Installing Front Axle

Fig 1: Identifying Front-Axle Cross Member

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1. Hexagon-head bolt for steering gear, M10
2. Hexagon-head bolt for front axle, M12 x 1.5 x 30, tightening torque: 100 Nm (74 ftlb.)
3. Hexagon-head bolt for front axle, M14 x 1.5 x 120, tightening torque: 160 Nm (118 ftlb.)
4. Hexagon-head bolt for front axle, M14 x 1.5 x 50, tightening torque: 160 Nm (118 ftlb.)
5. Hexagon-head bolt for front axle, M14 x 1.5 x 50, tightening torque: 160 Nm (118 ftlb.)
6. Hexagon-head bolt for coolant pipe, M6
7. Hexagon-head bolt for coolant pipe, M6
8. Holder for coolant pipe

Replace all lock nuts. Replace screw(s) securing universal joint (steering shaft) to steering gear and brake calliper to wheel carrier. 

1. Install front axle.
   1. 1.1. Raise the front axle with the spring strut at the left and right and position it.
      Fig 2: Installing Front Axle

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   2. 1.2. Screw in and tighten screws securing front axle to body -1 and 2-  . Screws -1-  = rear: M14 x 1.5 x 50/front: M14 x 1.5 x 120. Screws -2-  = M12 x 1.5 x 30.

      → Tightening torque, M14 front: 160 Nm (118 ftlb.) 

      → Tightening torque, M14 rear: 160 Nm (118 ftlb.) 

      → Tightening torque, M12: 100 Nm (74 ftlb.) 

      Fig 3: Identifying Front-Axle Assembly

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   3. 1.3. Screw in and tighten stud -3-  on transmission support -1-  .

      → Tightening torque: 20 Nm (15 ftlb.) 

      Fig 4: Identifying Transmission Support Stud

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   4. 1.4. Screw on and tighten nuts -2-  on transmission support -1-  .

      → Tightening torque: 65 Nm (48 ftlb.) 

2. Tighten spring struts at the spring-strut dome.
   1. 2.1. Secure spring struts at the spring-strut dome by screwing on and tightening the nuts -2-  .

      → Tightening torque: 33 Nm (24 ftlb.) 

      Fig 5: Identifying Spring Struts Fasteners

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   2. 2.2. Connect cable plug -1-  for the PASM line.
   3. 2.3. Secure trim panel in the luggage compartment.
3. Connect coolant hoses.

   Information 

   • The coolant hoses must lock with an audible click when pushed into the plug-in couplings. 

   Information 

   • Check O-rings on the plug-in couplings and replace them if necessary. 
   • Clean plug connection and coolant hoses before assembly. 
   • Coat O-rings and coolant hoses with Kluber Plus Gel (Part No. 000.043.205.93). 
   • Remove stoppers before fitting the coolant lines and hoses. 
   1. 3.1. Connect coolant hoses at the front.

      Press on coolant hoses -1-  until the spring clamps on the Henn couplings lock with an audible click.

      Fig 6: Identifying Coolant Hoses

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   2. 3.2. Connect coolant hose at the rear.

      Press on coolant hose -2-  until the spring clamp on the Henn coupling locks with an audible click.

4. Fit pressure and return lines at the steering gear.
   1. 4.1. Insert pressure and return lines with new sealing rings into the steering gear.
      Fig 7: Identifying Steering Gear Pressure And Return Lines

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   2. 4.2. Fit tension shackle -2-  for pressure and return lines at the steering gear by inserting the tension shackle -2-  and screwing in and tightening the screw -1-  .

      → Tightening torque: 23 Nm (17 ftlb.) 

5. Fit universal joint at the steering spindle. Use new fastening screw!
   1. 5.1. Steering wheel must be in center position.
      Fig 8: Steering-Wheel Holder

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   2. 5.2. Fit universal joint on the steering spindle.

      Fit universal joint on the steering spindle while paying attention to the installation position -see arrows-  .

      Fig 9: Identifying Universal Joint On Steering Spindle

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   3. 5.3. Screw in and tighten M8 screw -arrow-  on the universal joint.

      → Tightening torque: 23 Nm (17 ftlb.) 

      Fig 10: Locating Universal Joint

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6. For all-wheel drive vehicles: Fit the drive shafts on the transmission side.

   Fit drive shafts -1-  at the front by screwing in and tightening the screws.

   → Tightening torque: 39 Nm (29 ftlb.) 

   Fig 11: Identifying Drive Shaft

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7. Fit restraining straps on the fuel tank.

   Fit restraining straps -1-  and screw in and tighten screws -2-  .

   → Tightening torque: 23 Nm (17 ftlb.) 

   Fig 12: Identifying Restraining Straps

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8. Install diagonal braces and crash stop.
   1. 8.1. Install crash stop -3-  (all-wheel drive only).

      Fit crash stop -3-  and screw in and tighten screws -4-  .

      → Tightening torque: 100 Nm (74 ftlb.) 

   2. 8.2. Install diagonal braces -1-  .

      Fit diagonal braces -1-  and screw in and tighten screws -2-  .

      → Tightening torque: 100 Nm (74 ftlb.) 

   Fig 13: Identifying Diagonal Brace
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9. Fit brake calliper.

   Fit brake calliper -1-  and screw in and tighten M12 screws -2-  for brake calliper.

   Always replace M12 screws -2- for brake calliper before fitting. 

   → Tightening torque: 85 Nm (63 ftlb.) 

   Fig 14: Identifying Brake Calliper

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10. Fit connecting link on anti-roll bar.

    Fit connecting link -1-  on anti-roll bar and screw on and tighten nut -2-  .

    → Three-stage tightening procedure (1st stage: tighten to 50 Nm (37 ftlb.). 2nd stage: loosen by 90 degrees. 3rd stage: tighten to 65 Nm (48 ftlb.).: 65 Nm (48 ftlb.) 

    Fig 15: Identifying Connecting Link And Wheel Carrier

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11. Fit brake line holder and electric cable plug.
    1. 11.1. Connect electric cable plug -1-  for the wheel speed sensor and brake pad wear indicator.
    2. 11.2. Secure electric cable plug by screwing on and tightening the nut -2-  .
    3. 11.3. Fit brake line holder on the wheel carrier at the left and right by screwing on and tightening the nut -3-  .

       → Tightening torque: 10 Nm (7.5 ftlb.) 

    Fig 16: Identifying Brake Line Holder
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12. Fit connector on range adjustment sensor.