Volkswagen Cars 2000-05

Strut (MacPherson Strut) Assembly

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Overhaul (Coil Spring Removal & Installation)



Some special tools are required to disassemble the strut. First is a good quality spring compressor, usually available at larger parts stores. Also a special socket is needed to remove the upper strut nut. If necessary, it can be made by cutting away part of a 22mm socket. The same tool is required to remove the strut from the 1990-92 Golf and Jetta.


CAUTION
The coil spring is very strong and under considerable pressure. If the correct tools and techniques are not available, do not attempt this job. Improper handling of coil springs can cause serious or fatal injury.

  1. Remove the strut.
  2.  
  3. Anchor the strut in a vise so it cannot move and attach the spring compressor.
  4.  
  5. Compress the spring and remove the center nut at the top of the strut assembly. Remove the upper spring seat and spring. With the spring still in the compressor, place it where it will not be disturbed. The springs are color coded. When replacing, make sure both replacement springs have the same color code.
  6.  
  7. Use a pipe wrench to remove the threaded collar from the top of the strut. Remove the strut from the vice and pour the fluid into a drain pan.
  8.  
  9. Remove the strut rod and discard all the internal parts.
  10.  

To install:

  1. The new insert is probably a gas pressure shock absorber. Pour about 2 oz. of the old hydraulic oil into the strut and install the new insert. The fluid will help dissipate heat and extend the life of the insert.
  2.  
  3. Install the threaded collar and tighten it to 30 ft. lbs. (40 Nm).
  4.  
  5. Fit the spring into place, install the upper seat and start the nut onto the rod. It may be easier to tighten the nut before removing the spring compressor. Tighten the nut to 44 ft. lbs. (60 Nm) and carefully remove the spring compressor.
  6.  

Removal & Installation




WARNING
Do not remove both suspension struts at the same time or the axle beam will be hanging on the brake lines.

  1. On Cabrio, Golf, and Jetta, perform the following:
    1. Working inside the vehicle, remove the cap from the top shock mount and remove the top nut, washer and rubber bushings.
    2.  
    3. Remove the second nut.
    4.  
    5. Slowly lift the vehicle and safely support it. Do not place supports under the axle beam.
    6.  

  2.  
  3. Unbolt the strut from the axle and carefully remove the strut and spring from the vehicle. It may be necessary to press the axle down slightly.
  4.  

To install:

  1. Install the shock on the axle assembly. Do not tighten the nut until the vehicle is on the floor at normal riding height.
  2.  
  3. On the Cabrio, Golf, and Jetta, perform the following:
    1. Install the upper end of the strut to the body.
    2.  
    3. Tighten the lower nut to 11 ft. lbs. (15 Nm) and the upper nut to 18 ft. lbs. (25 Nm).
    4.  
    5. Install the wheel and lower the vehicle to the floor.
    6.  
    7. Tighten the lower strut mounting nut to 52 ft. lbs. (70 Nm).
    8.  

  4.  


WARNING
Do not remove both suspension struts at the same time or the axle beam will be hanging on the brake lines.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. On Cabrio, Golf, Jetta, perform the following:
    1. Working inside the vehicle, remove the cap from the top shock mount and remove the top nut, washer and rubber bushings.
    2.  
    3. Remove the second nut.
    4.  
    5. Slowly lift the vehicle and safely support it. Do not place supports under the axle beam.
    6.  

  4.  
  5. On the New Beetle and Passat, raise the vehicle and remove the upper mounting bolts through the wheel opening.
  6.  
  7. Unbolt the strut from the axle and carefully remove the strut and spring from the vehicle. It may be necessary to press the axle down slightly.
  8.  

To install:

  1. Install the shock on the axle assembly. Do not tighten the nut until the vehicle is on the floor at normal riding height.
  2.  
  3. On the Cabrio, Golf, Jetta, perform the following:
    1. Install the upper end of the strut to the body. Lower nut: 11 ft. lbs. (15 Nm) and Upper nut: 18 ft. lbs. (25 Nm).
    2.  
    3. Install the wheel and lower the vehicle to the floor.
    4.  
    5. Tighten the lower strut mounting nut to 52 ft. lbs. (70 Nm).
    6.  

  4.  
  5. On the New Beetle and Passat, perform the following:
    1. Install the upper end of the strut to the body and tighten the attaching bolt to 55 ft. lbs. (75 Nm).
    2.  
    3. Install the wheel.
    4.  
    5. Tighten the lower strut mounting nut to 44 ft. lbs. (60 Nm).
    6.  

  6.  


WARNING
Do not remove both suspension struts at the same time or the axle beam will be hanging on the brake lines.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. On Cabrio, Golf, Jetta, perform the following:
    1. Working inside the vehicle, remove the cap from the top shock mount and remove the top nut, washer and rubber bushings.
    2.  
    3. Remove the second nut.
    4.  
    5. Slowly lift the vehicle and safely support it. Do not place supports under the axle beam.
    6.  

  4.  
  5. On the New Beetle and Passat, raise the vehicle and remove the upper mounting bolts through the wheel opening.
  6.  
  7. Unbolt the strut from the axle and carefully remove the strut and spring from the vehicle. It may be necessary to press the axle down slightly.
  8.  

To install:

  1. Install the shock on the axle assembly. Do not tighten the nut until the vehicle is on the floor at normal riding height.
  2.  
  3. On the Cabrio, Golf, Jetta, perform the following:
    1. Install the upper end of the strut to the body. Lower nut: 11 ft. lbs. (15 Nm) and Upper nut: 18 ft. lbs. (25 Nm).
    2.  
    3. Install the wheel and lower the vehicle to the floor.
    4.  
    5. Tighten the lower strut mounting nut to 52 ft. lbs. (70 Nm).
    6.  

  4.  
  5. On the New Beetle and Passat, perform the following:
    1. Install the upper end of the strut to the body and tighten the attaching bolt to 55 ft. lbs. (75 Nm).
    2.  
    3. Install the wheel.
    4.  
    5. Tighten the lower strut mounting nut to 44 ft. lbs. (60 Nm).
    6.  

  6.  

 
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