Removing Front-Axle Carrier - V6

Fig 1: Identifying Front-Axle Carrier

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→ Wear personal protective gear.

→ Get someone to help if necessary.

→ Wear personal protective gear.

→ Get someone to help if necessary.

→ Wear personal protective gear.

→ Get someone to help if necessary.

Information 

• These removal and installation instructions apply to vehicles with level adjustment and steel springs. The points relating to level adjustment are not relevant for vehicles with steel springs. 

1. Open the engine compartment lid and secure with the bonnet stay 97040. 
2. Remove engine design covers.

   Information 

   • Point 3 is not necessary for a 6-cylinder engine. There is a perforated plate at both the front right and rear left of the engine for transporting and raising to the safety device. 
3. Remove -torque support-  from the engine. Then re-insert the fastening screw -arrow-  .
   Fig 2: Locating Engine Torque Support

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4. Position the safety device 10-222 A  correctly and fit the chain to the mounting -A-  . Fit the transport eyebolt 9700  for securing the engine -B-  (the bore for the transport eyebolt is located between cylinder 6 and 7 on the left cylinder bank).
   Fig 3: Securing Engine Using Special Tool

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5. Remove the front wheels. → Removing and installing wheel
6. Remove engine guard. → Removing engine guard

   Information 

   • The spring struts are not removed in order to remove the front axle carrier. 
   • Fix upper axle strut. The lower control arms are loosened on the front axle carrier and remain with the spring struts in the vehicle. 
7. Fix upper axle struts with spring compressor VW 552  . This involves tensioning axle strut slightly because top ball joint can otherwise get damaged. When doing this, engage the -connecting piece-  into the top opening of the wheel well (double panel, under the wheel housing cover) and into the axle strut (do not disconnect the air spring connection!).
   Fig 4: Fixing Upper Axle Struts Using Spring Compressor VW 552

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8. For easier removal of the outer tie rod end, swivel the relevant wheel carrier so that the tie rod extends fully. Remove the -outer tie-rod joints-  using press-out tool T10187  . When pressing out, screw fastening nut on flush (protects the ball joint thread).
   Fig 5: Removing Outer Tie-Rod Joints Using Press-Out Tool (T10187)

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9. The screw in the steering shaft is removed from the wheel well. Release the coolant hoses from the holders on the body. Release the -steering column screw (arrow)-  from the steering gear.
   Fig 6: Locating Steering Column Screw

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10. Remove the hydraulic lines from the steering gear (collect hydraulic fluid in a suitable container). Remove the heat shield of the steering, if necessary.
11. Mark the installation position of the cardan shaft and remove it from the front-axle final drive. Make sure that the cardan shaft does not become kinked (tie it up). → Removing Front Cardan Shaft
12. Remove drive shafts from the front-axle final drive. Make sure that the drive shafts do not become kinked (tie it up). → 404119 REMOVING AND INSTALLING FRONT DRIVE SHAFT 
13. Remove lower control arms from the front axle carrier. → 401719 REMOVING AND INSTALLING BOTTOM AXLE STRUT 
14. Remove stabiliser mount.

    Information 

    • The mounting points for the front axle carrier (1 and 3), both right and left, and the two positioning guides (4) that are pushed into the body are required for removing the front axle carrier. The other mounting points can be removed. 
    • The mounting points 1/11 (designation on the guide pin) are fitted into -Position 1- . Double codes (e.g. 11, 22) are also used for mounting the rear axle. 
      Fig 7: Identifying Mounting Frame

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    • A second worker is required in order to avoid damaging adjacent components when lowering the front axle carrier. 
    • For installation, it is a good idea to mark the installation position of the front axle carrier diagonally at least two places on the body. To do this, place the marks vertically with respect to the floor of the body using a felt-tip pen (e.g. mark along the front-axle carrier mount with the pen). 
      Fig 8: Marking On Front Axle Carrier

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15. Position the -workshop trolley-  with the correctly positioned mounting frame  under the front axle carrier.
    Fig 9: Identifying Workshop Trolley

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16. Mark the installation position of the front axle carrier diagonally at least two places on the body. → see Fig 10
    Fig 10: Marking Installation Position Of Front Axle Carrier

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17. The -arrows-  show the mounting points for the mounting frame in the front axle carrier (view from below here).
    Fig 11: Locating Front Axle Carrier Mounting Points

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18. Position the front axle carrier into the mounting points provided -(arrows)-  (points 4 in the body).
    Fig 12: Positioning Front Axle Carrier Into Mounting Points

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19. Remove the four fastening screws -(arrows)-  on the front-axle carrier.
    Fig 13: Locating Front-Axle Carrier Fastening Screws

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20. Lower the front axle carrier with steering, final drive and stabiliser. Be careful not to damage adjacent parts (e.g. cardan shaft, oil pan, body).
21. Remove accessories from the front axle carrier (steering, final drive, stabiliser). Get another worker to help.