DRIVE AXLE HEX BOLT CONNECTION, LOOSENING AND TIGHTENING
Special tools and workshop equipment required
- Angle wrench V.A.G 1756
| WARNING | When disassembling and performing repairs on vehicle, the drive axles must not be allowed to hang down and contact the stops in the joint by overflexing. |
Wheel bearing must not be burdened while drive axle threaded connection on the wheel side is loose.
If the bearings are loaded by the vehicle's own weight the wheel bearing will be damaged. The wheel bearings will be stressed and the life expectancy reduced. Therefore, observe the following
- Procedure for loosening hex bolt.
Vehicles without drive axle must not be moved, otherwise wheel bearing will be damaged. If vehicle must be moved, observe the following
Install an outer joint in place of the drive axle.
Tighten outer joint to 120 Nm.
Loosening
With vehicle still standing on its wheels, loosen hex bolt a maximum of 90°, otherwise wheel bearing will be damaged.
Raise vehicle enough that wheels hang freely.
Operate brake (second mechanic required).
Remove hex bolt -arrow-.
Scheme 1
Tightening
Replace hex bolt.
Note. Wheels must not yet touch the ground to tighten the drive axle, wheel bearing may otherwise be damaged.
Operate brake (second mechanic required).
Tighten hex bolt to 200 Nm.
Lower vehicle onto its wheels.
Turn bolt an additional 180°.
DRIVE AXLE TWELVE-POINT BOLT, LOOSENING AND TIGHTENING
Special tools and workshop equipment required
- Socket XZN 24 T10361
- Angle wrench V.A.G 1756
| WARNING | When disassembling and performing repairs on vehicle, the drive axles must not be allowed to hang down and contact the stops in the joint by overflexing. |
Wheel bearing must not be burdened while drive axle threaded connection on the wheel side is loose.
If the bearings are loaded by the vehicle's own weight the wheel bearing will be damaged. The wheel bearings will be stressed and the life expectancy reduced. Therefore, observe the following
- Procedure for loosening 12-point bolt.
Vehicles without drive axle must not be moved, otherwise wheel bearing will be damaged. If vehicle must be moved, observe the following
Install an outer joint in place of the drive axle.
Tighten outer joint to 120 Nm.
Loosening
With vehicle still resting on wheels, loosen 12-point bolt with T10361 maximum 90°, otherwise, wheel bearing will be damaged.
Raise vehicle enough that wheels hang freely.
Operate brake (second mechanic required).
Remove 12-point bolt -arrow-.
Tightening
Replace 12-point bolt.
Note. Wheels must not yet touch the ground to tighten the drive axle, wheel bearing may otherwise be damaged.
Operate brake (second mechanic required).
Tighten 12-point bolt to 70 Nm.
Lower vehicle onto its wheels.
Tighten 12-point bolt an additional 90°.
FASTENER TIGHTENING SPECIFICATIONS
| Component | Fastener Size | Nm |
|---|---|---|
| Ball Joint to Control Arm Nut (2) | ||
| Steel Control Arm | 60 | |
| Sheet Steel and Aluminum Control Arms | 100 | |
| Ball Joint to Wheel Bearing Housing Nut (2) | M12 x 1.5 | 60 |
| Bracket to Body Bolt (2) | M12 x 1.5 x 90 | 70 + 90° turn |
| Control Arm to Bracket Bolt 2, 3 | M12 x 1.5 x 110 | 70 + 180° turn |
| Coupling Rod to Stabilizer Bar Nut (2) | 65 | |
| Coupling Rod to Strut Nut (2) | 65 | |
| Cover Plate to Wheel Bearing Housing Bolt | 12 | |
| Drive Axle to Flange Shaft Bolt (4) | M8 | 40 |
| M10 | 70 | |
| Drive Axle Heat Shield Bolt | 25 | |
| Drive Axle to Wheel Hub Bolt 1, 2 | ||
| Hex Head | M16 x 1.5 x 80 | 200 + 180° turn |
| 12 Point | M16 x 1.5 x 80 | 70 + 90° turn |
| Front ABS Wheel Speed Sensor | M6 x 16 | 8 |
| Level Control System Sensor to Bracket Bolt | M6 x 16 | 9 |
| Level Control System Sensor to Control Arm Nut (2) | 9 | |
| Mounting Bracket to Body Bolt (2) | M12 x 1.5 x 90 | 70 + 90° turn |
| Mounting Bracket to Bracket Bolt (2) | 50 + 90° turn | |
| Pendulum Support Bracket to Pendulum Support/Transmission Bolt (2) | M10 x 75, strength class 8.8 | 40 + 90° turn |
| M10 x 75, strength class 10.9 | 50 + 90° turn | |
| Pendulum Support Bracket to Transmission Bolt (2) | M10 x 35, strength class 8.8 | 40 + 90° turn |
| M10 x 35, strength class 10.9 | 50 + 90° turn | |
| M10 x 75, strength class 8.8 | 40 + 90° turn | |
| M10 x 75, strength class 10.9 | 50 + 90° turn | |
| Pendulum Support Bonded Rubber Bushing Bolt 2, 5 | M14 x 1.5 x 70 | 100 + 90° turn |
| Steering Gear to Subframe Bolt (2) | 50 + 90° turn | |
| Strut to Strut Bearing Nut (2) | M14 x 1.5 | 60 |
| Strut to Strut Dome Bolt (2) | 15 + 90° turn | |
| Strut to Wheel Bearing Housing Pinch Bolt Nut (2) | M12 x 1.5 x 80 | 70 + 90° turn |
| Subframe to Body Bolt (2) | 70 + 90° turn | |
| Subframe Shield Bolt | 6 | |
| Subframe to Stabilizer Bar Clamp Bolt (2) | 20 + 90° turn | |
| Tie Rod End to Wheel Bearing Housing Nut (2) | M12 x 1.5 | 20 + 90° turn |
| Universal Joint to Steering Gear Bolt (2) | 30 | |
| Wheel Hub with Bearing to Wheel Bearing Housing Bolt (2) | M12 x 1.5 x 45 | 70 + 90° turn |
| Wheel Speed Sensor to Wheel Bearing Housing Bolt | 8 | |
| (1) Vehicle must not sit on the ground when tightening. (2) Always replace after removal. (3) Tighten in curb weight position. (4) Always replace bolts (and backing plates if equipped). (5) Only tighten if the pendulum support is bolted to the transmission. (6) Pre-tighten to 10 Nm in a diagonal sequence, then tighten in a diagonal sequence. | ||
| (1) | Vehicle must not sit on the ground when tightening. |
| (2) | Always replace after removal. |
| (3) | Tighten in curb weight position. |
| (4) | Always replace bolts (and backing plates if equipped). |
| (5) | Only tighten if the pendulum support is bolted to the transmission. |
| (6) | Pre-tighten to 10 Nm in a diagonal sequence, then tighten in a diagonal sequence. |
TIGHTENING SPECIFICATIONS
| Component | Tightening specification |
|---|---|
| Subframe to body Use new bolts | 70 Nm + 90° turn |
| Console to body Use new bolts | 70 Nm + 90° turn |
| Stabilizer bar to subframe Use new bolts | 20 Nm + 90° turn |
| Stabilizer bar to connecting link Use new nut Counterhold at joint pin inner multi-point fitting | 65 Nm |
| Shield to subframe M6 bolt is self-tapping | 6 Nm |
| Ball joint to steel control arm Use new nuts | 60 Nm |
| Ball joint to sheet steel or aluminum control arm Use new nuts | 100 Nm |
| Steering gear to subframe Use new bolts Always replace the clamp for steering gear generation 2. | 50 Nm + 90° turn |
| Exhaust system bracket to subframe, refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS . | |
TIGHTENING SPECIFICATION, PENDULUM SUPPORT TO THE TRANSMISSION
| CAUTION | From MY 2008, Heli-Coil inserts are installed in the threads for the pendulum support threaded connection in the 02Q manual transmissions. Difference, refer to FASTENER TIGHTENING SPECIFICATIONS . On these and all other transmissions, use strength class 10.9 bolts. If, in the 02Q manual transmissions, there is not Heli-Coil insert, then use 8.8 strength class bolts and the appropriate tightening specification. |
| Bolt | Tightening specification |
|---|---|
| M10 x 35 strength class 8.8: Use a new bolt | 40 Nm + 90° turn |
| M10 x 35 strength class 10.9: Use a new bolt | 50 Nm + 90° turn |
| M10 x 75 strength class 8.8: Use a new bolt | 40 Nm + 90° turn |
| M10 x 75 strength class 10.9: Use a new bolt | 50 Nm + 90° turn |
| Component | Tightening specification |
|---|---|
| Subframe to body Use new bolts | 70 Nm + 90° turn |
| Console to body Use new bolts | 70 Nm + 90° turn |
| Mounting bracket to body Use new bolts | 70 Nm + 90° turn |
| Subframe to console Use new bolts | 70 Nm + 90° turn |
| Control arm to steel control arm Use new nuts | 60 Nm |
| Control arm to sheet steel or aluminum control arm Use new nuts | 100 Nm |
| Stabilizer bar to connecting link Use new nut Counterhold at joint pin inner multi-point fitting | 65 Nm |
| Stabilizer bar to subframe Use new bolts | 20 Nm + 90° turn |
| Control arm to console Use a new bolt Tighten bolts in curb weight position | 70 Nm + 180° turn |
| Steering gear to subframe Use new bolts Always replace the clamp for steering gear generation 2. | 50 Nm + 90° turn |
| Universal joint to steering gear Use a new bolt | 30 Nm |
| CAUTION | From MY 2008, Heli-Coil inserts are installed in the threads for the pendulum support threaded connection in the 02Q manual transmissions. Difference FASTENER TIGHTENING SPECIFICATIONS . On these and all other transmissions, use strength class 10.9 bolts. If, in the 02Q manual transmissions, there is not Heli-Coil insert, then use 8.8 strength class bolts and the appropriate tightening specification. |
| Bolt | Tightening specification |
|---|---|
| M10 x 35 strength class 8.8: Use a new bolt | 40 Nm + 90° turn |
| M10 x 35 strength class 10.9: Use a new bolt | 50 Nm + 90° turn |
| M10 x 75 strength class 8.8: Use a new bolt | 40 Nm + 90° turn |
| M10 x 75 strength class 10.9: Use a new bolt | 50 Nm + 90° turn |
After installing, perform the basic setting on the steering angle sensor -G85- using the Vehicle Diagnostic, Testing and Information System VAS 5051.
| Component | Tightening specification |
|---|---|
| Suspension strut to wheel bearing housing Use new nut | 70 Nm + 90° turn |
| Suspension strut to body (suspension strut tower) Use new bolts | 15 Nm + 90° turn |
| Control arm to steel control arm Use new nuts | 60 Nm |
| Control arm to sheet steel or aluminum control arm Use new nuts | 100 Nm |
| Connecting link to suspension strut Use new nut Counterhold at joint pin inner multi-point fitting | 65 Nm |
| Drive axle to wheel hub "hex head bolt" Use a new bolt | 200 Nm + 180° turn |
| Drive axle to wheel hub "12-point bolt" Use a new bolt | 70 Nm + 90° turn |
| Component | Tightening specification |
|---|---|
| Ball joint to steel control arm Use new nuts | 60 Nm |
| Ball joint to sheet steel or aluminum control arm Use new nuts | 100 Nm |
| Drive axle to wheel hub "hex head bolt" Use a new bolt | 200 Nm + 180° turn |
| Drive axle to wheel hub "12-point bolt" Use a new bolt | 70 Nm + 90° turn |
| Drive axle to flange shaft/transmission "Multi-point socket head bolt M8" Use new bolts Use new backing plates | 40 Nm Pre-tighten to 10 Nm in diagonal sequence |
| Drive axle to flange shaft/transmission "Multi-point socket head bolt M10" Use new bolts Use new backing plates | 70 Nm Pre-tighten to 10 Nm in diagonal sequence |
| Component | Tightening specification |
|---|---|
| Suspension strut mount to damper Use new nut | 60 Nm |
TIGHTENING HOSE CLAMP ON OUTER JOINT
Attach V.A.G 1682 as shown in illustration. Be sure that edges of clamping pliers are seated in corners -arrows B- of hose clamp.
Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).
Note. A stainless steel clamp must be used due to hardness of CV boot material (compared to rubber). This clamp can only be tensioned using V.A.G 1682. Tightening Specifications 25 Nm. Use torque wrench -C- with adjustment range 5 to 50 Nm (e.g. V.A.G 1331). Be sure thread of spindle -A- of clamp tool moves freely. Grease with MOS 2 grease if necessary. If it does not move freely, e.g. due to dirt in thread, the required clamp tension will not be achieved at the specified torque.
Attach V.A.G 1682 as shown in illustration. Be sure that edges of clamping pliers are seated in corners -arrows B- of hose clamp.
Tension clamp by turning spindle with a torque wrench (do not tilt clamp tool).
Note. A stainless steel clamp must be used due to hardness of CV boot material (compared to rubber). This clamp can only be tensioned using V.A.G 1682. Tightening specifications: 25 Nm. Use torque wrench -C- with adjustment range 5...50 Nm (e.g. V.A.G 1331). Be sure thread of spindle -A- of clamp tool moves freely. Grease with MOS 2 grease if necessary. If it does not move freely, e.g. due to dirt in thread, the required clamp tension will not be achieved at the specified torque.