Removing Front-Axle Carrier

→ Wear personal protective gear.

→ Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

→ Do not spill fluids.

→ In the event of contact, wash the component or surface with water.

→ Replace components that are already damaged.

Information 

Secure upper trailing arm with the spring compressor VW 552  (pre-tension slightly). This must be done immediately before loosening the spring strut from the lower trailing arm. This prevents damage to the ball joint on the upper trailing arm as a result of the weight of the wheel bearing housing.

• Secure spring compressor VW 552 at the top  . → Securing spring compressor on front axle, top 
  Fig 1: Securing Spring Compressor On Front Axle (Top)

  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
• Secure spring compressor VW 552 at the bottom  . → Securing spring compressor on front axle, bottom 
  Fig 2: Securing Spring Compressor On Front Axle (Bottom)

  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  Fig 3: Identifying Front-Axle Carrier

  Courtesy of PORSCHE CARS NORTH AMERICA, INC.

1. Release and disconnect plug connection for rpm sensor on the wheel carrier on both sides. → rpm sensor connector 
   Fig 4: Disconnect RPM Sensor Connector

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. Disconnect plug coupling for brake-pad wear indicator -1-  and detach it from the holder -2-  .
   Fig 5: Disconnecting Connector For Brake-Pad Wear Indicator

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Loosen fastening screws -arrows-  on the brake calliper, but do not unscrew and remove fully.
   Fig 6: Removing Brake Caliper Fastening Screws

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. Unclip the PDCC line on the front-axle carrier (grille) from the 4 holders.
5. Mark the position of the subframe on the longitudinal member -arrows-  (e.g. using a felt-tip pen, makes installation easier).
   1. 5.1. This marking must be applied to at least two corners of the subframe. This gives a rough idea of the correct position for re-installation.
      Fig 7: Locating Front-Axle Carrier Marking

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Remove struts -2-  on both sides.
   Fig 8: Removing Struts

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   Collect power-steering fluid.

   • Before loosening the pressure and return lines (also PDCC), place a suitable container underneath to collect power-steering fluid. 
   • Wear protective goggles and gloves. 
7. Disconnect pressure and return lines for the steering on the steering gear.

   Remove the two mountings for the pressure line on the subframe.

   1. 7.1. Left center wheel housing: Remove the fastening nut of the power steering pressure line holder and undo the retaining eyelet (the holder is positioned in front of the rear mounting point for the subframe). → Fastening nut on holder 
      Fig 9: Identifying Nut On Holder

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   2. 7.2. Front left wheel housing: Disconnect the lower connection on the servo oil cooler (open the clamp on the power-steering return line and pull off the hose). The return line remains on the subframe during removal.
8. Mark the installation position of the steel flexi-pipes -2-  on the steel flexi-pipes themselves and on the valve block using a suitable touch-up stick -3-  .

   Information 

   Working with steel flexi-pipes

   • Steel flexi-pipes are particularly prone to kinking and pinching. 
   • Be particularly careful with steel flexi-pipes during removal, storage and reinstallation. 
   • Mark the installation position of the pipe with a paint marker during removal. 
   • Steel flexi-pipes must never be installed twisted. 
9. Unscrew cap screws on steel flexi-pipes -1-  .
   Fig 10: Identifying Steel Flexi-Pipes

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
10. Press upper trailing arm off the wheel bearing housing.
    1. 10.1. Secure the wheel bearing housing to prevent it from falling down (second mechanic required).
    2. 10.2. Loosen fastening nut -1-  (do not remove completely). When doing this, leave lock nut flush on the ball pin so as not to damage the thread.
       Fig 11: Identifying Nut On Upper Trailing Arm

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 10.3. Position the press-out tool T40010  over the ball joint and fit on the fastening nut.
    4. 10.4. Screw in hexagon on the press-out tool T40010  until the ball joint becomes detached from the cone.
       Fig 12: Pressing Off Upper Trailing Arm

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
11. Place elevating platform Master Gear unit elevating platform WE 1206  under the vehicle and move all assembly drivers -A, B, C, D, E, F-  to the same height at the correct position.
    Fig 13: Overview Of Assembly Drivers

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Carefully guide in the elevating platform and remove the spring compressor VW 552  on both sides -arrow-  .

    Fig 14: Securing Spring Compressor On Front Axle (Bottom)

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
12. Remove brake calliper and hang it in the wheel housing.

    Information 

    • Before moving the lifting platform, mark the position of the wheels on the workshop floor with a piece of chalk. This makes it easier to position the platform again for re-installation. 
    1. 12.1. Loosen fastening screws -arrows-  on the brake calliper, but do not remove the brake line. (Do not open the brake system!)
    2. 12.2. A second worker must remove the fastening nut from the upper trailing arm and tilt the wheel bearing housing out slightly.
    3. 12.3. Guide the brake calliper through between the spring strut and wheel bearing housing and suspend it at a suitable position in the wheel housing. Secure the wheel carrier to prevent it from tipping over using welding wire for example.
13. Fit the wheel hub holder -1-  on the left and right using assembly aids (threaded bolts for mounting wheels) -2-  to the wheel hub.
    Fig 15: Fitting Wheel Hub Holder

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
14. Remove bolts on lower trailing arm.
    1. 14.1. Raise the lifting platform slightly in order to relieve the pressure on the bolts on the lower trailing arm.
    2. 14.2. Remove the bolts on the lower left/right trailing arm -arrows-  .
       Fig 16: Locating Lower Spring-Strut Mounting

       Courtesy of PORSCHE CARS NORTH AMERICA, INC.
15. Detach front-axle carrier.
    Fig 17: Locating Marking And Fastening Screw On Front-Axle Carrier

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. 15.1. Remove fastening screws securing front-axle carrier to the longitudinal member.
16. Remove fastening screws for rear front-axle support -arrows-  .
    Fig 18: Locating Rear Front-Axle Support

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
17. Carefully guide out the elevating platform under the vehicle with the axle without hitting against adjacent components.
    1. 17.1. Remove the front bracket fort he power steering pressure line.

       Information 

       If you are replacing the supporting frame  , the accessories must also be converted as required following a visual inspection.