REMOVAL & INSTALLATION
Spring removal is not advises unless the proper tools and equipment are available. Compressed springs are extremely dangerous. Improper removal or the use of non-suitable tools or equipment could cause severe bodily injury. Do NOT proceed if safety is compromised.
Note the radio security code and disconnect the negative battery cable.
Remove the strut from the vehicle.
Clamp the Spring Compressor VAG 1752/2, or equivalent, in a vise.
Install the strut into a suitable spring compressor.
If installed, pry off the mounting bolt cap.
Compress the coil spring and remove the self-locking nut from the dampening rod. Hold the dampening rod with a hex tool and loosen the fastener with a suitably cut away tool. If the fastener is a flange nut, replace the nut during installation. On early Passat models, the retaining nut is a slotted, threaded sleeve.
Matchmark the position of the spring retainer plate and spring mount.
Remove the spring seat and related components noting the order of removal.
Remove the strut from the spring compressor.
Release the tension on the coil spring, and remove the spring out of the compressor.
Fig. Use a cut away socket to remove the spring retaining fastener while holding the dampening rod with a hex tool. Duplicate this tool by carefully grinding a portion of the side off a suitable deep well socket
Fig. The dampening rod of the shock is held with a hex tool while the spring retainer fastener is removed
Fig. An exploded view of the front strut assembly-1995 Passat GLS model illustrated
Fig. An exploded view of an early model Passat strut assembly-Passat GL model illustrated
Fig. A suitable strut type coil spring compressor must be used
Fig. Exploded view of a typical strut assembly
Fig. Install the strut rod boot or sleeve as shown
Fig. The base of the spring must be seated against the bottom of the strut assembly
Fig. Do NOT forget to install any removed components such as washers
Fig. Next put on the spring retainer
Fig. Turn the spring retainer to properly seat it on the spring
Fig. Mate the strut bearing with the spring retainer
Fig. Insert the spring plate fastener. Early model Passat slotted sleeve-retaining nut shown
Fig. Once the spring is securely fastened on the strut and the upper spring plate-retaining nut is tightened, slowly and carefully remove the spring compressor
Install the new spring into the compressor.
Compress the spring and insert the strut through the spring.
Install the spring seat and related components in the reverse order as they were removed and aligning the matchmarks.
Install and torque the spring retainer-to-dampening rod fastener as follows:
1990-93 Passat Models:
Slotted nut-to-dampener rod: 30 ft. lbs. (40 Nm)
1994-97 Passat Models:
Hex nut-to-dampener rod: 44 ft. lbs. (60 Nm)
A4, 1998-00 Passat Models:
Flanged nut-to-dampener rod (replace): 37 ft. lbs. (50 Nm)
The balance of installation is in reverse order of removal noting the following:
Carefully release the spring compressor and install the strut into the vehicle.