Removing and Installing Front Suspension Struts

The struts can be easily removed for replacement or for access to other components. Special tools may be necessary to remove the top flange nut. See the procedure below for more information. Use a stiff wire, or equivalent, to support the free-hanging lower control arm and avoid damage to the flexible brake lines. Use new self-locking flange nuts. Also, the strut mountings affect wheel alignment. Any time the struts have been removed and reinstalled, a wheel alignment is highly recommended.

To remove front struts:

1.	Loosen the wheel lug bolts, then raise the car and support it with jack stands which are designed for the purpose. The front wheels should be off the ground so that the suspension is not bearing any weight.

2.	Remove the wheel.

3.	Remove the nuts from the two bolts that hold the bottom of the strut to the wheel bearing housing, leaving the bolts in place. Remove the brake line from its guide at the bottom of the strut and secure it out of the way.

4.	Support the suspension and brake assembly so that it will not fall when the strut is removed.

5.	Using a hex wrench to hold the shock absorber rod, remove the flange nut and flange, as shown in Fig. 5-2.

6.	Remove the bolts from the bottom of the strut, and remove the strut.

Installation is the reverse of removal. Use a new self-locking nut to secure the flange to the top of the shock absorber rod and torque it to 60 Nm (44 ft. lb.). The bolts and nuts that hold the strut to the wheel bearing housing are one of two sizes. Torque nuts with 19 mm hex head to 80 Nm (59 ft. lb.). Torque nuts with 18 mm hex head to 95 Nm (70 ft. lb.).

Fig. 5-2.

Flange nut being loosened with hex wrench holding shock absorber shaft. Cutaway 22 mm deep socket shown (see inset) is Volkswagen special tool no 3078 (order no. T03 078 000 40 ZEL).