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Service
Workshop Manual
Passat 2006 ➤
Running gear, axles, steering
Edition 04.2011
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Service Department. Technical Information
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
40 - Front suspension
42 - Rear suspension
43 - Self-levelling suspension
44 - Wheels, tyres, vehicle geometry
48 - Steering
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2011 Volkswagen AG, Wolfsburg
K0059021520
Passat 2006 ➤
Running gear, axles, steering - Edition 04.2011
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1
Checklist for evaluating running gear of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Repairing front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Raising wheel suspension to unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Subframe, anti-roll bar, suspension links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Assembly overview: subframe, anti-roll bar, suspension links . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Assembly overview: front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Removing and installing front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Repairing thread in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.6 Lowering subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7 Removing and installing subframe without steering box . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.8 Removing and installing subframe with steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.9 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.10 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.11 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.12 Removing and installing suspension link with mounting bracket . . . . . . . . . . . . . . . . . . . . 38
3.13 Removing and installing suspension link with mounting bracket (left side for vehicles with
DSG or automatic gearboxes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.14 Renewing bonded rubber bush for suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.15 Renewing mounting bracket with suspension link bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.16 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4 Assembly overview: wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.1 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5 Assembly overview: suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.2 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6 Removing and installing drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.1 Loosening and tightening drive shaft hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.2 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft . . . . . . 73
6.3 Loosening and tightening twelve-point head bolt, without ribbing, securing drive shaft . . . . 74
6.4 Removing and installing drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . . 76
6.5 Removing and installing drive shafts with triple roller joint AAR2600i and AAR3300i (pushed
on) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.6 Removing and installing drive shafts with triple roller joint AAR3300i (bolted on) . . . . . . . . 82
7 Repairing drive shaft - overview of drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.1 Heat shields for drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8 Assembly overview: drive shaft with VL100 constant velocity joint . . . . . . . . . . . . . . . . . . 88
8.1 Dismantling and assembling drive shaft with VL100 constant velocity joint . . . . . . . . . . . . 90
8.2 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
8.3 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9 Assembly overview: drive shaft with VL107 constant velocity joint . . . . . . . . . . . . . . . . . . 98
9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint . . . . . . . . . . . . 100
10 Assembly overview: drive shaft with triple roller joint AAR2600i . . . . . . . . . . . . . . . . . . . . 105
10.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i . . . . . . . . . . . . . . 107
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Contents
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Passat 2006 ➤
Running gear, axles, steering - Edition 04.2011
11 Assembly overview: drive shaft with triple roller joint AAR3300i . . . . . . . . . . . . . . . . . . . . 112
11.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i . . . . . . . . . . . . . . 114
12 Assembly overview: drive shaft with triple roller joint AAR3300i for 6-speed automatic
gearbox 09M, four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
12.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i for 6-speed automatic
gearbox 09M, four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1 Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2 Repairing rear suspension (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.1 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.2 Rear axle in unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3 Assembly overview: subframe (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.1 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.2 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4 Assembly overview: transverse link, track rod (front-wheel drive) . . . . . . . . . . . . . . . . . . . . 140
4.1 Assembly overview: rear left vehicle level sender G76 , front-wheel drive up to model year
2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.2 Assembly overview: rear left vehicle level sender G76 , front-wheel drive from model year
2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.3 Removing and installing rear left vehicle level sender G76 up to model year 2007 . . . . . . 144
4.4 Removing and installing rear left vehicle level sender G76 from model year 2008 . . . . . . 145
4.5 Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.6 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.7 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5 Allocation of track rods to trailing arms (front- and four-wheel drive) . . . . . . . . . . . . . . . . . . 153
6 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) . . . . . . . . . . . . 155
6.1 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
6.2 Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 160
6.3 Removing and installing wheel bearing/wheel hub unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
6.4 Removing and installing trailing arm with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . 165
6.5 Repairing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
7 Assembly overview: shock absorber, coil spring (front-wheel drive) . . . . . . . . . . . . . . . . . . 172
7.1 Converting to Nivomat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
7.2 Converting to heavy-duty running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
7.3 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
7.4 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.5 Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8 Assembly overview: anti-roll bar (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
8.1 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
9 Repairing rear suspension (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
9.1 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
9.2 Rear axle in unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
10 Assembly overview: subframe, final drive (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . 187
10.1 Preparatory work for when installing a steel subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
10.2 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
10.3 Repairing aluminium subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
10.4 Repairing steel subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
11 Assembly overview: transverse link, track rod (four-wheel drive) . . . . . . . . . . . . . . . . . . . . 206
11.1 Rear left vehicle level sender G76 , four-wheel drive up to model year 2007 . . . . . . . . . . 209
11.2 Rear left vehicle level sender G76 , four-wheel drive from model year 2008 . . . . . . . . . . . . 210
11.3 Removing and installing rear left vehicle level sender G76 , four-wheel drive up to model year
2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
11.4 Removing and installing rear left vehicle level sender G76 , four-wheel drive from model year
2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
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Contents
Passat 2006 ➤
Running gear, axles, steering - Edition 04.2011
11.5 Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
11.6 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
11.7 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
12 Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) . . . . . . . . . . . . 218
12.1 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
12.2 Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 224
12.3 Removing and installing wheel bearing/wheel hub unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
12.4 Removing and installing trailing arm with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . 227
12.5 Repairing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
13 Assembly overview: shock absorber, coil spring (four-wheel drive) . . . . . . . . . . . . . . . . . . 234
13.1 Converting to Nivomat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
13.2 Converting to heavy-duty running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
13.3 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
13.4 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
13.5 Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
14 Assembly overview: anti-roll bar (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
14.1 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
15 Assembly overview: drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
15.1 Loosening and tightening drive shaft hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
15.2 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft . . . . . . 248
15.3 Loosening and tightening twelve-point head bolt, without ribbing, securing drive shaft . . . . 249
15.4 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
15.5 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
15.6 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
15.7 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
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43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1 Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
2 Components of adaptive chassis control DCC and fitting locations . . . . . . . . . . . . . . . . . . 262
2.1 Shock absorber damping adjustment button E387 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
2.2 Removing and installing front left body acceleration sender G341 . . . . . . . . . . . . . . . . . . 263
2.3 Removing and installing front right body acceleration sender G342 . . . . . . . . . . . . . . . . . . 264
2.4 Renewing bracket for front left/right body acceleration sender G341/G342 . . . . . . . . . . . . 265
2.5 Assembly overview: front left/right vehicle level sender G78/G289 for adaptive chassis control
DCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
2.6 Removing and installing front left/right vehicle level sender G78/G289 . . . . . . . . . . . . . . 268
2.7 Assembly overview: rear left vehicle level sender G76 for adaptive chassis control DCC, front-
wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
2.8 Removing and installing rear left vehicle level sender G76 for adaptive chassis control DCC,
front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
2.9 Assembly overview: rear left vehicle level sender G76 for adaptive chassis control DCC, four-
wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
2.10 Removing and installing rear left vehicle level sender G76 for adaptive chassis control DCC,
four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
2.11 Removing and installing electronically controlled damping control unit J250 . . . . . . . . . . 273
2.12 Basic setting of adaptive chassis control DCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
2.13 Cable routing left front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
2.14 Cable routing right front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
2.15 Cable routing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
3
Assembly overview: suspension strut for adaptive chassis control DCC . . . . . . . . . . . . . . 277
3.1
Removing and installing suspension strut for adaptive chassis control DCC . . . . . . . . . . . . 279
4
Assembly overview: shock absorber for adaptive chassis control DCC (front-wheel drive)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
4.1
Removing and installing rear body acceleration sender G343 (front-wheel drive) . . . . . . . . 287
4.2
Removing and installing shock absorber for adaptive chassis control DCC (front-wheel
drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
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