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How to change front suspension strut on VW Passat Alltrack (365) – replacement guide

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Important!

This replacement procedure can be used for:
VW Passat Alltrack (365) 2.0 TSI 4motion, VW Passat Alltrack (365) 1.8 TSI, VW Passat Alltrack (365) 1.8 TSI, VW Passat Alltrack (365) 2.0 TDI 4motion, VW Passat Alltrack (365) 2.0 TDI, VW Passat Alltrack (365) 2.0 TDI 4motion, VW Passat Alltrack (365) 2.0 TDI 4motion … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Shock Absorber for Passat Alltrack (365) and other VW models

Alternative products

Shock absorber

Replacement: suspension strut – VW PASSAT ALLTRACK (365). List of the tools you'll need:

                      Wire brush
                    
                      WD-40 spray
                    
                      Copper grease 
                    
                      Brake cleaner 
                    
                      Combination spanner #17
                    
                      Drive socket # 13 
                    
                      Drive socket # 16 
                    
                      Drive socket # 18 
                    
                      Drive socket # 21 
                    
                      Drive socket # 27 
                    
                      HEX bit No.H6.
                    
                      XZN socket bit # 12 
                    
                      Wheel impact socket #17
                    
                      Shock absorber socket
                    
                      Ratchet wrench
                    
                      Torque wrench
                    
                      Tap wrench
                    
                      Crow bar
                    
                      Hydraulic strut spring compressor
                    
                      Hydraulic transmission jack
                    
                      Fender cover
                    
                      Wheel chock

Buy tools

Replacement: suspension strut – VW PASSAT ALLTRACK (365). AUTODOC recommends:

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 – VW PASSAT ALLTRACK (365). 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

Remove the cowl grille seal.
Step 4

Raise up and remove the cowl grille.
Step 5

Clean the fasteners of the shock strut upper mount. Use WD-40 spray.
Step 6

Loosen the upper fastener of the shock strut mount. Use a drive socket #13. Use a ratchet wrench.
Step 7

Secure the wheels with chocks.
Step 8

Loosen the wheel hub fastener. Use a drive socket #27. Use a tap wrench.
Step 9

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 10

Raise the front of the car and secure on supports.

Step 11

Unscrew the wheel bolts.

Replacement: suspension strut – VW PASSAT ALLTRACK (365). Tip:
To avoid injury, hold up the wheel when unscrewing the bolts.
Step 12

Remove the wheel.
Step 13

Disconnect the wiring and the brake hose from the bracket on the shock strut. Use a crowbar.
Step 14

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

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

Step 16

Unscrew the nut and remove the stabilizer rod from the shock strut. Use a drive socket #18. Use a ratchet wrench.
Step 17

Remove the stabilizer rod.
Step 18

Unscrew the lower fastener connecting the shock strut to the steering knuckle. Use a drive socket #18. Use XZN #12. Use a ratchet wrench. Use a tap wrench.
Step 19

Remove the fastening bolt.
Step 20

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

AUTODOC recommends:
Replacement: suspension strut – VW PASSAT ALLTRACK (365). After applying the spray, wait a few minutes.Wear protective goggles.
Step 21

Unscrew the fastener connecting the ball joint to the suspension control arm. Use a drive socket #16. Use a tap wrench.
Step 22

Disconnect the spherical joint from the arm.
Step 23

Unscrew the fastener connecting the drive shaft to the wheel hub. Use a drive socket #27.
Step 24

Remove the fastening bolt.
Step 25

Remove the drive shaft.
Step 26

Prop up the steering knuckle. Use a hydraulic transmission jack.
Step 27

Clean the fasteners connecting the shock strut to the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 28

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 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 ALLTRACK (365)
Step 31

Remove the suspension strut.
Step 32

Set the shock absorber strut on the spring compressor tool.

Replacement: suspension strut – VW PASSAT ALLTRACK (365). 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 shock absorber dust cap and the bump stop.

AUTODOC recommends:
Replacement: suspension strut – VW PASSAT ALLTRACK (365). Carefully inspect the mount, the boot, and the bump stop of the shock absorber. Replace if necessary.
Step 39

Remove the spring.
Step 40

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

Replacement: suspension strut – VW PASSAT ALLTRACK (365). Tip from AUTODOC:
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 spring on the shock absorber.
Step 43

Install the dust sleeve and the bump stop on the new 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 HEX No.H6. Use a drive socket #21. Use a torque wrench. Tighten it to 60 Nm torque.

Replacement: suspension strut – VW PASSAT ALLTRACK (365). Professionals recommend:
Check to make sure the spring is positioned correctly. Avoid its misalignment.
Step 47

Decompress the spring.
Step 48

Remove the assembled shock strut.
Step 49

Install the shock strut into the wheel arch.
Step 50

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

AUTODOC recommends:
Important! Hold the suspension strut while screwing in the fastening bolts. VW PASSAT ALLTRACK (365)
Step 51

Treat the shock strut mounting seat on the steering knuckle. Use a wire brush. Use WD-40 spray.
Step 52

Fix the shock absorber strut on the steering knuckle.
Step 53

Install the fastening bolt.
Step 54

Tighten the lower fasteners connecting the shock strut to the steering knuckle. Use a drive socket #18. Use XZN #12. Use a ratchet wrench.

Step 55

Remove the support from under the steering knuckle.

AUTODOC recommends:
Replacement: suspension strut – VW PASSAT ALLTRACK (365). Lower the transmission jack smoothly, without jerks, to avoid damaging components and mechanisms.
Step 56

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

Mount the drive shaft into the wheel hub.
Step 58

Attach the ball joint to the control arm.
Step 59

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

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

AUTODOC recommends:
Important! Be sure to use new fasteners.
Step 61

Ιnstall the transverse stabilizer link.
Step 62

Tighten the fastener connecting the stabilizer link to the shock strut. Use a drive socket #18. Use a combination spanner #17. Use a torque wrench. Tighten it to 60 Nm torque.
Step 63

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

Install and tighten the drive shaft bolt. Use a drive socket #27.
Step 65

Treat the shock strut fasteners. Treat all joints of the arm. Use copper grease.
Step 66

Clean the brake disk surface. Use a wire brush.
Step 67

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

Step 68

Clean the brake disk surface. Use a brake cleaner.

Replacement: suspension strut – VW PASSAT ALLTRACK (365). Tip from AUTODOC experts:
After applying the spray, wait a few minutes.
Step 69

Install the wheel.

Replacement: suspension strut – VW PASSAT ALLTRACK (365). Professionals recommend:
To avoid injury, hold up the wheel when screwing in the fastening bolts.
Step 70

Screw in the wheel bolts. Use wheel impact socket #17.
Step 71

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 72

Treat the shock strut fasteners. Use copper grease.
Step 73

Install and secure the cowl grille.
Step 74

Install the cowl grille seal.
Step 75

Lower the car.

Step 76

Tighten the bolt connecting the drive shaft to the wheel hub. Use a drive socket #27. Use a torque wrench. Tighten it to 200 Nm torque.+180°

AUTODOC recommends:
Important! Be sure to use new fasteners.
Step 77

Tighten the wheel bolts using a criss-cross pattern. Use a torque wrench. Tighten it to 120 Nm torque.
Step 78

Remove the jacks and chocks.

Step 79

Remove the fender protection cover.

Step 80

Close the hood.

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