Replacing torsion bars (rear axle with independent suspension) (VW Beetle)

Removal

Loosen the wheel mounting bolts, lift the vehicle and place it on supports. Remove the wheel and release the shock absorber from below (on the flange of the axle shaft housing).

Release the stabilizer (if any) from the top of the balancer.



Use a center punch to mark the position of the hub flange in relation to the elastic lever. Disconnect the hub flange from the elastic arm. Pull back the axle shaft cover.

Caution! Make sure the axle shaft does not fall.

Disconnect the cable at the front of the parking brake lever.

Remove the 5 front wing mounting bolts.



Unscrew the elastic lever hub cover. Disconnect the outer rubber bushing. Use a crowbar to lift the elastic lever and remove the inner rubber bushing.





Remove the torsion bar by pushing the wing to the side with your hand.

Installation

Check the torsion bar for damage and replace if necessary. Paint over damaged areas of the protective coating on the elastic rod and lubricate the splines.

Caution! Do not swap the torsion bars, as they are pre-tightened in opposite directions. Observe the markings (the letter "R" or "L" on the end of the torsion bar). Make sure that the diameters of both torsion bars are the same.

Insert the torsion bar into the internal splines of the kidney pipe.

Adjust the wheel alignment (see section "Geometrical parameters of wheel installation").

Install the inner rubber bushing, covering its surface with talc. Install and adjust the elastic lever.

Install the outer rubber bushing, covering it with talc.

Caution! The larger cross-section of the rubber bushing, marked with the word "oben", must be on top.

Install the elastic arm cover and evenly tighten all four bolts with spring washers to a torque of 40 N⋅m (4.0 kg⋅cm). If necessary, tighten the cover with two longer bolts diagonally.

Thoroughly clean the mating surfaces of the elastic lever and the axle shaft support housing. Raise the elastic lever using the tensioning device so that the lower edge is located above the lower stop.




Secure the axle hub in accordance with the markings (not forgetting the spring washers), tighten the bolts to a torque of 110 Nm (11.0 kgfm). Secure the shock absorbers and stabilizer (if any).

Retract the parking brake cable and adjust it (see section "Adjusting the parking brake").

Caution! If the elastic arm has been replaced, the wheel alignment must be adjusted.

Install the wheel, lower the vehicle, tighten the wheel mounting bolts to 130 Nm (13.0 kgfm).