REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Transporter, Caravelle (1990 release)

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Volkswagen
	Transporter / Caravelle
		Instructions
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			Front suspension
				Total information
				Backup upper knuckle
				Shock absorber
				Semiaxes
					Refitting
					Disassembly and assembly
			Rear suspension
		A steering
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		Electrical

printable version

Disassembly and assembly

Dismantling of the half-line

1. Safety washer
2. Laying
3. Inside hinge synchronizer
4. Clip
5. Protective hinge synchronizer
Check for abrasions and cuts!
6. Axle

7. Clip
8. Disc spring
9. The sliding ring
10. Safety washer
11. Protective outer hinge synchronizer
12. Bag Clip
13. The outer hinge synchronizer

Dismantling

PERFORMANCE ORDER

1. Remove the axle shaft.
2. Cut the clamp on both sides of the protective cover of the hinge, hose clamps and remove. Push the back cover.
	3. Squeeze the external hinge. To do this, install the axle shaft in a vice with protected jaws and tighten. Remove the cover in the opposite direction. Screw device KAG-3207 M16 threaded part until the hinge of the synchronizer are not squeezed out of the profile shaft.
4. The internal hinge: compress and remove the retaining ring with suitable pliers (1) - see. Fig. Dismantling the half-line.
5. Squeeze the inner hinge suitable pressure, having rested with the ball hub.
6. The internal hinge: Remove the gasket (2) - see. Fig. Dismantling the half-line.

Assembly

PERFORMANCE ORDER

1. Replace brittle or defective protective covers axis.
2. Wear protective covers on the shaft with sleeve clamps.
3. To put on a profile shaft disc spring (8) and sliding ring (9). Belleville springs are set correctly (see. Fig. Dismantling the semi-axis). The large diameter of the cup spring (concave side) rests against the sliding ring.
4. Set the groove of the shaft the new safety washer.
5. Grease the external hinge 120 g grease VWG-6.3. At the same time press in about 80 grams of lubricant through the internal splines of the hub to the outer ball joint. About 40 g of grease applied to the inner side of the hinge.
A warning If there is only replaced by a protective cover of the hinge, when necessary, to add a lubricant.
6. Press in a plastic hammer on the outer hinge shaft as long as it does not stall the safety washer.
	7. Put on protective cover of the hinge and install it on a larger diameter bag clamp suitable pliers.
A warning Often equipped with the protective cover on the hinge case, it is pressed. As a result of the cover forms a vacuum that draws in operation lubricant inside. Therefore, after installation with a screwdriver from a smaller diameter, it is necessary to lift the cover slightly and align the pressure.
8. Push the bag clip to a smaller diameter.
9. The internal hinge: Drive 120 g grease VWG-6.3 on each side of the hinge. If it is replaced only by a protective cover of the hinge, if necessary, add lubricant.
	10. Drive the internal hinge a suitable press until it stops.
11. Set the groove of the shaft a new safety washer using expander pliers.
12. The internal hinge: to fix a protective cover of a bag clip and attach a new seal on the hinge, after removing it from the protective chamfer.
13. Install the shaft.

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Rear suspension