Washer
Bolt

removed


42-9
Tie rod
Closed in direction of travel

42-11, Tie rod, removing and
installing
Bolt

removed

Bolt

removed
Nut
Self-locking

removed

42-9
Left Rear Level Control System Sensor G76 , overview
Note :
As a replacement part, vehicle level sensor is only

available together with connecting link and upper
and lower retaining plates.
Replacing with subframe installed 42-11, Vehicle

level sensor, replacing in vehicle .
Headlamp Range Control Module J431
Subframe
Bolt

42-9
Left Rear Level Control System

Sensor G76
Complete with components
Lever - arrow - must face

toward outside of vehicle
Replace in vehicle 42-11,

Vehicle level sensor,
replacing in vehicle
After replacing, perform

basic setting of the
headlights
Headlights basic setting

Vehicle Diagnosis, Testing, and
Information System VAS 5051
in "Guided Fault Finding"
function
Vehicle level sensor, replacing in vehicle
Removing
- Disconnect connector - 1 - .
- Remove bolts - 2 - and - 3 - .
- Remove sensor.
Installing

Thereby, observe the following:
Sensor lever must face toward outside of vehicle.
- After replacing, perform basic setting for headlights.
Upper transverse link, removing and installing
Torque Wrench 40-200Nm VAG1332
Removing
- Remove wheel.

installing .
- Disengage wire - arrow A - for wheel speed sensor on

upper transverse link.
- Mark, e.g. using a felt-tip marker, position of eccentric

bolt - arrow - to subframe.
- Remove upper transverse link - 1 - .
Installing
- Install upper transverse link in vehicle and hand-tighten

bolts.
Only bolt on transverse link if dimension "a" is

obtained 42-8, Measure dimension !
- Fasten upper transverse link - 1 - to the subframe and

tighten the new nut - arrow - .
- Note position marking on eccentric bolt - arrow - to

subframe.
- Tighten bolt - 1 - for upper transverse link.
Note:
Make sure that a washer is installed between bolt

and wheel bearing housing.
- Engage wire - arrow A - for wheel speed sensor on

upper transverse link.
- Install wheel and tighten 44-2, Torque specification for

mounting wheels .

Lower transverse link, removing and installing
Torque Wrench 40-200Nm VAG1332
Removing
- Measure dimension from center of wheel to lower edge of

wheel housing 42-2, Rear axle in curb weight position .
- Remove wheel.

installing .
Vehicles with automatic vertical headlight aim control
- Remove connecting link - arrow A - of the Left Rear

Level Control System Sensor G76 .
- Mark, e.g. using a felt-tip marker, position of eccentric

bolt - arrow B - to subframe.
- Disengage rear exhaust system and lower.
- Remove bolt - arrow B - .
- Remove lower transverse link.
Installing
- Install lower transverse link in vehicle and hand-tighten

bolts.
Only bolt on transverse link if dimension "a" is

obtained 42-8, Measure dimension !
- Bolt upper transverse link to subframe and tighten new

nut only to tightening torque.
- Note applied marking of eccentric bolt - arrow B - to

subframe.
- Engage rear exhaust system.
Vehicles with automatic vertical headlight aim control
- Install connecting link - arrow A - of Left Rear Level


- Tighten bolt - arrow - for lower transverse link - 1 - .


mounting wheels .
Tie rod, removing and installing
Removing
- Remove wheel.

installing .
- Remove nut - 1 - and pull connecting link - 2 - out of

stabilizer bar.
- Remove bolt - arrow - for tie rod - 3 - .
- Remove nut - arrow - and remove bolt toward rear.
- Remove tie rod - 1 - .
Installing
- Install tie rod in vehicle and hand-tighten bolts.
The bolted connections of the tie rod must only be

fastened when the dimension "a" is achieved 42-8,

Measure dimension !
- Fasten tie rod - 1 - to subframe and tighten new nut -

arrow - .
- Tighten bolts - arrows - for stabilizer bar clamp.
- Tighten bolt - arrow - for tie rod - 3 - .
Note:
Make sure that a washer is installed between nut

and wheel bearing housing.
- Install connecting link - 2 - in stabilizer bar and tighten

nut - 1 - .


mounting wheels .

Wheel bearing housing, trailing arm - All Wheel Drive (AWD), assembly overview Стр. 1 из 22
42 - 12
Wheel bearing housing, trailing arm - All Wheel

Drive (AWD), assembly overview

travel.
Cover
Mounting bracket
Connecting link

housing
Bolt
Observe tightening
sequence 42-12, Position:
Trailing arm/wheel bearing
housing bolts

removed

42-9
Trailing arm

42-12, Trailing arm with
mounting bracket, removing
and installing
servicing 42-12, Trailing

arm, servicing
Drive axle
Assembly overview 42-15,

Drive axle, assembly
overview

42-15, Drive axle, removal
and installation
Multi-point socket head bolt

removed

42-9

installing
Right Rear ABS Wheel Speed

Sensor G44 / Left Rear ABS
Wheel Speed Sensor G46
Can be checked in Guided

Fault Finding using Vehicle

Diagnosis, Testing and
Information System VAS
5051
Before inserting sensor,

clean inner surface of
mounting hole and coat with
Polycarbamide grease G
000 650
Hex socket head bolt

42-9
Replacing 42-12, Bonded

rubber bushing for wheel
bearing housing, replacing
Nut
Self-locking

removed

42-9
Brake disc
Bolt
4 Nm
Bolt

removed

42-15, Connection of drive
axle hex bolt, loosening and
tightening
Wheel hub with wheel bearing
Sensor ring for ABS is

installed in wheel hub

42-12, Wheel bearing/wheel
hub, removing and
installing
The wheel bearing and wheel

hub are installed together in
one housing.
This wheel bearing/hub unit is

maintenance and adjustment
free. Adjusting and servicing
are not possible!
Bolt

42-9
Shield plate
Bolt

removed

42-9
Replacing 42-12, Trailing

arm, servicing
Bolt

42-9

removed
Wheel bearing housing, removing and installing

Removing

installing .
- Loosen outer drive axle connection 42-15, Connection

of drive axle hex bolt, loosening and tightening .
- Remove wheel.

using wire
- Remove ABS speed sensor from wheel bearing housing.

- Remove screws - arrows - and remove cover plate - 1 -

.
- Remove bolt for tie rod - 1 - , upper transverse link - 2 -

and lower transverse link - 3 - from wheel bearing housing
- 4- .
- Remove connecting link - arrow - from the wheel

bearing housing.
- Pull connecting link - 1 - out from trailing arm.
- Hold wheel bearing housing and remove bolts - arrows -

.
- Remove wheel bearing housing.

Installing
Installation is the reverse of removal, with special attention

to the following:
Only tighten bolts for trailing arm/wheel bearing housing if

all other components (especially spring and shock
absorber) of appropriate suspension are already installed.
To tighten, suspension must be unloaded. Only then will
trailing arm and wheel bearing housing move to required
The sequence of the following work steps must

absolutely be observed!
- Place trailing arm on wheel bearing housing with screws -

arrows - but do not tighten yet.
- Install connecting link - 1 - in trailing arm, do not tighten

nut.
- Lower suspension back using Engine/transmission jack

VAG 1383A and remove Wheel Hub Support T10149
from wheel hub.
- Tighten bolts - arrows - for trailing arm to tightening

torque, observe required position of components while
doing so 42-12, Position: Trailing arm/wheel bearing
housing bolts .
- Screw connecting link - 1 - on wheel bearing housing

and stabilizer.

Threaded connections to wheel bearing housing may

only be performed when dimension between wheel
hub center and lower edge of wheel housing,
measured before assembly, is achieved 42-8,
Measure dimension .


mounting wheels .
Bonded rubber bushing for wheel bearing housing,

replacing

required
Support Arm Bearing Inst. Tool

3346
Fitting Sleeve 3378
Tappet 3390
Torque Wrench 40-200 Nm VAG

1332
Removing
- Remove wheel.

installing .

using wire
Note:
Suspend brake caliper from body.
- Remove cover plate.
Pressing out bonded rubber bushing
- Attach tools as depicted in illustration.
Nut 3346/3
Tappet 3390
Spindle 3346/2
- Remove bonded rubber bushing by turning spindle.
Installing
Pulling in bonded rubber bushing
Nut 3346/3
Support Arm Bearing Inst. Tool 3346
Fitting Sleeve 3378
Spindle 3346/2
- Pull in bonded rubber bushing by turning spindle.
Note:
Do not use lubricant!
Carefully install bearing to avoid canting.
- Install cover plate.
Only install bolted connections on wheel bearing

housing when dimension "a" is obtained 42-8,
Measure dimension !
- Tighten bolt - arrow - for lower transverse link - 1 - .


mounting wheels .
Wheel bearing/wheel hub, removing and installing

Torque Wrench VAG 1410
Removing

installing .
- Remove the drive axle 42-15, Drive axle, removal and

installation .

using wire
Note:
Do not allow brake caliper to hang from brake line.
- Remove screws - 2 - .
- Remove wheel hub/wheel bearing unit from wheel

bearing housing.
Installing
Installation is in reverse order of removal, with special

attention to the following:

- Install a new hex head screw and tighten 42-15,

Connection of drive axle hex bolt, loosening and
tightening .
Trailing arm with mounting bracket, removing and

installing
Removing
- Remove wheel.

installing .
- Remove retainer - 1 - , pressing out inner pins of rivets -

arrows A - .
- Remove connecting link - 2 - from trailing arm.
- Remove bolts - arrows B - .
- Unclip electrical wire from mounting bracket.
- Mark installation position of mounting bracket on body.
- Remove trailing arm - 1 - with mounting bracket.
If trailing arm is being replaced, mounting bracket must be

removed from trailing arm.
- To do so, clamp trailing arm into vise so that mounting

bracket - 1 - makes contact at vise - arrow - .
Installation position of mounting bracket to trailing arm

must then be adjusted 42-5, Determining installation
position of mounting bracket to trailing arm .
Installation position of mounting bracket to trailing arm,

determining
Measure dimension - a - from center of bolt to outer edge

of mounting bracket.
Dimension - a - is 57.5 1 mm.
Mounting bracket
Trailing arm
- When dimension - a - is adjusted, tighten bolt.
Tightening torque 42-9, Rear axle - All Wheel Drive

Installing
Only tighten bolts for trailing arm/wheel bearing housing if

all other components (especially spring and shock
absorber) of appropriate suspension are already installed.

To tighten, suspension must be unloaded. Only then will
trailing arm and wheel bearing housing move to required
The sequence of the following work steps must

absolutely be observed!
- Attach trailing arm and mounting bracket with bolts -

arrows - to wheel bearing housing, but do not tighten.
- Install connecting link - 1 - in trailing arm, do not tighten

nut.
- Lift suspension using engine/transmission jack VAG

1383A and Wheel Hub Support T10149 until mounting
bracket makes contact with body.
- Tighten bolts - arrows - on old impressions.
- Lower suspension back using Engine/transmission jack

VAG 1383A and remove Wheel Hub Support T10149
from wheel hub.
- Tighten bolts - arrows B - for trailing arm to tightening

torque, observe required position of components while
doing so 42-5, Position: Trailing arm/wheel bearing
housing bolts .
- Tighten nut for connecting link - 2 - to wheel bearing

housing.
- Install retainer - 1 - by pressing in inner pins of rivets -

arrows A - .


mounting wheels .
Trailing arm, servicing


required
Thrust Plate VW 401
Thrust Plate VW 402
Bonded rubber bushing, pressing out
- Remove trailing arm 42-12, Trailing arm with mounting

bracket, removing and installing .
- Clamp trailing arm into vise so that mounting bracket - 1

- makes contact at vise - arrow - .
Tube T10230/3
Press piece T10230/10
Thrust Plate VW 401
Thrust Plate VW 402
- Press out bonded rubber bushing.
Pressing in bonded rubber bushing
- Place trailing arm on a level.

- Position trailing arm on level so that dimension - A - =

113 mm is reached.
- Mark vertical line on bushing of trailing arm - arrows - .
Position bonded rubber bushing on trailing arm so that

marked line is between protrusions - 1 - .
Note:
Ensure correct installation position of bonded rubber

bushing to trailing arm bushing.
Tube T10230/5
Thrust plate T10230/12 , chamfer must face bonded
rubber bushing
Thrust Plate VW 402
- Press in bonded rubber bushing flush.
- Install mounting bracket onto trailing arm 42-12,

Installation position of mounting bracket to trailing arm,
determining .
- Install trailing arm 42-12, Installing .

Shock absorber, coil spring - All Wheel Drive (AWD), assembly overview Стр. 1 из 11
42 - 13
Shock absorber, coil spring - All Wheel Drive

(AWD), assembly overview
Lower spring support
End of spring turned to stop
Assembly aid
Must not be used after

removal
Coil spring
Be aware of the various

suspension versions

42-13, Coil spring, removing

and installing
Upper spring support
Bolt

42-9
Bolt

42-9
Shock absorber


7, Vehicle data sticker ,
vehicle data plate.
Washer


installing
Coil spring, removing and installing

Spring Compressor Kit VAG1752
Spring Retainers VAG1752/3A
Adapter VAG1752/9 VAG1752/9 , not depicted
Removing
- Remove wheel.
- Insert spring compressor - 3 - .
Warning!
Be sure coil spring is properly seated in Spring

Retainers VAG1752/3A - 2 - (risk of accident).
- Use wrench or reversible ratchet for tightening spring

compressor.
- Compress coil spring until it can be removed.
- Remove spring.
Spring Retainers VAG 1752/3A

Adapter VAG 1752/9
Spring Compressor VAG 1752/1
Installing
Observe installation position!
End of spring - arrow - must rest against stop of lower

spring support.
- Install spring together with spring seat.
- Lower spring support has a pin.
- Insert this pin into hole of lower transverse link - arrow -

.
- Then insert upper spring support into upper end of

spring.
- Release tension of spring, guiding upper spring support

onto tab of body.
- Remove spring tensioner.

mounting wheels .
Shock absorber, removing and installing
Removing
- Remove wheel.
- Remove wheel housing liner

installing .
- Remove shock absorber.
Installing

Thereby, observe the following:
The bolted connections of the shock absorber to the

wheel bearing housing must only be fastened when
the dimension "a" is achieved 42-8, Measure
dimension !
- Install shock absorber and tighten bolts - arrows - .
- Tighten bolt - arrow - .

- Install wheel housing liner

mounting wheels .
Shock absorber, servicing

Shock absorber


7, Vehicle data sticker ,
vehicle data plate.
Protective cap
Protective tube
Support ring
Buffer stop
For shock absorber with

For shock absorber with

Nut

removed

42-9

42-13, Loosening and
tightening bolted connection
for shock absorber mount
Cover
For shock absorber without

Buffer stop
For shock absorber without

Shock absorber, disassembling and assembling

Shock Absorber Set T10001
Loosening and tightening bolted connection for shock

absorber mount
1 - Ratchet (commercially available)

2 - Socket T10001/9
3 - Ratchet T10001/11
4 - Socket T10001/1

Stabilizer bar - All Wheel Drive (AWD), assembly overview Стр. 1 из 5
42 - 14
Stabilizer bar - All Wheel Drive (AWD), assembly

overview

travel.
Stabilizer bar

Vehicle data plate.

42-14, Stabilizer bar,
Bushing
Always replace bushings on

both sides of vehicle
Clamp

removed

42-9
Nut
self-locking

removed

42-9

removed

42-9
Connecting link

housing
Subframe
Stabilizer bar, removing and installing

Removing
Note:
The following work steps are described for left side

of vehicle. These work steps apply also to right side
of vehicle.
- Remove nut - 1 - and pull connecting link - 2 - out of

stabilizer bar.
Note:
Do not loosen bolt - arrow - for tie rod - 3 - .

- Remove stabilizer bar.
Installing
- Install stabilizer bar into vehicle.
- Tighten bolts for stabilizer bar clamp - arrows - evenly.
- Install connecting link - 2 - in stabilizer bar and tighten

nut - 1 - .

- Install wheel and tighten. 44-2, Torque specification for

mounting wheels
Drive axle, assembly overview Стр. 1 из 17
42 - 15
Drive axle, assembly overview
Outer constant velocity joint
Replace only as a unit
Removing 42-15,
Pressing off outer constant
velocity joint
Installing: Drive onto shaft

until impact using plastic
hammer
Checking 42-15, Outer

constant velocity (CV) joint,
checking
Hex head screw


42-15, Connection of drive
axle hex bolt, loosening and
tightening

42-9

removed
Note :
Vehicle must not stand on wheels when loosening

and tightening
Drive axle
Clamp

removed
Tensioning 42-15,
Tensioning clamp on small
diameter
Protective boot
Check for tears and chafing
Material: (polyelastomer)
Clamp

removed
Tensioning 42-15,
Tightening clamp on outer
joint
Spring washer
Installation position 42-15,

Installation position of spring
washer and thrust washer on
outer joint
Thrust washer

washer and thrust washer on
outer joint
Circlip

removed
Insert in shaft groove
Constant velocity joint boots
Material:
Without ventilation bore
Check for tears and chafing
Drive off constant velocity

joint using drift
Before mounting onto

constant velocity joint, coat
sealing surface using D 454
300 A2
Clamp

removed
Tensioning 42-15,
Tensioning clamp on small
diameter
Backing plate

42-9
Always replace after

removal
Circlip

removed
Remove and install using

Circlip Pliers VW161A
Gasket

removed
Bonding surface on constant

velocity joint must be free of
grease and oil!
Inner constant velocity joint
Replace only as a unit
Pressing off 42-15,

Pressing off inner constant
velocity joint
Pressing on 42-15,
Pressing on inner constant
velocity (CV) joint
Checking 42-15, Inner

constant velocity (CV) joint,
checking
Spring washer
With inner splines

washer on inner joint
Connection of drive axle hex bolt, loosening and

tightening

Angle wrench V.A.G 1756
Wheel bearings must not be burdened when drive axle

connection is loose.
If the bearings are loaded by the vehicles own weight the

wheel bearing will be damaged. The wheel bearings will be
stressed and the life expectancy reduced. Therefore,
observe the following:
Procedure for loosening hex bolt.
Vehicles without drive axle must not be moved, otherwise

wheel bearing will be damaged. If vehicle must be moved,
observe the following:
- Install an outer joint in place of the drive axle.
- Tighten outer joint to 120 Nm.
Loosen hex bolt
- Loosen hex bolt a maximum of 90 when vehicle is still

on its wheels, otherwise wheel bearing will be pre-
damaged.
- Lift vehicle enough that wheels hang free.
- Apply brake (second technician required).

- Remove hex bolt - arrow - .
Bolting hex bolt
- Replace hex bolt.
Note:
Wheels may not yet touch ground for tightening drive

axle, otherwise wheel bearing may be pre-damaged.
- Apply brake (second technician required).
- Tighten hex bolt to 180 Nm.
- Lower vehicle onto its wheels.
- Turn bolt an additional 180 .
Drive axle, removal and installation
Removing
- Loosen drive axle fastener 42-15, Connection of drive

axle hex bolt, loosening and tightening
- Remove wheel.

installing .
- Remove bolts for tie rod - 1 - and lower transverse link -

3 - from wheel bearing housing - 4 - .
- Loosen input shaft at transmission flange.
- Swing wheel bearing housing upward and remove drive

axle from inner splines.
- Remove drive axle.
Installing
Installation is the reverse of removal, with special attention

to the following:

Connections to wheel bearing housing may only be

performed when dimension between wheel hub center
and lower edge of wheel housing, measured before
assembly, is achieved 42-8, Measure dimension
Disassembling and assembling


required
Thrust Plate VW 401
Thrust Plate VW 402
Punch VW 408A
Punch VW 411
Tube 37 mm dia. VW 416B
Thrust Pad VW 447H


required
Circlip Pliers VW 161A

1331

1332
CV Joint Boot Clamp Tool VAG

1682
Disassembling
- Drive off drive axle by hitting forcefully using plastic

hammer.
Pressing off outer constant velocity joint
- Press off CV boot from joint using drift.
- Remove circlip.
- Remove both clamps and slide CV boot toward outer

joint.
Pressing off inner constant velocity joint
Outer constant velocity (CV) joint, checking
Joint must be disassembled to replace grease when

severely soiled or if journal surface of balls must be
checked for wear and damage.
Removing
- Before disassembling mark ball hub position in relation to

the ball cage and housing using an electric scriber or oil
stone.
- Swivel ball hub and ball cage.
- Remove balls one after another.
- Turn cage, until two rectangular windows - arrow -

contact joint body.
- Lift out cage together with hub.
- Swing segment of hub into rectangular window of cage.

- Tilt hub out of cage.
6 balls for each joint belong to a tolerance group. Check

stub axle, hub, cage and balls for small indentations
(pitting) and signs of seizure. Excessive circumferential
backlash in joint can be detected via tip-in shock, in such
cases joint should be replaced. Flattening and running
marks of balls are no reason to replace joint.
Installing
- Press in half of total amount of grease (40 grams) into

joint body.
- Install cage with hub in the joint housing.
- Press in opposing balls in sequence, during this, previous

position of ball hub to ball cage and to joint body must be
re-established.
- Install new circlip into hub.
- Distribute remaining grease in cover.
- Constant velocity joint, checking for function
Constant velocity joint is properly assembled when ball hub

can be slid back and forth by hand over whole
compensation length.
Inner constant velocity (CV) joint, checking
Removing
Joint must be disassembled to replace grease when

severely soiled or if journal surface of balls must be
checked for wear and damage.
- Swivel ball hub and ball cage.
- Press out ball joint part in direction of - arrow - .
- Press balls out of cage.

Note:
The ball hub and joint are paired. Do not

interchange.
- Flip out ball hub from ball cage via running path of ball -
arrows - .
- Check joint part, ball hub, ball cage and balls for
indentations (pitting) and signs of seizure.
Excessive circumferential backlash in joint can be detected

via tip-in shock. In such cases the joint must be replaced.
Flattening and running marks of balls are no reason to
replace joint.
Installing
- Insert ball hub into ball cage via two chamfers. The hub
can be installed in any position. Press balls into cage.
There are 2 different distances between ball tracks of ball

hub, a larger and a smaller one.
- Insert hub with cage and balls upright into joint piece, a
smaller space - b - must face toward open side of joint
piece when doing this.
- Also observe chamfer on inner diameter of ball hub which

must be visible after swinging in.
- Swing in ball hub; to do so, swing hub far enough out of

cage - arrows - (as depicted in illustration).
- Swivel in hub with balls by pressing firmly on cage -

arrow - .
- Constant velocity joint, checking for function
Constant velocity joint is properly assembled when ball hub

can be slid back and forth by hand over whole
compensation length.
Assembling
Installation position of spring washer on inner joint
Spring washer
Installation position of spring washer and thrust washer on

outer joint
Spring washer
Thrust washer
- Press on joint until stop.
- Insert circlip.
Pressing on inner constant velocity (CV) joint
Note:
Chamfer on inner diameter of ball hub (splines) must

face contact shoulder of drive axle.
Tightening clamp on outer joint
- Use CV Joint Boot Clamp Tool VAG 1682 as depicted in

illustration. Make sure that the jaws of the clamp tool seat
in the corners - arrows B - of the hose clip.
- Tension clamp by turning spindle using a torque wrench

(do not tilt clamp tool).
Note:
A stainless steel clamp must be used due to

hardness of CV boot material (compared to rubber).
This clamp can only be tensioned using CV Joint
Boot Clamp Tool VAG 1682 .
Torque specification: 25 Nm
Use torque wrench - C - with adjustment range 5 to

50 Nm (e.g. Torque Wrench 5-50 Nm VAG 1331 ).
Be sure thread of spindle - A - of clamp tool moves

freely. Grease with MOS 2 grease if necessary.
If it does not move freely, e.g. due to dirt in thread,

required clamp tension will not be achieved at
specified torque.
Tensioning clamp on small diameter

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Volkswagen Passat B6 2005 - Rear suspension, servicing (front wheel drive) Стр.

Rear suspension, servicing (front wheel drive)

 Welding and straightening operations are not

 Always replace self-locking nuts.

 Always replaced corroded bolts/nuts.

 Bonded rubber bushings have a limited torsional

 Always replace bonded rubber bushings on both

I - Subframe, transverse link, tie rod

II - Wheel bearing housing, trailing

III - Shock absorber, coil spring 42-

IV - Stabilizer bar 42-7, Stabilizer

Rear axle in curb weight position

Special tools, testers and auxiliary items

 Engine/transmission jack V.A.G

 Tensioning Strap T10038

 Wheel Hub Support T10149

 All chassis component bolts with bonded rubber

Bonded rubber bushings have a limited torsional range.

Before axle components with bonded rubber bushings are

Otherwise the bonded rubber bushing will be distorted,

By raising axle on one side using engine/transmission jack

Before individual suspension is raised on one side, the

If the vehicle is not secured, there is a risk that it may

- Install wheel hub support T10149 with a wheel bolt.

The bolts may only be tightened if dimension - a - is

Dimension - a - is dependent on ride height of the installed

Suspension 1) Ride height - a - in mm

1) The suspension that the vehicle is equipped with is

- Raise wheel bearing housing using engine/transmission

 Do not raise or lower vehicle while

 Do not leave engine and transmission lift under

- Tighten respective bolts/nuts.

- Lower steering knuckle.

- Move engine/transmission jack V.A.G 1383 A away from

- Remove wheel hub support T10149 .

Rear axle, torque specifications (front wheel drive)

Threaded fasteners Thread Torque specification (Nm)

3) Replace each time it is removed

Left Rear Level Control System Sensor G76

Threaded fasteners Thread Torque specification (Nm)

Wheel bearing housing

Threaded fasteners Thread Torque specification (Nm)

1) Replace each time it is removed

Threaded fasteners Thread Torque specification (Nm)

1) Replace each time it is removed

Lower transverse link

Threaded fasteners Thread Torque specification (Nm)

Threaded fasteners Thread Torque specification (Nm)

1) Replace each time it is removed

Threaded fasteners Thread Torque specification (Nm)

Connecting link to wheel bearing housing M10 40 1)

1) Replace each time it is removed

Subframe, transverse link, tie rod - Front Wheel

 For camber adjustment

 After loosening, perform

 Torque specifications 42-

 Replace each time it is

 Only tighten threaded

Welding and straightening operations are not

Always replace self-locking nuts.

Always replaced corroded bolts/nuts.

Bonded rubber bushings have a limited torsional

Always replace bonded rubber bushings on both

Engine/transmission jack V.A.G

Tensioning Strap T10038

Wheel Hub Support T10149

All chassis component bolts with bonded rubber

Do not raise or lower vehicle while

Do not leave engine and transmission lift under

For camber adjustment

After loosening, perform

Torque specifications 42-

Replace each time it is

Only tighten threaded

Inner bore with tab

For toe adjustment

After loosening, perform

Inner bore with tab

Torque specification Topic

Replace each time it is

Only tighten threaded

Bracket for rear muffler

Torque specification Topic

Replace each time it is

Lower transverse link

Removing and installing

Torque specification Topic

Replace each time it is

Only tighten threaded

Replace each time it is

Stone protection plate

Hex head bolt

Torque specification Topic

Torque specification Topic

Replace each time it is

Replace each time it is

Only tighten threaded

Upper transverse link

Removing and installing

Torque specification Topic

Replace each time it is

Only tighten threaded

Wheel bearing housing

Removing and installing

Replace each time it is

Only tighten threaded

Locked in direction of travel

Torque specification Topic

Replace each time it is

Replace each time it is

Torque specification Topic

Replace each time it is

Only tighten threaded

The level control system sensor is only available as

Replace with subframe installed.

Headlamp Range Control Module J431

Lower transverse link

Torque specification Topic

Left Rear Level Control System

Complete with attachments

Lever - arrow - must face

After replacing, perform

Torque wrench V.A.G 1331

Torque wrench V.A.G 1332