Volkswagen Cars 2000-05

Steering Knuckle & Spindle

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Removal & Installation





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Fig. The halfshaft must be removed from the knuckle-spindle. If it is stuck, use a brass drift and lightly tap it through the knuckle-spindle



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Fig. View of axle shaft nut and washer



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Fig. Removal of the knuckle-spindle assembly

  1. Detach the negative battery cable.
  2.  
  3. Remove the wheel cover and or center cap.
  4.  
  5. While the vehicle is still on the ground, loosen the drive axle (halfshaft) retaining nut.
  6.  


CAUTION
Do not remove the drive axle retaining nut if the vehicle is up on jackstands. A significant amount of torque is needed to remove this nut and may cause the vehicle to fall off the stands.

  1. Crack the lug nuts loose at this time.
  2.  
  3. Lift and then support the vehicle with jackstands.
  4.  
  5. Remove the front wheel and tire assembly.
  6.  
  7. Remove the driveaxle (halfshaft) retaining nut and its washer.
  8.  
  9. Detach the Antilock Brake System (ABS) sensor.
  10.  
  11. Remove the brake disc from the hub.
  12.  
  13. Detach the caliper from the hub assembly.
  14.  
  15. Hang the caliper from a piece of mechanics wire.
  16.  


WARNING
Do not allow the caliper to hang from the brake hose. This will lead to premature hose failure.

  1. Remove the tie rod end nut.
  2.  
  3. Use a tie rod end separator to pull the tie rod end from the steering knuckle.
  4.  
  5. Matchmark the balljoint and then remove the retaining bolts.
  6.  
  7. Matchmark the position of the strut to steering knuckle bolt and then remove the necessary nuts and bolts.
  8.  
  9. Free the steering knuckle from the strut by pulling it out. This is a great time to remove the splined axle shaft from the spindle. If the axle halfshaft is lodged in the spindle use a brass drift and hammer to knock it through the spindle.
  10.  


WARNING
Use caution not to damage the threads on the halfshaft when knocking the it through the spindle.


NOTE
If tapping on the axle shaft ceases to loosen it, use a puller to press it out of the hub.

  1. Once the halfshaft is removed from the spindle, support it so that it does not pull the inner joint out of the socket.
  2.  

To install:


NOTE
Replace all self locking nuts that have been removed from the suspension. Nuts of this design were created with a one time use in mind. They will not stay tight if reused.

  1. Clean and then engage the drive axle (halfshaft) splines with the spindle. Install the nut and use it to pull the driveshaft back into the spindle.
  2.  
  3. Install the steering knuckle with the strut.
  4.  
  5. Align the balljoint with the control arm.
  6.  
  7. Install the control arm to balljoint fasteners.
  8.  
  9. Align the ball joint with the matchmarks that were made and then tighten the fasteners.
  10.  
  11. Install the tie-rod end into the steering knuckle and install the nut. Tighten the nut to 26 ft. lbs. (35Nm).
  12.  
  13. Install the brake discs and then the calipers. If applicable, install the ABS wheel sensor.
  14.  
  15. Tighten the drive axle retaining nut to 66 ft. lbs. (89 Nm).
  16.  
  17. Install the tire and tighten the lug nuts to 81 ft. lbs. (109 Nm).
  18.  

 
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