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Replacement of REAR suspension on 4Motion Passats

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  Quote ___/ __/ _/ Quote  Post ReplyReply Direct Link To This Post Topic: Replacement of REAR suspension on 4Motion Passats
    Posted: 08-Oct-2008 at 03:11
Hey there.

I recently purchased a set of H&R Sport springs for my W8, and in the process of finding out how the heck to install them, it came to my attention that there was a need for a DIY write-up here on P'dubya. So, here it is! Hope this can help you guys!


Tools needed:

- 12-18mm wrenches
- 12-18mm sockets
- 1/2" wrench and socket
- 3/4" wrench and socket
- Crescent wrench
- spring compressor
- torque wrench
- vise
- Vise Grips
- needle nose pliers
- hammer
- floor jack
- jack stand


First, install a jack stand near the wheel you will working on. NEVER WORK UNDER YOUR CAR WITHOUT A JACK STAND!!!




Next, remove the two caliper bolts on the rear of the carrier. You do not need to remove the carrier. Use 1/2" and 15mm wrenches.



Once you have the caliper off the the rotor you will want to start removing the upper control arm rear bolts. These are a bit time consuming to remove due to their location and accessibility.    Use




Bentley manual tells you to remove the control arm completely, but I found this unnecessary to do so. Removing the rear two bolts will provide enough room to remove the strut and spring.



Once the two bolts are removed push the arm down. Next, remove the two sway-bar attachments located on the sub-frame and right below the third upper control arm bolt attachment. Use a 13mm wrench.



Now you will unbolt the strut from the lower control arm and the upper strut mount. Use a 18mm wrench and a 18mm socket.
The strut is attached to the body by two bolts, which can be undone using a 1/2' socket ad driver.


This helps to remove the lower bolt!



One the strut is unbolted you will need to use some brute force for this next step.

Place your foot on the outer part of the upper control arm area as seen below:


Grasp the strut with both hands and pull it toward you as you push the control arm down with your foot. This might take you several attempts. Eventually the top of the strut will clear the upper strut housing and you'll be able pull it free. Don't give up! It WILL come out!




Now you need to remove the spring from around the strut body. I like HermanH's use of the vise in steadying the strut.

At this time you will attach the spring compressors. Keep the two pieces at 180 degrees from each other and tighten the bolts evenly with a 3/4" socket and driver. ALWAYS show respect to the spring compressors!!!



Once compressed sufficiently the spring will begin to move free of the shock body. At this point you will need a Vise Grip, 16mm shallow socket, and a needle nose pliers. Grip the socket with the VG as high up as possible. Follow the progression of work demonstrated by the following pictures:




Use the pliers to grip the end of the strut rod while turning the socket with the VG.
Soon the bolt will spin free and the upper housing and spring will be removable.




At this time I am only replacing springs. I can't decide on coilovers or new shocks with these springs. Install the new spring accordingly. Be sure to line up the bolt holes in the same vertical plane as the lower strut attachment. Bentley says to torque the keeper bolt to the strut rod to 37 ft lbs....but this difficult to do, considering the toll arrangement. Get the bolt as tight as possible to avoid any rattling.




Now, reinstall the strut with the pointy guide pins on the outside of the top attachment plate.




Reattach everything in the reverse order they were unbolted.



DO NOT FORGET TO TORQUE YOUR LUG NUTS TO 89 ft lbs!!!! (cue ktyl2469)

(front wheel drop)



Enjoy!!!




Mike
"I agree that the W8 is a great car--when it works... "
-dstathos-

^Pure Genius! Why didn't I write that?!?

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  Quote fitzski Quote  Post ReplyReply Direct Link To This Post Posted: 08-Oct-2008 at 07:44
Mike... you da man.

Great job.
2003 Passat W8 Variant
(Pacific Blue, Tan, 6sp)
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  Quote ___/ __/ _/ Quote  Post ReplyReply Direct Link To This Post Posted: 08-Oct-2008 at 14:02
Originally posted by fitzski

Mike... you da man.

Great job.


Thanks! Hope this can help someone!


"I agree that the W8 is a great car--when it works... "
-dstathos-

^Pure Genius! Why didn't I write that?!?

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  Quote SirRangeALot Quote  Post ReplyReply Direct Link To This Post Posted: 08-Oct-2008 at 23:32
Originally posted by ___/ __/ _/

Enjoy!!!


I'll bet you do!

Nice job -- great write-up!
Get a wagon. Bitches love wagons.
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  Quote ___/ __/ _/ Quote  Post ReplyReply Direct Link To This Post Posted: 08-Oct-2008 at 23:57
thanks, Jeremy. I just ordered Bilstein Sport shocks today......:)


"I agree that the W8 is a great car--when it works... "
-dstathos-

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  Quote SirRangeALot Quote  Post ReplyReply Direct Link To This Post Posted: 09-Oct-2008 at 10:35
zomg...you installed the springs on stock shocks? BAD Michael...BAD!
Get a wagon. Bitches love wagons.
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  Quote ___/ __/ _/ Quote  Post ReplyReply Direct Link To This Post Posted: 10-Oct-2008 at 15:41
Originally posted by SirRangeALot

zomg...you installed the springs on stock shocks? BAD Michael...BAD!



Hey, what can I say? I couldn't wait!!!

Shocks will be in Tuesday'ish of next week.....


Mike

Edited by ___/ __/ _/ - 10-Oct-2008 at 21:42
"I agree that the W8 is a great car--when it works... "
-dstathos-

^Pure Genius! Why didn't I write that?!?

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  Quote t0kie Quote  Post ReplyReply Direct Link To This Post Posted: 10-Oct-2008 at 17:41
Mike, you did it . I wish you are local here so you can help me :). I was thinking to do it too, since Jeremy & you did it already & seems like nicer with the drop, but we'll see. So the front DIY is the same as the regular FWD Passat?

Edited by t0kie - 10-Oct-2008 at 23:41
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  Quote SirRangeALot Quote  Post ReplyReply Direct Link To This Post Posted: 10-Oct-2008 at 23:46
Originally posted by t0kie

seems like nicer with the drop


Oooooooooooooooooh yeeeeeeeeeeeeeeeeeah! Do it!
Get a wagon. Bitches love wagons.
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  Quote ___/ __/ _/ Quote  Post ReplyReply Direct Link To This Post Posted: 11-Oct-2008 at 14:05
Originally posted by t0kie

Mike, you did it . I wish you are local here so you can help me :). I was thinking to do it too, since Jeremy & you did it already & seems like nicer with the drop, but we'll see. So the front DIY is the same as the regular FWD Passat?



Yes, exactly the same. HermanH did the write-up on that a few years ago. The difference is (this may be the difference between B5 and B5.5) you don't have to remove the upper plate that attaches to the chassis.


Mike
"I agree that the W8 is a great car--when it works... "
-dstathos-

^Pure Genius! Why didn't I write that?!?

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