Front shock absorber strut repair (VW Passat B5)

Contents: Disassembly ↓ Installation ↓

Shock absorber strut elements

1 - flange nut 50 Nm,
2 - bearing,
3 - washer,
4 - upper spring plate,
5 - cylindrical coil spring,
6 - stop. Installed in the upper spring plate,
7 - protective cover,
8 - protective cover,
9 - spring support,
10 - lower spring plate,
11 - shock absorber

Shock absorber spring compressor

The original text is available on the website: VWMANUAL.ru

1 - spring compression device,
2 - fixture grips,
3 - device for fastening the shock absorber strut

Disassembly

1. Secure the front shock absorber strut in a vice with soft jaws and, using a special device, compress the spring so that it moves away from the top of the strut, see Fig. Device for compressing the shock absorber spring.

When using a special device for compressing springs, make sure that the spring coils are securely gripped and that the spring is compressed from opposite sides. The spring has a very high compression force, so use only a very reliable tool. Never tie the spring with wire.

2. Secure the shock absorber rod with a wrench to prevent it from turning and, using a second open-end wrench, unscrew the central nut securing the shock absorber rod.

3. Remove the bearing, washer and upper spring plate from the shock absorber rod.

4. Remove the spring together with the spring compressor.

4. Remove the spring together with the spring compressor.

5. Remove the protective cover (1) and spring support (2). Using a plastic hammer, knock the lower spring plate (3) upwards.

Installation

Correct hole position (arrow) when installing the lower spring plate on the shock absorber

1 - lower spring plate,
2 - shock absorber,
A - axle of the lower shock absorber mount fork

Correct positioning of the upper spring plate

F - front of the car,
R - right shock absorber strut,
L - left shock absorber strut,
A - 11° ±2 minutes,
1 - lower shock absorber mounting axle

Tightening the shock absorber rod mounting nut

1 - key to hold the shock absorber rod from turning,
2 - torque wrench for tightening the shock absorber rod mounting nut

Warning: When installing, it is necessary to use springs with the same technical characteristics on one axle of the vehicle (with the same color marking).

1. Check the shock absorber for signs of fluid leaks. Check the entire length of the shock absorber rod for pitting. Check the shock absorber body for mechanical damage. Set the shock absorber in a vertical position and check its operation by moving the shock absorber rod through its full stroke. Also check the operation of the shock absorber by moving the shock absorber rod up and down a distance of 50-100 mm. In all cases, the shock absorber rod should move smoothly with noticeable resistance. If the shock absorber rod moves jerkily or there is mechanical damage, the shock absorber must be replaced.

2. Secure the shock absorber in a vice with soft jaws.

3. Install the lower spring plate on the shock absorber, with the hole in the spring plate perpendicular to the hole in the fork of the lower shock absorber mount (see Fig. Correct position of the hole (arrow) when installing the lower spring plate on the shock absorber). The deviation of the hole in the lower spring plate from the perpendicular position should be no more than ±2°.

4. Install the support spring and protective cover.

4. Install the support spring and protective cover.

5. Install the coil spring so that its lower end is correctly positioned in the lower spring plate.

6. Install the upper spring plate so that the axis passing through the mounting threaded holes is at an angle of 11° relative to the axis of the lower shock absorber mount (see fig. Correct positioning of the upper spring plate). Please note that the upper spring plate mount for the left and right shock absorbers is different.

7. While holding the shock absorber rod from turning, screw on a new shock absorber rod mounting nut with a flange and tighten it to a torque of 50 Nm, see Fig. Tightening the shock absorber rod mounting nut.

8. Carefully remove the spring compressor.