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How to change front suspension strut on VW Passat 3C B6 Variant – replacement guide

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Important!

This replacement procedure can be used for:
VW Passat Variant (3C5) 2.0 TDI, VW Passat Variant (3C5) 1.6 FSI, VW Passat Variant (3C5) 2.0 FSI, VW Passat Variant (3C5) 1.9 TDI, VW Passat Variant (3C5) 2.0 TDI 16V, VW Passat Variant (3C5) 1.6, VW Passat Variant (3C5) 2.0 TDI, VW Passat Variant (3C5) 2.0 TDI, VW Passat Variant (3C5) 2.0 TDI, VW Passat Variant (3C5) 2.0 TFSI, VW Passat Variant (3C5) 3.2 FSI 4motion, VW Passat Variant (3C5) 2.0 TDI 16V 4motion, VW Passat Variant (3C5) 2.0 FSI 4motion, VW Passat Variant (3C5) 2.0 TDI 4motion, VW Passat Variant (3C5) 1.4 TSI, VW Passat Variant (3C5) 1.8 TSI, VW Passat Variant (3C5) 2.0 TDI, VW Passat Variant (3C5) 1.4 TSI EcoFuel, VW Passat Variant (3C5) 2.0 TDI, VW Passat Variant (3C5) 2.0 BlueTDI, VW Passat Variant (3C5) 1.6 TDI, VW Passat Variant (3C5) 2.0 TDI 4motion, VW Passat Variant (3C5) 1.8 TSI … View more

The steps may slightly vary depending on the car design.

How to change a front shock strut on VW PASSAT B6 (3C5) [TUTORIAL AUTODOC]

Alternative products

Shock absorber

Replacement: suspension strut – Passat B6 3C Variant. Tools you'll need:

                      Wire brush
                    
                      WD-40 spray
                    
                      Brake cleaner 
                    
                      Copper grease 
                    
                      HEX bit no.H6.
                    
                      XZN socket bit # 14 
                    
                      12-point socket # 24
                    
                      Drive socket # 13 
                    
                      Drive socket # 16 
                    
                      Drive socket # 18 
                    
                      Drive socket # 19 
                    
                      Drive socket # 21 
                    
                      Wheel impact socket #17
                    
                      Ratchet wrench
                    
                      Torque wrench
                    
                      Shock absorber socket
                    
                      Pin punch
                    
                      Tap wrench
                    
                      Clip removal tool
                    
                      Crow bar
                    
                      Hydraulic strut spring compressor
                    
                      Hydraulic transmission jack
                    
                      Fender cover
                    
                      Wheel chock

Buy tools

Replacement: suspension strut – VW Passat 3C5. Tip from AUTODOC experts:

Both shock struts of the front suspension should be replaced simultaneously.
The replacement procedure is identical for the left and right shock struts of the front suspension.
All work should be done with the engine stopped.

Replacement: suspension strut – Passat Variant B6. Use the following procedure:

Step 1

Open the bonnet.
Step 2

Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
Step 3

Detach the windscreen washer nozzle hose. Use a clip removal tool.
Step 4

Remove the clips of the plastic cowl grille.
Step 5

Raise the wiper plastic cowl grille.
Step 6

Clean the fasteners of the shock strut upper mount. Use a wire brush. Use WD-40 spray.
Step 7

Loosen the upper fastener of the shock strut mount. Use a drive socket #13. Use a ratchet wrench.
Step 8

Secure the wheels with chocks.
Step 9

Loosen the wheel hub bolt. Use drive 12-point socket #24. Use a tap wrench.
Step 10

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 11

Raise the front of the car and secure on supports.
Step 12

Unscrew the wheel bolts.

AUTODOC recommends:
Important! Hold the wheel while unscrewing the fastening bolts. VW Passat B6 3C Variant
Step 13

Remove the wheel.
Step 14

Clean the stabiliser link fasteners. Use a wire brush. Use WD-40 spray.
Step 15

Unscrew the fastener connecting the stabilizer link to the shock strut. Use a drive socket #18. Use a ratchet wrench.
Step 16

Remove the stabilizer rod.
Step 17

Disconnect the wiring and the brake hose from the bracket on the shock strut. Use a crowbar.
Step 18

Clean the fasteners connecting the shock strut to the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 19

Unscrew the lower fastener connecting the shock strut to the steering knuckle. Use a drive socket #18. Use XZN #14. Use a tap wrench. Use a ratchet wrench.
Step 20

Remove the fastening bolt. Use drive 12-point socket #24.
Step 21

Clean all joints of the arm. Use a wire brush. Use WD-40 spray.
Step 22

Unscrew the fastener connecting the ball joint to the suspension control arm. Use a drive socket #16. Use a ratchet wrench.
Step 23

Disconnect the ball joint from the arm. Use a crowbar.
Step 24

Remove the drive shaft. Use a pin punch.

Replacement: suspension strut – Passat 3C5. Tip:
Make sure that the drive shaft is not unloaded (when the car is jacked).
Step 25

Prop up the steering knuckle. Use a hydraulic transmission jack.
Step 26

Remove the fastening bolt.
Step 27

Release the lower fastener connecting the shock strut to the steering knuckle. Use a special drive socket to remove the shock absorber. Use a ratchet wrench.
Step 28

Clean the fasteners connecting the shock strut to the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 29

Disconnect the steering knuckle from the shock absorber strut.
Step 30

Unscrew the top fastening of the shock strut mount.

AUTODOC recommends:
Important! Hold the suspension strut while unscrewing the fastening bolts. VW Passat Variant B6
Step 31

Remove the suspension strut.

Step 32

Set the shock absorber strut on the spring compressor tool.

Replacement: suspension strut – Passat B6 3C Variant. Tip from AUTODOC:
Note that when using a spring compressor, spring coils need to be securely gripped, compressing the spring on the opposite sides.Ensure the correct position of the spring in the retainer.Make sure that the spring coils tightly entered the lock handles.
Step 33

Compress the spring.
Step 34

Treat the shock strut rod. Use a wire brush. Use WD-40 spray.
Step 35

Remove the strut piston rod nut. Use HEX No.H6. Use a drive socket #21. Use a ratchet wrench.
Step 36

Remove the top strut mount.
Step 37

Release the coil spring.
Step 38

Remove the spring.
Step 39

Remove the shock absorber dust cap and the bump stop.

AUTODOC recommends:
Replacement: suspension strut – VW Passat 3C5. Carefully inspect the mount, the boot, and the bump stop of the shock absorber. Replace if necessary.
Step 40

Remove the old shock absorber from the hydraulic coil spring compressor.

Replacement: suspension strut – VW Passat 3C5. AUTODOC recommends:
Before installing a new shock absorber you should pump it manually 3-5 times.
Step 41

Install the new shock absorber on the hydraulic coil spring compressor.
Step 42

Install the dust sleeve and the bump stop on the new shock absorber.
Step 43

Install the spring on the shock absorber.
Step 44

Compress the spring.

Step 45

Install the upper strut mount and the strut mount bearing.
Step 46

Tighten the shock strut piston rod nut. Use a drive socket #19. Use HEX No.H6. Use a torque wrench. Tighten it to 60 Nm torque.

Replacement: suspension strut – VW Passat 3C B6 Variant. AUTODOC experts recommend:
Check to make sure the spring is positioned correctly. Avoid its misalignment.
Step 47

Treat the shock strut rod. Use copper grease.
Step 48

Decompress the spring.
Step 49

Remove the assembled shock strut.
Step 50

Install the shock strut into the wheel arch.
Step 51

Screw the top fastening of the shock strut mount. Do not tighten it.

Replacement: suspension strut – Passat B6 3C Variant. Tip from AUTODOC:
To avoid injuries, hold the shock strut when screwing the fastening bolts in.
Step 52

Clean the mounting seats of the shock strut. Use a wire brush. Use WD-40 spray.
Step 53

Fix the shock absorber strut on the steering knuckle.
Step 54

Install the fastening bolt.
Step 55

Screw in the fastener that connects the shock strut to the steering knuckle. Use a drive socket #18. Use XZN #14. Use a ratchet wrench.
Step 56

Clean the splines of the drive shaft CV joint. Use a wire brush. Use WD-40 spray.
Step 57

Remove the support from under the steering knuckle.

AUTODOC recommends:
Replacement: suspension strut – Passat Variant B6. Lower the transmission jack smoothly, without jerks, to avoid damaging components and mechanisms.
Step 58

Mount the drive shaft into the wheel hub.
Step 59

Clean the mounting seats and the thread of the suspension arm. Use a wire brush. Use WD-40 spray.
Step 60

Attach the ball joint to the control arm.
Step 61

Tighten the ball joint fastener. Use a drive socket #16. Use a torque wrench. Tighten it to 60 Nm torque.
Step 62

Tighten the lower fasteners connecting the shock strut to the steering knuckle. Use XZN #14. Use a drive socket #18. Use a ratchet wrench. Use a torque wrench. Tighten it to 70 Nm torque.+90°

AUTODOC recommends:
Important! Be sure to use new fasteners.
Step 63

Connect the fastener of the ABS sensor cable to the shock absorber strut. Fasten the brake hose on the strut. Use a crowbar.
Step 64

Ιnstall the transverse stabilizer link.
Step 65

Tighten the fastener connecting the stabilizer link to the shock strut. Use a drive socket #18. Use a torque wrench. Tighten it to 65 Nm torque.
Step 66

Install and tighten the drive shaft bolt. Use drive 12-point socket #24. Use a ratchet wrench.
Step 67

Treat all joints of the arm. Treat the shock strut fasteners. Use copper grease.
Step 68

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 69

Clean the brake disk surface. Use a brake cleaner.

Replacement: suspension strut – VW Passat 3C5. Tip from AUTODOC experts:
After applying the spray, wait a few minutes.
Step 70

Install the wheel.

Replacement: suspension strut – Passat Variant B6. Tip:
To avoid injury, hold up the wheel when screwing in the fastening bolts.
Step 71

Screw in the wheel bolts. Use wheel impact socket #17.
Step 72

Lower the car.
Step 73

Tighten the upper fastener of the shock absorber strut mount. Use a drive socket #13. Use a torque wrench. Tighten it to 15 Nm torque.+90°

AUTODOC recommends:
Important! Be sure to use new fasteners.
Step 74

Treat the fasteners of the shock strut mount. Use copper grease.

Step 75

Install and secure the cowl grille.
Step 76

Install the fasteners of the wiper plastic cowl grille.
Step 77

Attach the windscreen washer nozzle hose.
Step 78

Tighten the wheel bolts using a criss-cross pattern. Use wheel impact socket #17. Use a torque wrench. Tighten it to 120 Nm torque.
Step 79

Tighten the bolt connecting the drive shaft to the wheel hub. Use drive 12-point socket #24. Use a torque wrench. Tighten it to 200 Nm torque.+180°

AUTODOC recommends:
Important! Be sure to use new fasteners.
Step 80

Remove the fender protection cover.
Step 81

Close the hood.
Step 82

Remove the jacks and chocks.

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