SM 22

Service AG.
Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Workshop Manual
Crafter 2006 ➤
rrectness of i
l purpos
Running gear, axles, steering
nf
ercia
Edition 12.2015
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
40 - Front suspension
42 - Rear suspension
44 - Wheels, tyres, vehicle geometry
48 - Steering
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
Technical information should always be available to the foremen and mechanics, because their
iv
o
pr
cum
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
r
fo
en
ng
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
t.
yi Co
op
matter of course, be observed.
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
All rights reserved.
AG.
No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg K0059031220

Crafter 2006 ➤
Running gear, axles, steering - Edition 12.2015
lksw
agen
AG. Volkswagen AG dContents
oes
not
Vo gu
d by ara
ise nte
r
00 - Technical dataaut . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e o.r a. .
ho
.................... 1
ss c
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ce
e
nl
pt
1.1 General notes on tyre pressure indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
du
an
itte
y li
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
erm
ab
ility
2.1 Raising wheel suspension to unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ot p
wit
, is n
3 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
h re
hole
3.1 Checklist for evaluating running gear on accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . 5
spec
es, in part or in w
t to the co
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
rrectness of i
1.1 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Overview - front axle, Crafter 4MOTION with Achleitner four-wheel drive . . . . . . . . . . . . . . 8
l purpos
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Assembly overview - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
nform
ercia
2.2 Removing and installing subframe with steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

m
at
2.3 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
om
ion
c
2.4 Removing and installing coupling rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
in t
or
his
e
2.5 Removing and installing saddle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

at
do
riv
2.6 Removing and installing leaf spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

p
cum
for
en
g
3 Suspension strut, upper suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

n
t.
yi Co
op
3.1 Assembly overview - suspension strut, upper suspension link . . . . . . . . . . . . . . . . . . . . . . 36
C py
t. rig
gh ht
3.2 Assembly overview - suspension strut, upper suspension link, Crafter 4MOTION with
pyri by
Vo
o
by c
Achleitner four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
lksw
cted agen
Prote AG.
3.3 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4 Removing and installing suspension strut, Crafter 4MOTION with Achleitner four-wheel
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.5 Removing and installing upper suspension link, Crafter 4MOTION with Achleitner four-wheel
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4 Lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1 Assembly overview - lower suspension link, swivel joint - Crafter . . . . . . . . . . . . . . . . . . . . 47
4.2 Assembly overview - lower suspension link, swivel joint, Crafter 4MOTION with Achleitner
four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.3 Removing and installing lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.4 Removing and installing lower suspension link, Crafter 4MOTION with Achleitner four-wheel
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.5 Removing and installing bonded rubber bushes for lower suspension link . . . . . . . . . . . . 57
5 Wheel bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1 Assembly overview - wheel bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.2 Assembly overview - wheel bearing unit, Crafter 4MOTION with Achleitner four-wheel
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.3 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.4 Removing and installing wheel bearing housing, Crafter 4MOTION with Achleitner four-wheel
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.5 Removing and installing wheel hub, Crafter 4MOTION with Achleitner four-wheel drive . . 69
5.6 Checking wheel bearing play, Crafter 4MOTION with Achleitner four-wheel drive . . . . . . 72
5.7 Adjusting wheel bearing play, Crafter 4MOTION with Achleitner four-wheel drive . . . . . . 74
5.8 Removing and installing outer tapered roller bearing, Crafter 4MOTION with Achleitner four-
wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.9 Removing and installing inner tapered roller bearing, Crafter 4MOTION with Achleitner four-
wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.1 Assembly overview - drive shaft, Crafter 4MOTION with Achleitner four-wheel drive . . . . 81
6.2 Removing and installing drive shaft, Crafter 4MOTION with Achleitner four-wheel drive . . 82
Contents i
Crafter 2006 ➤
6.3 Dismantling and assembling drive shaft, Crafter 4MOTION with Achleitner four-wheel
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.4 Checking outer constant velocity joint, Crafter 4MOTION with Achleitner four-wheel drive
........................................................................ 90
42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.1 Assembly overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.2 Assembly overview - rear axle, vehicles with twin wheels . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.3 Measuring length on U-bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.4 Removing and installing leaf spring stop buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.5 Removing and installing leaf spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.6 Removing and installing leaf spring, vehicles with twin wheels . . . . . . . . . . . . . . . . . . . . . . 100
1.7 Renewing leaf spring rubber bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.8 Renewing leaf spring rubber bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.9 Removing and installing shackle, vehicles with twin wheels . . . . . . . . . . . . . . . . . . . . . . . . 106
1.10 Renewing shackle rubber bush, vehicles with twin wheels . . . . . . . . . . . . . . . . . . . . . . . . 107
1.11 Removing and installing spring bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.12 Removing and installing rear axle shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.13 Removing and installing rear axle shaft, vehicles with twin wheels . . . . . . . . . . . . . . . . . . 112
1.14 Renewing shrink ring, vehicles with twin wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2 Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.1 Assembly overview - anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.2 Assembly overview - anti-roll bar, vehicles with twin wheels . . . . . . . . . . . . . . . . . . . . . . . . 116
2.3 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.4 Removing and installing anti-roll bar, vehicles with twin wheels . . . . . . . . . . . . . . . . . . . . 117
2.5 Removing and installing coupling rods, Crafter 4MOTION with Achleitner four-wheel drive
........................................................................ 118
2.6 Renewing anti-roll bar bushes, vehicles with twin wheels . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.7 Renewing coupling nrod AG.bushes,
Volkswagevehicles
n AG d with twin wheels . . . . . . . . . . . . . . . . . . . . . . . . 122
wage oes
3 Suspension y Vstrut, shock absorber, spring t.gu. a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
olks no 124
db
3.1 Removing ir se and installing shock absorbers . . . a.nt.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
r 124
tho eo
4 Wheel
au bearing assembly, trailing arm . . . . . . . . . .r a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
ss
4.1 Assembly overview - wheel bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
ce
le
un
pt
4.2 Assembly overview - wheel bearing unit, vehicles with twin wheels . . . . . . . . . . . . . . . . . . 127
an
d
itte
y li
4.3 Removing and installing wheel bearing unit, vehicles with twin wheels . . . . . . . . . . . . . . . . 128
rm
ab
pe
ility
4.4 Removing and installing wheel hub, vehicles with twin wheels . . . . . . . . . . . . . . . . . . . . . . 131
ot
wit
, is n
4.5 Adjusting wheel bearing play, vehicles with twin wheels . . . . . . . . . . . . . . . . . . . . . . . . . . 132
h re
hole
spec
44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

es, in part or in w
t to the co
1 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1.1 Specified torque for wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.2 Renewing wheel bolts, vehicles with twin wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
rrectness of i
2 Tyre pressure monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

l purpos
2.1 Assembly overview - tyre pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

2.2 Removing and installing tyre pressure sensor G222 / G223 / G224 / G225 . . . . . . . . . . . . 141
nform
ercia
2.3 Changing wheels on vehicles with Tyre Pressure Monitoring System . . . . . . . . . . . . . . . . 144
m
2.4 Changing tyres on vehicles with tyre pressure monitoring system . . . . . . . . . . . . . . . . . . . . 145
a
com
tion in
3 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

r
te o
thi
3.1 Notes for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

s
iva
do
3.2 Necessity of wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

r
rp
cum
fo
3.3 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

en
ng
t.
yi Co
3.4 Test prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Cop py
t. rig
3.5 Determining ride height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
gh ht
pyri by
Vo
o
3.6 Specified values for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
c by lksw
cted agen
Prote
3.7 Specified values for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
AG.
ii Contents
Crafter 2006 ➤
3.8 Adjusting camber on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

3.9 Adjusting toe on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.10 Adjusting caster on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4 Front camera for driver assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.1 Calibrating front camera for driver assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.1 Removing and installing steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2.1 Assembly overview - steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2.2 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.3 Removing and installing control unit for electronic steering column lock J764 . . . . . . . . . . 168
3 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.1 Assembly overview - steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.2 Repairing steering rack . . . . . .ge. n. A. G. ..V.ol.ks. w. a.g.en. A. G
. .d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
wa oe
3.3 Adjusting steering rack y. V.o.lk.s . . . . . . . . . . . . . . . . . . .s.no. t.g.u . . . . . . . . . . . . . . . . . . . . . . . . . 173
b a
3.4 Removing and installing ris
ed steering rack . . . . . . . . . . . . . . . . r.an. . . . . . . . . . . . . . . . . . . . . . .
tee 178
o
3.5 Removing and installing
aut
h
steering stop limit, Crafter 4MOTION with or Achleitner four-wheel
a
drive . . . . . . .s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c. . . . . . . . . . . . . . . . . . . 181
ce
e
nl
3.6 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
pt
du
an
itte
3.7 Removing and installing track rod ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
y li
erm
ab
3.8 Removing and installing boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
ility
ot p
wit
4 Hydraulic power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
, is n
h re
4.1 Assembly overview - hydraulic lines, reservoir, 4-cylinder diesel engine . . . . . . . . . . . . . . 193
hole
spec
4.2 Assembly overview - vane pump, 4-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 195
es, in part or in w
t to the co
4.3 Assembly overview - vane pump, 5-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 196
4.4 Checking power steering fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.5 Bleeding steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
rrectness of i
4.6 Check steering for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
l purpos
4.7 Checking vane pump delivery pressure, 4-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . 199
4.8 Checking vane pump delivery pressure, 5-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . 201
nf
ercia
4.9 Removing and installing vane pump, 4-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . . . 204
orm
4.10 Removing and installing vane pump, 5-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . . . 206
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Contents iii
Crafter 2006 ➤
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
iv Contents
Crafter 2006 ➤
00 – Technical data
1 General information
(VRL008764; Edition 12.2015)
⇒ “1.1 General notes on tyre pressure indicator”, page 1
1.1 General notes on tyre pressure indicator

• It is extremely important to adhere to the instructions and
warnings in the following descriptions.
• Check whether the tyre pressure sensor should also be re‐
placed ⇒ Vehicle diagnostic tester.
Note
Volkswagen AG
♦ Ensure that the tyre does not contact the tyre pressure sensor
swa
gen AG
.
does
during removal or fitting. by
Vol
k not
gu
ara
ed
ris with wa‐ nte
♦ The tyre pressure sensor must not come into contact
tho eo
ter or be blown upon with compressed air when
ss
a the rim is
u ra
c
cleaned.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. General information 1
Crafter 2006 ➤
2 Repair instructions
⇒ “2.1 Raising wheel suspension to unladen position”,
page 2
2.1 Raising wheel suspension to unladen position

AG. Volkswagen AG d
Special tools and workshop agen oes
olksw not
equipment required d by
V gu
ara
ise nte
r
♦ Engine and gearbox jack - ut
ho eo
ra
V.A.G 1383 A- ss a c
ce
e
nl
♦ Tensioning strap - T10038-
pt
du
an
itte
y li
♦ Support - T10149-
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2 Rep. gr.00 - Technical data

Crafter 2006 ➤
– Before starting work, measure distance -a- from centre of

wheel to edge of wheel housing using, e.g., a measuring tape
.
The measurement must be performed in the unladen position
(normal position).
– Note measured value. This will be needed when the nuts and
bolts are tightened.
Raise wheel suspension:
Caution
All bolts on running gear components with bonded rubber

bushes may be tightened only when the component is in the
unladen position (normal position).
olkswagen AG
en AG. V
The bonded rubber bushes are otherwise constantly tensionedolks
wag does
not
and have a shorter service life. ed
byV gu
ara
ris nte
ho eo
aut ra
ss c
Axle components with bonded rubber bushes must therefore be
ce
e
nl
brought to a position equivalent to the operating (unladen) posi‐
pt
du
an
tion before tightening.
itte
y li
erm
ab
To simulate this position on the lifting platform, raise the respec‐
ility
ot p
tive wheel suspension with the engine and gearbox jack - V.A.G
wit
, is n
1383 A- and support - T10149- .
h re
hole
spec
es, in part or in w
Before the axle on one side is raised, both sides of the vehicle
t to the co
must be strapped to the lifting platform arms with tensioning
straps - T10038- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
WARNING
. C rig
ht ht
rig by
copy Vo
by lksw
If the vehicle is not strapped down, it may slip off the lifting Prote
cted AG.
agen
platform.
– Turn wheel hub until one of the wheel bolt holes is at the top.
2. Repair instructions 3
Crafter 2006 ➤
– Attach support - T10149- with a wheel bolt -A-.

Respective nuts and bolts may be tightened only when dimension
-a- between the centre of wheel hub and edge of wheel housing,
measured before starting work, has been attained ⇒ page 3 .
– Raise wheel bearing housing using engine and gearbox jack

until dimension -a- is attained.
WARNING
♦ Do not lift or lower vehicle while engine and gearbox jack

is under vehicle.
♦ Do not leave engine and gearbox jack under vehicle lon‐
ger than necessary.
– Tighten respective nuts and bolts.

– Lower wheel bearing housing.
– Pull engine and gearbox jack out from under vehicle.
– Remove support - T10149- . agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
3 Evaluating accident vehicles

⇒ “3.1 Checklist for evaluating running gear on accident vehicles”,
page 5
3.1 Checklist for evaluating running gear on

accident vehicles
Damage to running gear may go unnoticed during repairs to load-
bearing and suspension parts of accident vehicles. Under certain
circumstances, this undiscovered damage could lead to serious
consequential damage during later vehicle operation. Therefore,
the following parts of accident vehicles must be examined in the
manner and order described independent of wheel alignment
which may have to be performed. If no deviations from specifica‐
tions are measured during wheel alignment, there are no defor‐
mations of the running gear.
Visual inspection and functional check of steering system
♦ Visual examination for cracks and deformation.
♦ Examination for play in track rod joints and steering rack.
♦ Visual examination for defective boots and bellows.
AG. Volkswagen AG d
♦ Examination of electrical wiring and hydraulic lines and hoses wage
n oes
olks not
for chafing, cuts and kinks. db
y V gu
ara
e nte
ris
♦ Check of hydraulic lines, threaded connections and thosteering eo
rack for leaks. s au ra
c
s
ce
le
♦ Check of steering rack and lines for secure seating.

un
pt
an
d
itte
y li
♦ Check for perfect function over total steering lock. Operate
erm
ab
steering from lock to lock. In the process, the steering wheel
ility
ot p
must turn with a constant force without resistance.
wit
is n
h re
ole,
Visual and functional examination of running gear
spec
• Adhere to the sequence of the following inspection steps!
t to the co
♦ Check all components shown in the assembly overviews for
deformation, cracks and other damage.
rrectne
♦ Renew damaged parts.
s
♦ Align wheels on a Volkswagen AG-approved wheel alignment
s o
stand
cial p
f inform
Visual and functional check of wheels and tyres
mer
atio
m
♦ Check for true running and imbalance ⇒ VW ServiceNet;

o
n
c
Technical information; Reference guides; Wheel and Tyre

i
or
n thi
e
Guide; General; Imbalance due to wheels and tyres .

t
sd
iva
o
pr
♦ Check tread and sidewalls of tyres for cuts and damage from
um
r
fo
blows ⇒ VW ServiceNet; Technical information; Reference

en
ng
t.
yi Co
guides; Wheel and Tyre Guide; General; Tyre damage . . Cop py
rig
ht ht
rig
♦ Check tyre pressure; see tyre inflation pressure sticker in fuel py by
o Vo
tank flap or ⇒ Maintenance ; Booklet 10.2 .
by c lksw
cted agen
Prote AG.
If rim of wheel and/or tyre is damaged, renew tyre. This also ap‐
plies if the circumstances of the accident and the damage to the
vehicle indicate possible damage which is not visible.
A further factor in the decision is the age of the tyre. Tyres should
not be older than 6 years.
Generally, in case of doubt:
• Whenever a safety risk cannot be excluded, the tyre(s) must
be renewed.
3. Evaluating accident vehicles 5

Crafter 2006 ➤
Entire vehicle
Also check other vehicle systems such as:
♦ Brake system including ABS
♦ Visual and functional examination of exhaust system and pas‐
senger protection
Specifications and notes for testing and adjusting can be found in
the respective workshop manual in ELSA.
The examination for accident vehicles described here refers to
the running gear and does not purport AG. Vto
olkbe
swaa
gecomplete
n AG d exami‐
nation of the entire vehicle. agen oes
o lksw not
V y gu
db ara
Electronic vehicle systems
or
ise nte
h eo
ut r
Systems relevantss to safety including, for example,
a ABS/EDL, air‐ ac
bag systems, electronically regulated running gear systems and
ce
le
un
pt
driver assist systems must be checked for possible saved fault
an
d
itte
messages using the ⇒ Vehicle diagnostic tester. If faults are
y li
rm
ab
saved in the event memories of the systems mentioned above,
pe
ility
repair the faults according to the instructions in workshop man‐
ot
wit
, is n
uals in ELSA. Following repairs, read event memories of the
h re
affected systems again to ensure that complete function has been
hole
spec
restored.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
40 – Front suspension olksw

agen
AG. Volkswagen AG d
oes
not
y V gu
d b ara
ise nte
1 Front axle or eo
th
au ra
ss c
⇒ “1.1 Overview - front axle”, page 7
ce
e
nl
pt
du
an
⇒ “1.2 Overview - front axle, Crafter 4MOTION with Achleitner
itte
y li
four-wheel drive”, page 8
erm
ab
ility
ot p
1.1 Overview - front axle
wit
, is n
h re
hole
spec
es, in part or in w
I-
t to the co
⇒ “2.1 Assembly overview -
subframe”, page 9
rrectness of i
II -
l purpos
lower suspension link, swivel

joint - Crafter”, page 47
nf
ercia
III -
orm
m
atio
m
wheel bearing assembly”,

o
n in
c
page 61
or
thi
te
sd
a
IV -
iv
o
r
rp
cu
o
m
f
suspension strut, upper sus‐
en
ng
t.
yi
pension link”, page 36
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Front axle 7
Crafter 2006 ➤
1.2 Overview - front axle, Crafter 4MOTION with Achleitner four-wheel drive
I-
subframe”, page 9
II -
lower suspension link, swivel
joint, Crafter 4MOTION with
Achleitner four-wheel drive ”,
page 49
III -
wheel bearing unit, Crafter
4MOTION with Achleitner four-
wheel drive”, page 63
IV -
suspension strut, upper sus‐
pension link, Crafter 4MO‐
TION with Achleitner four-
wheel drive”, page 37
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
8 Rep. gr.40 - Front suspension

Crafter 2006 ➤
2 Subframe
⇒ “2.1 Assembly overview - subframe”, page 9
⇒ “2.2 Removing and installing subframe with steering rack”, page
12
⇒ “2.3 Removing and installing anti-roll bar”, page 26
⇒ “2.4 Removing and installing coupling rod”, page 28
⇒ “2.5 Removing and installing saddle plate”, page 30
⇒ “2.6 Removing and installing leaf spring”, page 31
2.1 Assembly overview - subframe

⇒ “2.1.1 Assembly overview - subframe, Crafter”, page 9
⇒ “2.1.2 Assembly overview - subframe, Crafter 4MOTION with
Achleitner four-wheel drive”, page 10
AG. Volkswagen AG d
agen
2.1.1 Assembly ksw overview - subframe,ot g Crafter
es n o
Vol
by ua
ed ran
oris tee
th or
1- Subframe au ac
ss
ce
le
❑ Removing and installing

un
pt
⇒ page 12 an
d
itte
y li
erm
ab
2 - Bolt ility
ot p
❑ Can only be renewed

wit
is n
with subframe removed.

h re
ole,
spec
3 - Nut
t to the co
❑ Always renew after re‐

moving
4 - Extension for subframe
rrectne
5 - Nut
ss

o
cial p
moving
inform
❑ Does not have to be re‐

mer
atio
leased to remove and

om
install subframe
n
c
i
or
n thi
❑ 170 Nm
te
sd
iva
o
pr
6 - Bolt
um
r
fo
en
ng

t.
yi Co
op
moving C py
t. rig
gh ht
❑ 170 Nm yri
p by
co Vo
by lksw
cted
7 - Washer
agen
Prote AG.
8 - Gearbox mounting
9 - Rear final drive carrier
❑ Bolted to subframe ex‐
tension
10 - Bolt
moving
❑ 60 Nm
11 - Bolt
❑ For gearbox mounting ⇒ Item 8 (page 9) ⇒ Rep. gr. 39
❑ Always renew after removing
2. Subframe 9
Crafter 2006 ➤
12 - Bolt
❑ 120 Nm +270°
13 - Bolt AG. Volkswagen AG d
agen oes
❑ Always renew after o lksw
removing not
y V gu
d b ara
❑ 170 Nm orise nte
th eo
s au ra
c
s
ce
e
nl
pt
2.1.2 Assembly overview - subframe, Crafter
du
an
itte
y li
4MOTION with Achleitner four-wheel
erm
ab
ility
ot p
drive
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
It is not permitted to carry out welding and straightening oper‐
ations on load-bearing or wheel-guiding suspension compo‐
nents.
rrectness of i
Always renew self-locking nuts.
l purpos
Always renew corroded nuts and bolts.
nf
ercia
orm
m
atio
om
n in
c
1 - Subframe
or
thi
e

t
sd
iva
⇒ page 16 .
r
rp
cu
o
m
f
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
The identification plate of the front
p by
co Vo
by lksw
final drive is located on the right side Prote
cted AG.
agen
of the subframe.
2 - Bolt
moving
❑ 120 Nm +270°
3 - Nut
moving
❑ Does not have to be re‐
leased to remove and
install subframe
❑ 170 Nm
4 - Bolt
moving
❑ 170 Nm
5 - Extension for subframe

Crafter 2006 ➤
6 - Washer
7 - Bolt
❑ Always renew after removing.
❑ 170 Nm
8 - Adapter
9 - Bolt
❑ 30 Nm
10 - Bolt
❑ When loosening and tightening, counterhold at nut ⇒ Item 11 (page 11)
11 - Nut
❑ 50 Nm
12 - Nut
13 - Bolt
❑ 60 Nm
14 - Rear final drive carrier
❑ Bolted to subframe extension
15 - Bolt
❑ 40 Nm
16 - Washer
17 - Bump stop AG. Volkswagen AG d
agen oes
lksw not
18 - Washer d by
Vo gu
ara
ise nte
r
19 - Bolt ut
ho eo
ra
a
❑ Always renew after removing ss c
ce
le
un
❑ 170 Nm
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
11
agen
Prote AG.
2. Subframe
AG. Volkswagen AG d
Crafter 2006 ➤ agen oes
olksw not
yV gu
Running gear, axles, steering - Edition 12.2015 ed b ara
nte
ris
ho eo
ut ra
2.2 Removing and installing subframe with s a c
s
ce
e
steering rack
nl
pt
du
an
itte
y li
⇒ “2.2.1 Removing and installing subframe, Crafter”, page 12
erm
ab
ility
ot p
⇒ “2.2.2 Removing and installing subframe, Crafter 4MOTION
wit
, is n
with Achleitner all-wheel drive”, page 16
h re
hole
spec
2.2.1 Removing and installing subframe, Crafter
es, in part or in w
t to the co
Special tools and workshop
rrectness of i
equipment required
l purpos
♦ Hose clamps, up to 25 mm
- 3094-
nf
ercia
♦ Engine and gearbox jack -
or
V.A.G 1383 A- with univer‐
m
m
atio
sal support - V.A.G
om
1359/2- .
n in
or c
thi
e
♦ Support bracket - 10 - 222

t
sd
iva
o
A-
r
rp
cu
o
m
f
en
ng
♦ Ball joint puller - 3287 A-

t.
yi Co
Cop py
♦ Tensioning strap - T10038- ht. rig
rig ht
py by
o Vo
♦ Adapter - 10 - 222 A 9/1-
by c lksw
cted agen
(2x)
Prote AG.
♦ Ball joint puller - T50002-

Crafter 2006 ➤
♦ Drip tray for workshop hoist - VAS 6208-
AG. Volkswagen AG d
agen oes
ksw
Removing byV
ol not
gu
d ara
ise nte
or eo
h
aut ra
Note ss c
ce
e
nl
pt
du
♦ Remove subframe together with steering rack.
an
itte
y li
erm
ab
♦ Remove steering rack from subframe.
ility
ot p
wit
, is n
h re
– Remove complete air filter housing ⇒ Rep. gr. 23 .
hole
spec
– Remove coolant pipe -1- from plenum chamber bulkhead
es, in part or in w
-arrow A-.
t to the co
– Then remove clamp -arrow B- for coolant pipes -1- from right
longitudinal member -2-.
rrectness of i
– Remove washer fluid reservoir from left longitudinal member
l purpos
⇒ Electrical system; Rep. gr. 92 ; Repairing windscreen

washer system .
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Insert support bracket - 10-222A- with adapters - 10-222A/

9/1- .
2. Subframe 13
Crafter 2006 ➤
Note
When inserting adapter - 10-222A/9/1- , do not damage coolant

pipes -1- on right longitudinal member -2-.
– Remove left and right saddle plates ⇒ page 30 .

– Turn wheels to straight-ahead position.
– Remove ignition key with steering wheel in centre position.
Volkswa
– Raise vehicle and strap
swa it down ⇒ Maintenance
gen AG
. gen AG
does ; Booklet 10.2 .
k not
y Vol gu
db ara
ise nte
WARNING
thor eo
au ra
c
ss
If the vehicle is not strapped down, it may slip off the lifting
ce
le
un
pt
platform.
an
d
itte
y li
erm
ab
ility
ot p
– Remove front wheels.
wit
is n
h re
– Remove noise insulation ⇒ General body repairs, exterior;
ole,
spec
Rep. gr. 50 ; Body - front; Noise insulation .
t to the co
– Unscrew bolt -arrow- for steering column universal joint.
– Then pull universal joint off steering rack.
rrectnes
Note
s o
cial p
f inform
The following work sequence is described for the left side of the
mer
vehicle. The procedure for the right side of the vehicle is identical.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
– Loosen nut -A- on track rod ball joint but do not remove com‐
C py
t. rig
gh
pletely.
ht
pyri by
Vo
co lksw
by
Leave nut screwed on a few turns to protect thread on pin.
cted agen
Prote AG.
– Press track rod ball joint off wheel bearing housing using ball
joint puller - 3287 A- . Now unscrew nut -4-.
Note
When pressing off, do not damage rubber grommet or heat shield

-B-.
– Then remove leaf spring ⇒ page 31 .

– Position engine and gearbox jack - V.A.G 1383 A- with uni‐
versal support - V.A.G 1359/2- under right suspension link.
– Remove right wheel bearing housing.
– Removing right suspension link.
– Clamp off pressure line for steering rack with hose clamps, up
to 25 mm - 3094- . Remove pressure line from steering rack.
– Position engine and gearbox jack - V.A.G 1383 A- under gear‐
box and apply slight pressure.

Crafter 2006 ➤
– Remove gearbox carrier from gearbox and subframe (exten‐

sion for subframe), unscrew bolts -1- and -2-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Secure engine/gearbox assembly to body with retaining tool -
ility
ot p
VW 785/1 B- .
wit
, is n
h re
– In doing so, position thrust pad - 3062- (smaller diameter of
hole
-3062- points to pressure plate) between pressure plate of re‐
spec
taining tool and gearbox.
es, in part or in w
t to the co
– Remove engine/gearbox jack - V.A.G 1383 A- from gearbox.
– Position engine and gearbox jack - V.A.G 1383 A- with uni‐
rrectness of i
versal support - V.A.G 1359/2- under subframe.
l purpos
– Remove wires, bracket for speed sensor cable and brake wear
indicator from subframe.
nform
mercia
at
– Remove power steering line -1- from subframe -arrow A-.
om
ion
c
in t
r
– Unscrew bolt -arrow B- from left and right engine mounting.

o
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Detach pressure line -1- from subframe -arrow-.
2. Subframe 15
Crafter 2006 ➤
– Unscrew securing bolts -1- to -3- for subframe Carefully

AG. Volklower
swagen AG
agen does
subframe. Volksw not
g y ua
db ran
Installing rise tee
tho or
au
Install in reverse order. Note the following
ss points: ac
ce
le
un
pt
an
d
itte
y li
Note rm
ab
pe
ility
ot
Bonded rubber bushes can be twisted only to a limited extent.
wit
, is n
Therefore, tighten the bolted connections of components with
h re
hole
bonded rubber bushes only when the wheel bearing housing has
spec
been raised (unladen state) ⇒ page 2 .
es, in part or in w
t to the co
– Install noise insulation beneath subframe ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Body - front; Noise insulation .
rrectness of i
– Install front wheels.
l purpos
Specified torques
nform
ercia
♦ ⇒ “2.1 Assembly overview - subframe”, page 9

m
♦ ⇒ “5.1 Assembly overview - wheel bearing assembly”,
a
com
tio
page 61
n in
r
te o
thi
♦ ⇒ “3.1 Assembly overview - steering rack”, page 169
s
iva
do
r
rp
c
♦ ⇒ “3.2 Repairing steering rack”, page 172
um
fo
en
ng
t.
yi
♦ ⇒ “1.1 Specified torque for wheel bolts”, page 135
Co
Cop py
t. rig
gh
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.
ht
pyri by
Vo
gr. 50 ; Assembly overview - noise insulation .
o
by c lksw
cted agen
Prote AG.
2.2.2 Removing and installing subframe, Crafter 4MOTION with Achleitner all-
wheel drive

Crafter 2006 ➤

equipment required
- 3094-
♦ Support bracket - 10 - 222
A-
♦ Adapter - 10 - 222 A /9-
♦ Drip tray for workshop hoist
- VAS 6208-
♦ Scissor-type assembly
platform - VAS 6131 A-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Engine and gearbox jack - V.A.G 1383 A- with universal sup‐

l purpos
port - V.A.G 1359/2- .

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Subframe 17
Crafter 2006 ➤
♦ Retaining tool - VW 785/1 B-
♦ Thrust washer - 3062-
AG. Volkswagen AG d
agen oes
lksw not
Removing d by Vo gu
ara
rise nte
tho eo
au ra
c
Note ss
ce
le
un
pt
an
d

itte
y li

erm
ab
ility
ot p
wit
been raised (unladen position) ⇒ page 2 .

is n
h re
ole,
spec
– Remove left and right floor covering ⇒ General body repairs,

interior; Rep. gr. 70 ; Cab floor covering .

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Unscrew securing bolts -arrows- for shock absorber -A-.

– Draw off brake fluid using brake filling and bleeding equipment
- VAS 5234- or extraction unit upgrade kit - V.A.G 1869/4-
⇒ Maintenance ; Booklet 10.2 .
WARNING
♦ Do not under any circumstances allow brake fluid to come

into contact with fluids that contain mineral oils (e.g. oil,
petrol, cleaning agents). Mineral oils damage the seals
and rubber grommets in the brake system.
♦ Brake fluid is poisonous. Also due to its corrosive effect
brake fluid must not come into contact with paintwork.
♦ Brake fluid is hygroscopic, which means it absorbs mois‐
ture from the ambient air and. Vshould therefore always be
AG olkswagen AG d
stored in air-tight containers.
swagen oes
k n ol ot g
yV
♦ Rinse off spilled
ise
d b brake fluid using plenty of water.uara
n r tee
ho
♦ Alwayss aobserve
ut the relevant environmental regulations for
or
ac
disposal
s
ce
e
nl
pt
du
an
itte
y li
erm
– Remove air filter housing ⇒ Rep. gr. 23 .
ab
ility
ot p
– Remove washer fluid reservoir from left longitudinal member

wit
, is n
⇒ Electrical system; Rep. gr. 92 ; Repairing windscreen

h re
hole
washer system . spec

es, in part or in w
t to the co
– Insert support bracket - 10 - 222 A- with adapters - 10 - 222 A
9/1- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
Note
ht
pyri by
Vo
o
by c lksw
cted agen
Prote
When inserting adapter - 10 - 222 A /9- , do not damage lines
AG.
-1- on right longitudinal member -2-.

– Remove ignition key with steering wheel in centre position.
– Raise vehicle and strap it down ⇒ Maintenance ; Booklet 10.2 .
WARNING
platform.
– Remove front wheel housing liner ⇒ General body repairs,

exterior; Rep. gr. 66 ; Wheel housing liners .
2. Subframe 19
Crafter 2006 ➤
– Disconnect left and right connectors -1- and unclip wiring har‐
ness.
Rep. gr. 50 ; Body - front; Noise insulation . Volkswa AG. gen AG
agen does
– Remove transfer box ⇒ Controls, housing;
Vol
ksw Rep. gr. 34 ; not
gu
Transfer box, Crafter 4MOTION with d byAchleitner four-wheel ara
e nte
drive . ris
tho eo
au ra
c
Is it necessary to renew the subframe?
ss
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
wit
If the subframe must be renewed, the front final drive must be
is n
h re
removed beforehand. Later the front final drive cannot be re‐
ole,
spec
moved anymore without additional efforts!
t to the co
• Yes: ⇒ page 20
• No: ⇒ page 20
rrectne
Subframe must be renewed
ss
– Remove front final drive ⇒ Final drive, front differential; Rep.
o
cial p
f
gr. 39 ; Front final drive .
inform
mer
Subframe is not to be renewed
atio
om
n
c
i
– Pull off bleeder hose -arrow- and attach it on side.
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Disconnect pneumatic lines -arrows- for front differential lock

solenoid valve - N571- -1- ⇒ Power transmission; Rep. gr.
39 ; Final drive, differential, differential lock .
– Disconnect connector -2- for front axle final drive differential
lock switch - F101- ⇒ Power transmission; Rep. gr. 39 ; Final
drive, differential, differential lock .
– Carefully cut through any cable ties. Lay cable for front axle
final drive differential lock switch - F101- to side.
Continuation for all vehicles

AG. Volkswagen AG d
agen oes
olksw not
d by
V gu
ara Crafter 2006 ➤
e nte
horis Running gear, e axles, steering - Edition 12.2015
aut or
ac
ss
– Unscrew nuts -1- and remove diesel particulate filter -2- from
ce
e
nl
subframe.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Unscrew bolt -arrow- for steering column universal joint.
nform
ercia
– Pull universal joint off steering rack.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Clamp off return line using hose clamp, up to 25 mm - 3094- .
– Clamp off pressure line using hose clamps, up to 25 mm -

3094- .
– Use drip tray for workshop hoist - VAS 6208- to catch hydraulic
oil that runs out.
– Seal or cover open lines/connections.
2. Subframe 21
Crafter 2006 ➤
– Open clamp -arrow- and pull hose -1- off reservoir for power-
assisted steering -1-.
– Unscrew bolts -2- and pull line -1- off power-assisted steering
vane pump.
– Unclip wiring harness -1- and lay it to side.
– Unscrew nut -2-, pull off wiring harness and lay it to side.
Note
On the right side of the vehicle the threaded coupling is located

behind the guard plate for the brake line.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
– Unbolt brake lines -1- from brake hose -arrow-. Seal brake
itte
y li
erm
hose and brake line using sealing plugs from repair kit - 1H0
ab
ility
698 311 A- .
ot p
wit
is n
– Unbolt guard plate for brake line on right side.

h re
ole,
spec
WARNING
t to the co
Danger of burns.
rrectne
Parts of the exhaust system may be hot.

Let exhaust system cool off prior to removal.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Disconnect brake line -2- from connecting piece -1-.

– Seal connecting piece -2- using sealing plugs from repair kit -
1H0 698 311 A- .
– Unclip brake line -1- from clips -3-.

– Position engine and gearbox jack - V.A.G 1383 A- under gear‐
box and apply slight pressure.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
– Remove gearbox carrier from gearbox and subframe (exten‐
ce
e
nl
pt
sion for subframe) -3-. Unscrew bolts -1- and -2-.

du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Secure engine/gearbox assembly to body with retaining tool -

nf
ercia
VW 785/1 B- .
orm
m
– In doing so, position thrust pad - 3062- (smaller diameter of

atio
m
-3062- points to pressure plate) between pressure plate of re‐

o
n in
or c
taining tool and gearbox.

thi
te
sd
iva
– Remove engine/gearbox jack - V.A.G 1383 A- from gearbox.

o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Subframe 23
Crafter 2006 ➤
– Unscrew bolt -arrow- from engine mounting on left and right

-1-.
– Place scissor-type assembly platform - VAS 6131 A- under‐
neath vehicle and align it.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or e
h
aut Crafter 2006or➤ ac
s
s Running gear, axles, steering - Edition 12.2015
ce
e
nl
pt
du
an
itte
– Unscrew bolts -1- to -3- for subframe Carefully lower subframe
y li
erm
ab
onto scissor-type assembly platform - VAS 6131 A- .
ility
ot p
Installing
wit
, is n
h re
hole
Install in reverse order. Note the following points:
spec
es, in part or in w
t to the co
WARNING
Pay attention to the following when doing any repair work:
rrectness of i
♦ To avoid damage to any lines/wires (e.g. line for power-
l purpos
assisted steering or wire for front right speed sensor -
G45- ), route all the various lines/wires so that they are in
nform
ercia
their original positions.
m
♦ To prevent damage to the lines/wires, make sure there is
at
om
io
an adequate clearance from all moving or hot compo‐
n
c
in t
r
nents.
o
his
ate
do
riv
♦ Cut through cable ties carefully and fit them at the same
p
cum
locations during installation.
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Note Prote
cted AG.
agen

– Install transfer box ⇒ Rep. gr. 39 ; Transfer box; Removing

and installing transfer box .
– Install air filter housing ⇒ Rep. gr. 23 .
– Install washer fluid reservoir from left longitudinal member ⇒
Electrical system; Rep. gr. 92 ; Repairing windscreen washer
system .
– Install front wheel housing liner ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Removing and installing noise insu‐
lation .
– Bleed brake system ⇒ Maintenance ; Booklet 10.2 .
– Bleed steering ⇒ Running gear, axles, steering; Rep. gr. 48 ;
Hydraulic power steering; Bleeding steering after conversion .
– Perform wheel alignment ⇒ page 149 .
Specified torques
♦ ⇒ “2.1.2 Assembly overview - subframe, Crafter 4MOTION
with Achleitner four-wheel drive”, page 10
♦ ⇒ “3.1.2 Assembly overview - steering rack, Crafter 4MOTION
Component Specified torque
Input shaft of front axle differ‐ 76 Nm
ential lock
2. Subframe 25
Crafter 2006 ➤
2.3 Removing and installing anti-roll bar

⇒ “2.3.1 Removing and installing anti-roll bar, Crafter”,
page 26
⇒ “2.3.2 Removing and installing anti-roll bar, Crafter 4MOTION
2.3.1 Removing and installing anti-roll bar,

Crafter
Note
Renew anti-roll bar if corrosion protective layer is damaged.
Removing
– Remove leaf spring ⇒ page 31 .
– Loosen coupling rod on anti-roll bar ⇒ page 47 .
– Unscrew bolts -arrows- and remove clamps -A-.
– Remove anti-roll bar -C- with anti-roll bar bush -B- to left out
of vehicle.
– Check anti-roll bar -B- and clamps -A- for wear and damage
and renew if necessary.
Installing
Note
Whilst installing the anti-roll bar ensure that the surface is not
damaged. Rectify paint work damage if necessary and protect
against corrosion with underseal.
AG. Volkswagen AG d
agen oes
lksw not
– Install bolts for anti-roll bar. d by Vo gu
ara
rise nte
tho eo
– Align anti-roll bar. s au ra
c
s
ce
le
Dimension -A- between anti-roll bar -1- and subframe -2- must be
un
pt
59.5 mm.
an
d
itte
y li
erm
ab
– Tighten anti-roll bar bolts.

ility
ot p
wit
– Install leaf spring ⇒ page 31 .

is n
h re
ole,
Specified torques
spec
♦ ⇒ “4.1 Assembly overview - lower suspension link, swivel joint

t to the co
- Crafter”, page 47
rrectne
2.3.2 Removing and installing anti-roll bar,

ss o
cial p
Crafter 4MOTION with Achleitner four-

inform
wheel drive
mer
atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo
Renew anti-roll bar if corrosion protective layer is damaged.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
26
cop Vo
by lksw
Rep. gr.40 - Front suspension Prote
cted AG.
agen
Crafter 2006 ➤
Special tools and workshop equipment required

♦ Torque wrench - V.A.G 1332-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
♦ Tensioning strap - T10038- aut
ho eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nf
ercia
o
Note
rm
m
atio
om
n in
or c
thi
te
sd
a
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
– Raise vehicle and strap it down ⇒ Maintenance ; Booklet 10.2 . C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
WARNING cted agen
Prote AG.
platform.
– If fitted, remove noise insulation ⇒ General body repairs, ex‐

terior; Rep. gr. 50 ; Body - front; Noise insulation .
– Loosen coupling rod nuts -2- on both sides. Counterhold on
thread -1- using a Torx socket.
2. Subframe 27
Crafter 2006 ➤
– Unscrew bolts -arrows- and remove clamps -A-.

– Remove anti-roll bar -C- with anti-roll bar bearing -B- and cou‐
pling rods.
– Check anti-roll bar -B- and clamps -A- for wear and damage
and renew if necessary.
Installing
Note
♦ Tighten bolted connections to coupling rods only if the vehicle

is standing on its wheels and is unladen or if the vehicle is
raised and is in the unladen position (normal position)
⇒ page 2 . AG. Volkswagen AG d
agen oes
ksw
♦ Whilst installing the anti-roll bar ensure that the surface is not by Vol not
gu
damaged. Rectify paint work damage if necessary and protectrise d ara
nte
against corrosion with underseal. utho eo
ra
s a c
♦ When installing, ensure that the outer edges of the rubber
s
ce
e
nl
bush ⇒ Item 22 (page 50) lie against stop of anti-roll bar.
pt
du
an
itte
y li
erm
ab
– Tighten anti-roll bar bolts hand-tight.
ility
ot p
wit
– Centre anti-roll bar.
, is n
h re
hole
– Fit coupling rods on coupling rod bracket.
spec
es, in part or in w
– Tighten anti-roll bar bolts.
t to the co
Specified torques
rrectness of i
♦ ⇒ “4.2 Assembly overview - lower suspension link, swivel joint,
Crafter 4MOTION with Achleitner four-wheel drive ”,
l purpos
page 49
nform
ercia
2.4 Removing and installing coupling rod

m
at
om
⇒ “2.4.1 Removing and installing coupling rod, Crafter”,
ion
c
page 28
in t
or
his
ate
⇒ “2.4.2 Removing and installing coupling rod, Crafter 4MOTION
do
priv
c
um
for
en
ng
t.
yi
2.4.1 Removing and installing coupling rod,
Co
Cop py
t. rig
Crafter
gh ht
pyri by
Vo
co lksw
by
cted
Removing
agen
Prote AG.
– Unbolt coupling rod -A- from saddle plate and anti-roll bar.
Installing
Note
♦ When installing coupling rod, note correct installation position:

♦ Bend is located in lower area -arrow- and points backwards
(towards rear axle).
Specified torques
♦ ⇒ “4 Lower suspension link, swivel joint”, page 47

Crafter 2006 ➤
2.4.2 Removing and installing coupling rod,

Crafter 4MOTION olksw with Achleitner all-
agen
AG. Volkswagen AG d
oes
not
wheel driveised byV gu
ara
n
r tee
ho
sa
ut equipment required or
ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
Note

WARNING
platform.
2. Subframe 29
Crafter 2006 ➤
– Loosen coupling rod nut -2-. Counterhold on thread -1- using

a Torx socket.
– Unscrew bolt -arrows- and remove coupling rod bracket -1-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
le
un
pt
an
d
itte
y li
erm
ab
– Press coupling rod -2- off anti-roll bar.

ility
ot p
wit
is n
– Rubber may remain on coupling rod. If so, lever off coupling

h re
rod rubber from anti-roll bar using a small screw driver.

ole,
spec
Installing
t to the co

rrectne
Note
ss

o
cial p
f i

nform
mer

atio
om
n
c
i
or
n thi
– Press coupling rod rubber into coupling rod.

te
sd
iva
o
r
– Press coupling rod with rubber installed onto anti-roll bar.

p
cum
r
fo
en
ng
t.
– Continue installation in reverse order.
yi Co
Cop py
t. rig
Specified torques gh ht
pyri by
Vo
co lksw
by
♦ ⇒ “4.2 Assembly overview - lower suspension link, swivel joint, Prote
cted AG.
agen
page 49
2.5 Removing and installing saddle plate

Removing
WARNING
Leaf spring is tensioned!

Crafter 2006 ➤
Note
The saddle plate can only be removed when the vehicle is stand‐
ing on its wheels.
– Remove bolts -1-.

– Then remove bolts -2-.
– Remove saddle plate -3- together with lower spring bearing.
Installing
Note
The saddle plate can only beageninstalled correctly

AG. Volkswagen AG d when the vehicle
oes
is standing on its wheels.
yV
olksw not
g b ua
ed ran
oris tee
th or
au ac
– Install saddle
ss plate -3- together with lower spring bearing.
ce
le
Tighten bolts -1- and -2-.

un
pt
an
d
itte
y li
Specified torques
erm
ab
ility
ot p
♦ ⇒ “4.1 Assembly overview - lower suspension link, swivel joint wit

is n
h re
ole,
spec
t to the co
rrectness
2.6 Removing and installing leaf spring

o
cial p
f inform
mer

atio
m

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Subframe 31
Crafter 2006 ➤
♦ Engine and gearbox jack - V.A.G 1383 A-
Removing
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
Note rised
nte
ho eo
aut ra
♦ Bonded rubber bushes can be twisted only to a limited extent. ss c
ce
e

nl
pt
du
bonded rubber bushes only when the wheel bearing housing
an
itte
y li
has been raised (unladen state) ⇒ page 2 .
erm
ab
ility
ot p
♦ Before inserting leaf spring, coat spring bearing with lubricant,
wit
, is n
e.g. soft soap.
h re
hole
spec
♦ Before installing leaf spring, check that upper spring bearings
es, in part or in w
are attached to subframe.
t to the co
– Remove left and right saddle plates ⇒ page 30 .
rrectness of i
l purpos
WARNING
nform
ercia
m
at
platform.
om
ion
c
in t
or
his
ate

do
priv
cum
for

en
ng
t.
yi
Co
Cop py
t. rig
gh
– Detach brake caliper and tie to body with wire ⇒ Brake sys‐
ht
pyri by
Vo
o
tems; Rep. gr. 46 . by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Then attach left saddle plate -A- (with lower spring bearing
installed) to subframe with 3 bolts M12 × 1.5, approx. 60 mm
long -arrows 1-.
Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
♦ Do not use original bolts again ed
ris nte
ho eo
ut ra
♦ Do not tighten bolts! ss a c
ce
e
nl
pt
du
– Tighten the 3 bolts until the saddle plate lies on the leaf spring.
an
itte
y li
erm
ab
ility
ot p
Caution
wit
, is n
h re
hole
♦ Always make sure that the bolts are screwed far enough
spec
into the thread to avoid damaging the thread.
es, in part or in w
t to the co
♦ If the thread is damaged (e.g. torn out), the subframe must
be renewed.
rrectness of i
l purpos
– Only loosen threaded connections -arrows 2- for suspension

link -B- to subframe to relieve pre-tension from rubber bushes
of suspension link.
nf
ercia
or
– Remove left wheel bearing housing ⇒ page 65 .
m
m
atio
om
n in
c
– Unscrew nut -arrow- from spring stop plate -3- for left and right
or
thi
e
coupling rod on anti-roll bar -1-.

t
sd
iva
o
r
rp
cu
– Unscrew left and right spring stop plate bolts -2- from suspen‐
o
m
f
en
sion link.
ng
t.
yi Co
op py
– Remove spring stop plates -3-. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Both spring stop plates must be removed because otherwise

damage may occur when the leaf spring is refitted.
– Remove left suspension link ⇒ page 51 .
2. Subframe 33
Crafter 2006 ➤
– Support leaf spring -1- with engine and gearbox jack - V.A.G
1383 A- .
– Remove left saddle plate again, by alternately unscrewing the
3 × M12 × 1.5 bolts of approx. 60 mm in length ⇒ page 33 .
– Lower engine and gearbox jack - V.A.G 1383 A- together with
leaf spring.
– Remove leaf spring to left from subframe.
Installing
Note
♦ Bonded rubber bushes can be twisted only to a limited extent.

bonded rubber bushes only when the wheel bearing housing
has been raised (unladen state) ⇒ page 2 .
♦ Before inserting leaf spring, coat spring bearing with lubricant,
e.g. soft soap.
♦ Before installing leaf spring, check that upper spring bearings
are attached to subframe.
– When installing, push leaf spring -1- onto right outerVspring

. olkswagen AG
bearing to stop. swa
gen AG does
olk not
yV gu
– Insert press tool - V.A.G 1383 A- into
ise
d engine
b and gearbox jack ara
nte
- VW 409- so that the spring is guided
thor on insertion. eo
au ra
c
– Position engine/gearbox jackss- V.A.G 1383 A- under left side
ce
le
of leaf spring. Tension leaf spring by carefully raising the en‐

un
pt
an
gine and gearbox jack - V.A.G 1383 A- .

d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Then attach left saddle plate -A- (with installed lower spring
bearing) to subframe with 3 × M12 × 1.5 bolts of approx. 60 mm
long -arrows 1-.
– Tighten the 3 bolts until the saddle plate lies on the leaf spring.
– Install left suspension link -B- ⇒ page 51 .
– Then install spring stop plates.
– Install left wheel bearing housing ⇒ page 65 .
– Then remove left saddle plate again, by alternately unscrew‐
ing the 3 × M12 × 1.5 bolts of approx. 60 mm long
⇒ page 33 .
– Fit left and right brake caliper with brake carrier ⇒ Brake sys‐
tems; Rep. gr. 46 .
gr. 50 ; Body - front; Noise insulation .
– Install left and right saddle plates ⇒ page 30 .
Specified torques agen
AG. Volkswagen AG d
oes
olksw not
V
♦ ⇒ “4.1 Assembly overview ed b-ylower suspension link, swivel jointguar
an
- Crafter”, page 47 horis tee
ut or
a ac
♦ ⇒ “5.1 Assembly overview
ss - wheel bearing assembly”,
page 61
ce
le
un
pt
an
d
itte

y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Subframe 35
Crafter 2006 ➤
3 Suspension strut, upper suspension

link
⇒ “3.1 Assembly overview - suspension strut, upper suspension
link”, page 36
⇒ “3.2 Assembly overview - suspension strut, upper suspension
link, Crafter 4MOTION with Achleitner four-wheel drive”,
page 37
⇒ “3.3 Removing and installing suspension strut”, page 39
⇒ “3.4 Removing and installing suspension strut, Crafter 4MO‐
TION with Achleitner four-wheel drive”, page 40
⇒ “3.5 Removing and installing upper suspension link, Crafter
4MOTION with Achleitner four-wheel drive”, page 44
3.1 Assembly overview - suspension strut, upper suspension link
1 - Nut
moving
⇒ page 37 .
❑ 110 Nm
2 - Upper spring plate
3 - Bonded rubber bush
4 - Lower spring plate
5 - Protective sleeve
6 - Shock absorber
❑ Can be renewed sepa‐ n AG. Volkswagen AG do
rately lkswage es n
o ot g
yV ua
❑ Removing and installing ir se
d b ran
⇒ page 39 utho tee
or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
Unbolting and bolting nut for shock absorber piston rod.

1- Torque wrench
2- Tool insert - T10001/8-
3- Ratchet handle - T10001/11-
4- Tool insert - T50013-
3.2 Assembly overview - suspension strut,

upper suspension link, Crafter 4MO‐
TION with Achleitner four-wheel drive
WARNING

nents.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Suspension strut, upper suspension link 37

Crafter 2006 ➤
1 - Nut
moving
❑ Projection 18 mm
2 - Washer
3 - Bump stop
4 - Bolt
moving
❑ 28 Nm +60°
5 - Washer
6 - Spring plate
7 - Sleeve
8 - Suspension strut mounting
9 - Shock absorber mounting
10 - Nut
moving
❑ 30 Nm
11 - Bump stop
❑ Allocation ⇒ Electronic
Parts Catalogue “ET‐
KA” .
12 - Nut
moving
13 - Bolt
❑ Always renew after re‐ AG. Volkswagen AG d
moving agen oes
olksw not
y V gu
❑ 85 Nm rise
d b ara
nte
tho eo
14 - Washer s au ra
c
s
ce
le
15 - Spring seat
un
pt
an
d
itte
16 - Coil spring
y li
erm
ab
❑ Surface of spring coil must not be damaged.

ility
ot p
wit
❑ Allocation ⇒ Electronic Parts Catalogue “ETKA”

is n
h re
ole,
❑ Removing and installing ⇒ page 40

spec
17 - Spring plate
t to the co
18 - Gas-filled shock absorber

rrectne
19 - Bolt
s

s o
cial p

inform
mer
❑ 116 Nm
atio
m
20 - Shim
o
n
c
i
or
n thi
e
21 - Washer
t
sd
iva
o
pr
22 - Nut
um
r
fo
en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
38
c by lksw
cted agen
Rep. gr.40 - Front suspension Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise Crafter 2006
nte ➤
h eo
aut Running gear, axles, steering - Edition 12.2015 ra
ss c
ce
e
nl
3.3 Removing and installing suspension
pt
du
an
itte
y li
strut
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
WARNING
platform.
– Remove front wheel.

– Remove front wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liners .
– Release electrical wiring from retainer on shock absorber -4-
for brake wear indicator -2- and speed sensor -3-.
– Remove brake caliper -1- and secure it to body ⇒ Repairing
front brake; Rep. gr. 46 ; Removing and installing brake cali‐
per, Brembo .
– Position engine and gearbox jack - V.A.G 1383 A- beneath
suspension link on wheel bearing housing and exert slight
counter-pressure.
– Mark installation position of wheel bearing housing on shock
absorber, e.g. with a felt-tip pen.
– If fitted, remove shock absorber upper cover in cab.

Crafter 2006 ➤
– Remove securing bolts -arrows- for shock absorber -A-.

– Lower engine and gearbox jack - V.A.G 1383 A- slightly and
remove shock absorber from front wheel housing.
Installing
Note

. Volkswagen AG
gen AG does
swa
– Install front wheel housing liner by ⇒
VolkGeneral body repairs, ex‐ not gu
terior; Rep. gr. 66 ; Wheelrishousing
ed liners . ara
nte
ho eo
– Install front wheel. aut ra
ss c
ce
e
Specified torques
nl
pt
du
an
itte
♦ ⇒ “3.1 Assembly overview - suspension strut, upper suspen‐
y li
erm
ab
sion link”, page 36
ility
ot p
wit
, is n
h re
page 61
hole
spec
es, in part or in w
t to the co
3.4 Removing and installing suspension
rrectness of i
strut, Crafter 4MOTION with Achleitner
four-wheel drive
l purpos

nf
ercia

rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Strut holder - V.A.G 1752/1- with spring retainer - V.A.G

1752/7-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara Crafter 2006 ➤
ise nte
r
ut
ho Running gear, axles, steering - Editioneo
ra 12.2015
s a c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Removing
Note

– Remove left and right floor covering ⇒ General body repairs,


Crafter 2006 ➤
– Unscrew nut -A- and remove washer -B-.

WARNING
platform.

– Remove rear stop buffer ⇒ Item 11 (page 38) .
– Install support - T10149- on brake disc or on wheel flange.
– Raise support - T10149- by approx. 10 mm using engine and
gearbox jack - V.A.G 1383 A- .
Note
Raising the support releases the tensile force from the suspen‐
sion strut and damage to the thread is avoided. G. Volkswage
A n AG d
agen oes
olksw not
V
– Compress coil spring using strut holder d b - V.A.G 1752/1- .
y gu
ara
rise nte
tho eo
u ra
– Loosen 2 inner bolts -arrows-ssfor
a wiring harness retainer from c
upper suspension link -1- and lay brackets aside.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Loosen bolt -1-.

– Loosen engine and gearbox jack - V.A.G 1383 A- and lower
nf
ercia
it.
rm
m
atio
m
– Pull gas-filled shock absorber -2- downwards.

o
n in
or c
thi
– Remove coil spring -3- upwards.

te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Remove gas-filled shock absorber -2- upwards.
WARNING
AG. Volkswagen AG d
Always observe the relevant environmental regulations for dis‐ksw
agen oes
not
posal of gas-filled shock absorber! y Vol gu
db e
ara
ris nte
utho eo
ra
a c
Installing ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
– Insert gas-filled shock absorber -2-.
h re
hole
spec
– Fit coil spring, washer and stop buffer onto gas-filled shock
es, in part or in w
absorber.
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
– Fit washer -B- and tighten nut -2- only hand-tight.
s
iva
do
r
rp
c
– Raise support - T10149- using engine and gearbox jack -
um
fo
en
V.A.G 1383 A- .
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Start bolt -1- and tighten by hand.

Crafter 2006 ➤
– Tighten the two inner bolts -arrows- of upper swivel joint -1-
first hand-tight and then to specified torque.
– Release tension from coil spring using strut holder - V.A.G
1752/1- .
Note
♦ Ensure coil spring is seated correctly.

♦ Always renew self-locking nuts and bolts.
– Install front wheel.

– Lower vehicle »onto its wheels«.
– Tighten upper shock absorber nut ⇒ Item 1 (page 38) .
– Install left and right floor covering ⇒ General body repairs,
Specified torques
sion link, Crafter 4MOTION with Achleitner four-wheel drive”,
page 37
3.5 Removing and installing upper suspen‐

sion link, Crafter 4MOTION withoAchleit‐
lksw
agen
AG. Volkswagen AG d
oes
not
ner four-wheel drive ised byV gu
ara
n r tee
tho
sa
u or
ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Removing
es, in part or in w
t to the co
Note
rrectness of i

l purpos

nform
mercia
at
om

ion
c
in t
or
his
te
WARNING
a
do
priv
cum
for
en
ng
t.
yi Co
platform. ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
– If fitted, remove noise insulation ⇒ General body repairs, ex‐

terior; Rep. gr. 50 ; Body - front; Noise insulation .
– Remove gas-filled shock absorber with coil spring
⇒ page 40 .

Crafter 2006 ➤
– Loosen the two front bolts -arrows- of upper swivel joint -1-.
– Unscrew both nuts -2- from bolts -1- (front and rear), pull out
both bolts -1- and remove upper suspension link -3-.
G. Volkswagen
– Leave support - T10149- and engine l
agen
A
kswand gearbox jack - V.A.G
AG do
es n
1383 A- installed on vehicle dtobysupport
Vo
the weight. ot g
ua
e ran
ris tee
Suspension link must be renewed:
ut
ho or
sa ac
– Loosen nut ⇒ Item 12s (page 49) .
ce
e
nl
pt
du
– Remove swivel joint from adapter plate using ball joint puller -
an
itte
y li
T50002- .
erm
ab
ility
ot p
Installing
wit
, is n
h re
hole
spec
– Coat suspension link rubber bushes with assembly oil.
es, in part or in w
t to the co
– Press upper suspension link -3- into its mountings and insert
bolt -1-. Tighten nut -2- first hand-tight and then to specified rrectness of i
torque.
l purpos
Note
nform
ercia

m
at
om

ion
c
in t
or

his
ate
do
priv
cum
or
– Install gas-filled shock absorber with coil spring ⇒ page 40 .

f
en
ng
t.
yi Co
op
– Install front wheel. C py
t. rig
gh ht
yri by
Specified torques cop Vo
by lksw
cted agen
Prote
AG.

page 49
sion link, Crafter 4MOTION with Achleitner four-wheel drive”,
page 37

Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
ksw
4 Lower suspension link, swivel joint d by Vol not
gu
ara
rise nte
⇒ “4.1 Assembly overview - lower suspension
aut link, swivel joint -
ho eo
ra
Crafter”, page 47 ss c
ce
e
nl
⇒ “4.2 Assembly overview - lower suspension link, swivel joint,
pt
du
an
itte
Crafter 4MOTION with Achleitner four-wheel drive ”, page 49
y li
erm
ab
⇒ “4.3 Removing and installing lower suspension link”,
ility
ot p
page 51
wit
, is n
h re
hole
⇒ “4.4 Removing and installing lower suspension link, Crafter
spec
4MOTION with Achleitner four-wheel drive”, page 53 es, in part or in w
t to the co
⇒ “4.5 Removing and installing bonded rubber bushes for lower
suspension link”, page 57
rrectness of i
4.1 Assembly overview - lower suspension link, swivel joint - Crafter
l purpos
1 - Subframe
nform
ercia

m
⇒ page 12 .
at
om
ion
c
2 - Nut
in t
or
his
e

at
do
riv
moving
p
cum
for
❑ 20 Nm for 8.8
en
ng
t.
yi Co
op
❑ 25 Nm for 10.9 C py
t. rig
gh ht
yri by
3 - Bolt cop Vo
by lksw
cted agen
❑ Always renew after re‐ Prote AG.
moving
❑ When loosening and
tightening, counterhold
at nut
⇒ Item 9 (page 48)
4 - Bolt
moving
❑ Longer bolt, points to
centre of vehicle
❑ Do not interchange with
bolt
❑ 105 Nm +90°
5 - Bolt
moving
❑ Shorter bolt, points out‐
wards
❑ Do not interchange with
bolt ⇒ Item 4 (page 47)
❑ 60 Nm
6 - Saddle plate
❑ Renewing ⇒ page 57 .
8 - Suspension link
❑ Removing and installing ⇒ page 51 .
4. Lower suspension link, swivel joint 47

Crafter 2006 ➤
9 - Nut
❑ 170 Nm +90°
10 - Bump stop
11 - Wheel bearing housing
12 - Nut
❑ M20 x 1.5 n AG. Volkswagen AG do
swage es n
❑ 170 Nm yV
olk ot g
u b ara
ed nte
13 - Upper spring
tho
ris bearing e or
u
❑ Insertss into subframe
a ac
ce
e
nl
14 - Leaf spring
pt
du
an
itte
y li
erm
ab
ility
ot p
15 - Outer spring bearing
wit
, is n
❑ To renew, remove saddle plate and spring stop plate and release securing bolts for suspension link.
h re
hole
spec
16 - Lower spring bearing
es, in part or in w
t to the co
❑ Insert into saddle plate
17 - Saddle plate rrectness of i
Note
l purpos
Can only be removed and installed

when vehicle is standing on its
nform
ercia
wheels.
m
at
om

on
c
in t
or
18 - Bolt, M12
his
ate
do
riv

p
cum
for
❑ Qty. 3
en
ng
t.
yi Co
op
❑ 105 Nm +90° C py
t. rig
gh ht
yri by
19 - Bolt, M8 cop Vo
by lksw
cted agen
❑ Qty. 7 Prote AG.
❑ 25 Nm
20 - Clamp
21 - Anti-roll bar bush
❑ Position on mark -arrow- on anti-roll bar ⇒ Item 26 (page 48)
22 - Bolt
❑ 58 Nm
23 - Nut
❑ 105 Nm
24 - Coupling rod
25 - Nut
❑ 105 Nm
26 - Anti-roll bar

Crafter 2006 ➤
AG. Volkswagen AG d
Running
kswagengear, axles, steering
oesn- Edition 12.2015
ol ot g
yV ua
db ran
4.2 Assembly overview - lower suspension
e
ris tee
tho or
au
link, swivel joint, Crafterss 4MOTION with ac
ce
e
Achleitner four-wheel drive
nl
pt
du
an
itte
y li
erm
ab
WARNING
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
nents.
t to the co
rrectness of i
l purpos
1 - Subframe
nf
ercia
or
m
m
atio
⇒ page 16 .
om
n in
or c
thi
e
Note
t
sd
iva
o
r
rp
cu
The identification plate of the front
o
m
f
en
ng
final drive is located on the right side

t.
yi Co
op
of the subframe.
C py
ht. rig
rig ht
py by
co Vo
2 - Upper suspension link
by lksw
cted agen
Prote AG.
⇒ page 44
3 - Nut
moving
❑ 125 Nm
4 - Bolt
moving
❑ When loosening and
tightening, counterhold
at nut
5 - Nut
moving
❑ 140 Nm
6 - Swivel joint
7 - Clip
8 - Retainer
❑ For ABS line.
9 - Bracket
10 - Bolt
❑ 182 Nm
11 - Adapter
12 - Nut

Crafter 2006 ➤
❑ 170 Nm
❑ Tapered hole must be free of oil and grease.
❑ If necessary, clean with a dry cloth but do not use cleaning solutions.
Note
♦ The wheel bearing housing pro‐

vides two holes for securing front
right speed sensor - G45- or
front left speed sensor - G47- .
Turning the front right speed
sensor - G45- or front left speed
sensor - G47- during installation
may result in malfunction. Mark
installation position prior to re‐
moval.
♦ Before inserting front right speed
sensor - G45- or front left speed
sensor - G47- , clean inner sur‐
faces of hole and coat them with
lubricating paste ⇒ Electronic
Parts Catalogue (ETKA) .
14 - Nut
❑ M20 x 1.5 lkswage es n
o ot g
❑ 170 Nm byV ua
d ran
ir se tee
o
15 - Bolt auth or
ac
ss
ce
e
nl
pt
du
❑ 60 Nm
an
itte
y li
erm
ab
16 - Nut
ility
ot p
wit
, is n
h re
❑ 105 Nm
hole
spec
17 - Bracket
es, in part or in w
t to the co
❑ For coupling rod
18 - Coupling rod
rrectness of i
l purpos
19 - Rubber mounting
20 - Bolt
nform
ercia
❑ Renew after removing

m
at
❑ 105 Nm +90°
om
ion
c
in t
or
21 - Anti-roll bar
his
ate
do

priv
cum
for
en
ng
t.
yi Co
op
23 - Clamp
C py
t. rig
gh ht
yri by
24 - Bolt cop Vo
by lksw
cted agen
Prote AG.
❑ 75 Nm
25 - Bolt

Crafter 2006 ➤
26 - Lower suspension link
28 - Nut
❑ 200 Nm
4.3 Removing and installing lower suspen‐

sion link
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Removing
m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum

fo
en
g

n
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.
WARNING
platform.

Crafter 2006 ➤
. Volkswagen AG
Running gear, axles, ksteering
swa
gen AG- Edition 12.2015does
n
ol ot g
yV ua
db ran
– Remove front wheel. ris
e
tee
ho
ut or
– Remove noisessinsulation ⇒
General body repairs, a
exterior; ac
ce
e
nl
pt
du
an
– Only loosen threaded connections -arrows 2- for suspension
itte
y li
erm
link -B- to subframe to relieve pre-tension from rubber bushes
ab
ility
of suspension link.
ot p
wit
, is n
– Remove wheel bearing housing ⇒ page 65 .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
– Unscrew nut -arrow- from spring stop plate -3- for coupling rod
m
m
atio
on anti-roll bar -1-.
om
n in
or c
– Unscrew spring stop plate bolts -2- from suspension link.
thi
te
sd
iva
– Remove spring stop plate -3-.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Pull out bolts -arrows 2- and remove suspension link -B- from
subframe.
Note
The saddle plate -A- remains installed during the removal and
installation of the suspension link.
Installing
en AG. V
olkswagen AG
wag does
olks not
byV gu
ara
ed
Note tho
ris nte
eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– Install wheel bearing housing ⇒ page 65 .
h re
ole,
spec
t to the co
Specified torques
rrectne
♦ ⇒ “4.1 Assembly overview - lower suspension link, swivel joint
s
s o
cial p
f in
form
page 61
mer
atio
m

o
n
c
i
or
n thi
te
sd
a
4.4 Removing and installing lower suspen‐

iv
o
pr
cum
r
sion link, Crafter 4MOTION with Achleit‐

fo
en
ng
t.
yi Co
ner four-wheel drive Cop py
ht. rig
rig ht
by
Special tools and workshop equipment required copy Vo
by lksw
cted agen
Prote
AG.

Crafter 2006 ➤
♦ Claw spanner - T50034-

AG. Volkswagen AG d
Removing agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
Note s aut ra
c
s
ce
le
un
Bonded rubber bushes can be twisted only to a limited extent. pt

an
d

itte
y li
rm
bonded rubber bushes only when the wheel bearing housing has ab
pe
ility
ot
wit
, is n
h re
hole

spec
es, in part or in w
t to the co
WARNING
rrectness of i
platform.
l purpos

nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
The wheel bearing housing provides two holes for securing front
iva
do
r
right speed sensor - G45- or front left speed sensor - G47- .

rp
cum
fo
Turning the front right speed sensor - G45- or front left speed
en
ng
t.
yi
sensor - G47- during installation may result in malfunction. Mark
Co
op py
installation position prior to removal.
. C rig
ht ht
rig by
copy Vo
by lksw
– Remove front right speed sensor - G45- or front left speed
cted agen
Prote AG.
sensor - G47- ⇒ Brake system; Rep. gr. 45 ; Electrical and
electronic components and their locations ABS/TCS/ESP .

Crafter 2006 ➤
– Unscrew bolt -arrows- and remove coupling rod bracket -1-.

– Loosen track rod ball joint ⇒ page 189 .
– Remove any dirt from hub cap.
– Lever off hub cap using a commercially available chisel.
Note
♦ The hub cap will be damaged during removal and must be

renewed.
♦ The hub cap is bonded in which makes removal difficult.
AG. Volkswagen AG d
– Release outer slotted nut -1- by bending locking plate lksw
agen oes
not
-arrow- back. d byV
o gu
ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Unscrew outer slotted nut -3-, remove locking plate -2- and
unscrew slotted nut -1-.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
– Unscrew both nuts -2- from bolts -1- (front and rear), pull out rig ht
py by
both bolts -1- and pull lower suspension link -3- out of sub‐ co Vo
by lksw
frame.
cted agen
Prote AG.
– Pull wheel bearing housing towards outside and pull outer

constant velocity joint out of wheel bearing.
– Tie up constant velocity joint on side.

Crafter 2006 ➤
– Slightly loosen nut -2- of swivel joint -1-.
– Fit ball joint puller - T50002- and press swivel joint out of wheel
bearing housing.
– Remove lower suspension link.
Installing
Note

– Coat suspension link rubber bushes

wage with assembly doil.
n AG. Volkswagen AG o
e ks s no
Vol t
– Fit lower suspension link,
d b press swivel joint into wheel bearing
y gu
ara
se nte
housing and screwthon
o nut by hand.
ri
eo
au ra
– Insert outer constant
ss velocity joint into wheel bearing. c
ce
le
un
pt
– Press lower suspension link -3- into its mountings and insert
an
d
itte
bolt -1-.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Tighten nut -2- first hand-tight and then to specified torque.

– Tighten swivel joint nut.
– Install coupling rod bracket to suspension link.
– Install track rod ball joint ⇒ page 189 .
– Install front right speed sensor - G45- or front left speed sensor
- G47- ⇒ Brake system; Rep. gr. 45 ; Electrical and electronic
components and their locations ABS/TCS/ESP .
– Install slotted nuts and locking plate.
– Setting wheel bearing play ⇒ page 74 .
– Install new hub cap.
Volkswagen AG
swa
gen AG
.
does
olk not
y V gu
Specified torquesedb ara
nte
ris
ho eo
♦ ⇒ “4.2 aut Assembly overview - lower suspension link, swivel r a joint,
c
Crafter
ss
4MOTION with Achleitner four-wheel drive ”, page 49
ce
le
un
pt
♦ ⇒ “5.2 Assembly overview - wheel bearing unit, Crafter 4MO‐
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,

spec
t to the co
4.5 Removing and installing bonded rubber

bushes for lower suspension link
rrectnes
Note
s o
cial p
f inform
The work procedure applies for Crafter and Crafter 4MOTION

mer
models with Achleitner all-wheel drive!

atio
om
n
c
i
or

thi
te
sd
va
♦ Press tool - VW 412-

i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
♦ Removing and installing tool - VW459/2- AG. Volkswagen AG d

agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Thrust piece - 3236-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
♦ Thrust plate - VW401- opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.
Removing
– Remove lower suspension link.
♦ Crafter ⇒ page 51
♦ Crafter 4MOTION with Achleitner all-wheel drive ⇒ page 53

Crafter 2006 ➤
Pressing out bonded rubber bush

– Press out bonded rubber bush as illustrated.
1- Press tool - VW412-
2- Thrust piece - 3236- n AG. Volkswagen AG do
lkswage es n
o ot g
3- Bonded rubber bushed by V ua
ran
ir s tee
4- Suspension linkautho
or
ac
ss
5- Removing and installing tool - VW459/2-
ce
le
un
pt
an
d
6- Thrust plate - VW401-

itte
y li
rm
ab
Pressing in bonded rubber bush
pe
ility
ot
wit
, is n
– Apply tyre assembly paste to bonded rubber bush.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Align bonded rubber bush centrally to suspension link and
l purpos
press in as shown in diagram.

1- Press tool - VW412-
nform
ercia
2- Bonded rubber bush

m
a
com
tio
3- Suspension link
n in
r
te o
thi
4- Removing and installing tool - VW459/2-
s
iva
do
r
rp
c
5- Thrust plate - VW401-
um
fo
en
ng
t.
– Carefully press in bonded rubber bush until press tool -
yi Co
op py
VW412- comes into contact with shoulder of bonded rubber t. C rig
gh ht
bush. yri
p by
co Vo
by lksw
cted agen
Prote AG.
– Push in bonded rubber bush further using thrust piece - 3236-

-2-, as shown in diagram, in order to force out shoulder on
rubber bush out of suspension link eye on thrust piece side.
Note
Bonded rubber bush is not yet in its installation position and must
be pressed back slightly.

Crafter 2006 ➤
AG. Volkswagen AG d
Running gear, axles, steering - Edition 12.2015 olkswagen oes
not
yV g b ua
ed ran
– Press bush back until it projects evenly on both rsides
is -a- and tee
tho
-b-. s au or
ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
5 Wheel bearing assembly

⇒ “5.1 Assembly overview - wheel bearing assembly”,
page 61
⇒ “5.2 Assembly overview - wheel bearing unit, Crafter 4MOTION
⇒ “5.3 Removing and installing wheel bearing housing”,
page 65
⇒ “5.4 Removing and installing wheel bearing housing, Crafter
4MOTION with Achleitner four-wheel drive”, page 67
⇒ “5.5 Removing and installing wheel hub, Crafter 4MOTION with
⇒ “5.6 Checking wheel bearing play, Crafter 4MOTION with
⇒ “5.7 Adjusting wheel bearing play, Crafter 4MOTION with
Achleitner four-wheel drive ”, page 74
⇒ “5.8 Removing and installing outer tapered roller bearing,
Crafter 4MOTION with Achleitner four-wheel drive”, page 75
n AG . Volkswage
⇒ “5.9 Removing and installing
wageinner tapered roller
n AG d
oebearing,
s no
Crafter 4MOTION with Volks
Achleitner four-wheel drive”, paget gu 78
by a
ed ran
ris te
5.1 Assembly
au
tho overview - wheel bearing assembly
eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
5. Wheel bearing assembly 61

Crafter 2006 ➤
1 - Shock absorber
❑ Can be renewed sepa‐
rately
❑ Dismantling and assem‐
bling ⇒ page 36 .
⇒ page 39 wage
es ks not
Vol gu
2 - Bolt ed
by ara
nte
ris
❑ ⇒ Brake usystem;
tho Rep. eo
ra
gr. 46 ss a c
ce
le
un
3 - Brake caliper
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
⇒ page 65 .
is n
h re
ole,
5 - Brake disc
spec
6 - Bolt
t to the co
❑ ⇒ Brake system; Rep.
gr. 46
rrectne
7 - Wheel bolt
❑ Only for vehicles with
ss o
twin wheels on rear
cial p
f i
axle.
nform
mer

atio
m
⇒ page 135
o
n
c
i
or
8 - Wheel flange
thi
te
sd
va
❑ Only for vehicles with

i
o
pr
cum
twin wheels on rear

r
fo
en
ng
axle.
t.
yi Co
op py
. C rig
ht ht
rig
⇒ page 135 py by
co Vo
by lksw
cted
9 - Bolt
agen
Prote AG.

❑ 170 Nm
10 - Bolt
❑ For securing heat shield to wheel bearing housing.
❑ 10 Nm
11 - Heat shield
❑ For track rod ball joint
12 - Track rod ball joint
13 - Nut
❑ M14 x 1.5
❑ 50 Nm +60°
14 - Bolt
15 - Nut
❑ M14 x 1.5
❑ 140 Nm +120°
16 - Bolt

Crafter 2006 ➤
❑ 28 Nm +60°
5.2 Assembly overview - wheel bearing unit,

wheel drive
WARNING

nents.
Always renew corroded nuts and bolts. n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
1 - Wheel bearing housing ss
au ac
ce
e
nl
pt
du
⇒ page 67
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
The wheel bearing housing provides
hole
two holes for securing front right
spec
speed sensor - G45- or front left
es, in part or in w
t to the co
speed sensor - G47- . Turning the
front right speed sensor - G45- or
front left speed sensor - G47- during
rrectness of i
installation may result in malfunc‐
tion. Mark installation position prior
l purpos
to removal.
nform
ercia
2 - Nut
m
at
om
i
moving
on
c
in t
r
❑ 50 Nm +60°
o
his
ate
do
riv

p
cum
for
❑ Check that dust caps

en
ng
t.
yi
are undamaged and
Co
op py
correctly seated.
t. C rig
gh ht
yri by
❑ Tapered pin must be cop Vo
by lksw
free of oil and grease.
cted agen
Prote AG.
❑ If necessary, clean with

a dry cloth but do not
use cleaning solutions.
⇒ page 189
4 - Radial shaft seal
Caution
Do not damage or soil ra‐
dial shaft seal during in‐
stallation.
5 - Inner tapered roller bearing

❑ Renew if damaged.

Crafter 2006 ➤
Note
Only reinstall clean bearings, do not

wash bearings.
6 - Outer tapered roller bearing

Note
Only reinstall clean bearings, do not

wash bearings.
7 - Radial shaft seal
Caution
Do not damage or soil ra‐
dial shaft seal during in‐
stallation.
8 - Wheel hub
AG. Volkswagen AG d
ksw
agen oes
n
Vol ot g
d by ua
ran
e
ris
Caution tho
tee
or
au ac
Wheel bearings must not
ss
ce
le
be subjected to load after

un
pt
bolt securing drive shaft

an
d
itte
y li
to wheel hub has been

rm
ab
loosened.
pe
ility
ot
wit
, is n
If wheel bearings are loa‐

h re
hole
ded with weight of vehi‐

spec
cle, bearing will be dam‐

es, in part or in w
t to the co
aged. This reduces the

service life of the wheel
bearing.
rrectness of i
Do not attempt to move

l purpos
the vehicle without the

drive shafts fitted as this
would damage the wheel
nform
ercia
bearing. If a vehicle nev‐

ertheless has to be
m
a
com
ti
moved, comply with the

on in
following:
r
te o
thi
s
iva
do
Install
• an outer joint in‐
r
rp
cum
stead of the drive shaft.

fo
en
ng
t.
yi Co
Cop py
.
9 - Slotted nut
t rig
gh ht
pyri by
Vo
❑ Initial torque specification: 200 Nm
co lksw
by
cted agen
Prote
❑ Turn back by 160°.
AG.
❑ Final torque setting: 200 Nm.

10 - Locking plate

Crafter 2006 ➤
11 - Slotted nut
❑ 200 Nm
12 - Wheel bolt
❑ Specified torque ⇒ page 135
13 - Wheel flange
• Not for 3.5 t vehicles
14 - Bolt
• Not for 3.5 t vehicles
❑ 190 Nm
5.3 Removing and installing wheel bearing housing

equipment required
♦ Engine and gearbox jack -
V.A.G 1383 A-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Removing
cted agen
Prote AG.

Crafter 2006 ➤
WARNING
platform.

– Loosen nut -A- on track rod ball joint but do not remove com‐
pletely.
joint puller - 3287 A- and now remove nut -A-.
Note
♦ When pressing off, do not damage rubber grommet or heat

shield -B-.
♦ If wheel bearing housing is renewed, heat shield -B- must be
attached to new wheel bearing housing.
– Loosen securing nut for suspension link to wheel bearing

housing until it is flush with swivel joint thread.
wage es n
– Remove wire -2- for brake pad wear indicator and yV
speed
olk s sen‐ ot g
sor wire -3- from wheel bearing housing andisshock
ed
b absorber ua
ran
-4-. thor tee
or
au ac
s
– Detach brake caliper -1- and tie to body with wire.
s
ce
e
nl
pt
du
Wheel bearing housing is to be renewed an

itte
y li
erm
ab
– Remove brake disc from wheel bearing housing ⇒ Brake sys‐ ility
ot p
tems; Rep. gr. 46 ; Repairing front brakes .

wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i

l purpos
suspension link on wheel bearing housing and exert slight

counter pressure.
nf
ercia
– Unscrew nuts -arrows- and pull out bolts.

rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Press wheel bearing housing off swivel joint of suspension

link.
– Lower engine and gearbox jack - V.A.G 1383 A- and remove
from suspension link.
– Completely unscrew nut -A- from swivel joint and remove
wheel bearing housing.
Installing
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Note rised
nte
ho eo
aut ra
ss c
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
– Attach brake caliper and brake disc to wheel bearing housing
, is n
h re
⇒ Brake systems; Repair group 46; Repairing front brakes .
hole
spec
es, in part or in w
t to the co
– Check wheel alignment ⇒ page 149 . rrectness of i
l purpos
Specified torques
nform
ercia
page 61
m
at

om
ion
c
in t
or
his
e
5.4 Removing and installing wheel bearing

at
do
priv
housing, Crafter 4MOTION with Achleit‐

um
for
en
ng
ner four-wheel drive

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.

Crafter 2006 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec

t to the co
Removing
rrectne
Note
ss o

cial p
f in

form
mer
atio

om
n
c
i
or
n thi
e

t
sd
iva
o
pr
cum
r
fo
WARNING
en
ng
t.
yi Co
Cop py
t. rig
If the vehicle is not strapped down, it may slip off the lifting gh ht
yri by
platform. cop Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
Note

electronic components and their locations ABS/TCS/ESP .
– If fitted, remove wheel flange ⇒ page 135 .
– Remove brake caliper together with brake carrier and secure
with wire so that weight of brake caliper does not stress or
damage brake hose ⇒ Brake systems; Rep. gr. 46 ; Brakes
- mechanism .
– Remove brake disc ⇒ Brake systems; Rep. gr. 46 ; Brakes -
mechanism .
– Remove lower suspension link ⇒ page 53 .
– Slightly raise wheel bearing housing with engine and gearbox
jack - V.A.G 1383 A- and support - T10149- .
– Loosen bolts -arrows- of upper swivel joint -1-.
– Remove wheel bearing housing towards front.
Installing
AG. Volkswagen AG d
Note agen oes
olksw not
byV gu
ara
ed
Tighten bolted connections to wheel bearing housing only if the
ris nte
tho eo
vehicle is standing on its wheels and is unladen
s auor if the vehicle ra
c
is raised and is in the unladen position (normal position)
s ce
le
⇒ page 2 .
un
pt
an
d
itte
y li
rm
ab

pe
ility
ot
wit
– Check wheel bearing play ⇒ page 72 .

, is n
h re
hole
Specified torques
spec
es, in part or in w

t to the co

rrectness of i
Crafter 4MOTION with Achleitner four-wheel drive ”, page 49

l purpos

nform
ercia
5.5 Removing and installing wheel hub,

m

a
com
tion in
wheel drive
r
te o
thi
s
iva
do

r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
♦ Claw spanner - T50034- pe
ility
ot
wit
♦ Commercially available plastic head hammer
, is n
h re
hole
Removing
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
r
te o
thi
WARNING
s
iva
do
r
rp
cum
fo
en
g
platform.
n
t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
– Remove front wheel. by c lksw
cted agen
Prote AG.
- mechanism .
– Remove brake disc ⇒ Brake systems; Rep. gr. 46 ; Brakes -
mechanism .
Note

renewed.

Crafter 2006 ➤
– Release outer slotted nut -1- by bending locking plate

-arrow- back.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
– Remove outer slotted nut -4- using claw spanner - T50034- .
itte
y li
erm
ab
– Remove locking plate -3- and unscrew inner slotted nut -2-
ility
ot p
using special wrench - T50034- .
wit
, is n
h re
– Pull off wheel hub -1- in -direction of arrow-. To do this, care‐
hole
spec
fully knock against wheel hub from behind using a plastic head
es, in part or in w
hammer.
t to the co
– Check wheel hub and wheel bearing for damage and renew if
necessary.
rrectness of i
Installing
l purpos
nf
ercia
or
Caution
m
m
atio
om
n in
c
When placing parts down or when fitting them, ensure that

or
thi
there is no dirt on the parts.
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
– Apply sufficient universal grease ⇒ Electronic Parts Catalogue

t.
yi Co
op
(ETKA) to outer tapered roller bearing -2-. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Fit wheel hub -1- with outer tapered roller bearing -2- on wheel
bearing housing.
– Coat contact surface of slotted nut to wheel hub with universal
grease ⇒ Electronic Parts Catalogue (ETKA) , and tighten nut
using special wrench - T50034- .
– Coat contact surfaces of new hub cap with sealant ⇒ Elec‐
tronic Parts Catalogue (ETKA) .
Note
Due to the air-tight conditions and the metal contact, the sealant
starts to cure immediately after the installation of the hub cap to
the wheel bearing housing ⇒ Electronic Parts Catalogue (ETKA) .

– Installing brake disc ⇒ Brake systems; Rep. gr. 46 ; Brakes -
mechanism .
– Install brake caliper with brake carrier ⇒ Brake systems; Rep.
gr. 46 ; Brakes - mechanism .
– If fitted, install wheel flange ⇒ page 135 . AG. Volkswagen AG d
agen oes
lksw not
– Install front wheel. d byV
o gu
ara
ise nte
r
Specified torques ut
ho eo
ra
s a c
♦ ⇒ “5.2 Assembly overview - wheel bearing unit, Crafter 4MO‐ s
ce
le

un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
5.6 Checking wheel bearing play, Crafter
, is n
h re
hole
spec
es, in part or in w
drive
t to the co
♦ Universal dial gauge holder - VW 387- rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
♦ Dial gauge - VAS 6079-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
♦ Guide pin - T10200- au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
n in
r
te o
thi
- mechanism .
s
iva
do
r
rp
cum
– Secure dial gauge - VAS 6079- -2- with universal dial gauge
fo
en
g
holder - VW 387- -1- to wheel bearing housing.

n
t.
yi Co
Cop py
– Screw in a guide pin - T10200- -3- on the opposite side of the
t. rig
gh ht
yri
measuring point of universal dial gauge holder - VW 387- -1-.
p by
co Vo
by lksw
cted agen
– Screw in a commercially available bolt “M 14 × 1.5” -4- on op‐
Prote AG.
posite side of guide pin - T10200- -3-.

– »Tilt« wheel bearing back and forth and read wheel bearing
play on universal dial gauge holder - VW 387- -1-.
Wheel bearing play on front axle: 0.01 … 0.02 mm
– If the specified values are not achieved, adjust wheel bearing
play ⇒ page 74 .
– If fitted, install wheel flange ⇒ page 135 .
Specified torques

Crafter 2006 ➤
5.7 Adjusting wheel bearing play, Crafter

drive
Removing
- mechanism .
– Lever off hub cap using a commercially
wage
n AGavailable
. Volkswagchisel.
en AG
doe
olks s no
yV t gu
edb ara
ris nte
Note tho eo
au ra
c
ss
ce
le
un
pt
renewed.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
– Release outer nut -1- by bending locking plate -arrow- back.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Unscrew outer slotted nut -3- using gclaw

en AG.spanner - T50034-
Volkswagen AG
does
swa
and remove locking plate -2-.
y Volk not
gu b ara
ed nte
– Unscrew inner slottedthnut
or -1- using claw spanner - T50034- .
is
e or
au ac
– Coat contact surfacess of inner slotted nut -1- to wheel hub with
ce
le
universal grease ⇒ Electronic Parts Catalogue (ETKA) , and
un
pt
tighten nut to pre-tightening torque ⇒ Item 9 (page 64) .
an
d
itte
y li
erm
ab
– Loosen inner slotted nut -1-, turn wheel hub, and loosen wheel
ility
ot p
hub by carefully knocking against wheel hub using e.g. a com‐
wit
is n
mercially available plastic head hammer.
h re
ole,
spec
– Tighten inner slotted nut -1- until there is no more wheel bear‐
ing play.
t to the co
– Loosen inner slotted nut -1- by 160°. Then, tighten it
⇒ Item 9 (page 64) .
rrectne
– Insert brake locking plate -2-.
ss o
cial p
f
Note
inform
mer
Locking plate -2- must be renewed (⇒ Electronic Parts Catalogue
atio
m
“ETKA” ).
o
n
c
i
or
n thi
te
sd
a
– Grease outer slotted nut -3- with universal grease ⇒ Electronic

iv
o
pr
c
Parts Catalogue (ETKA) and tighten it.
um
r
fo
en
ng
t.
yi
– Check wheel bearing play. If necessary, repeat the work pro‐
Co
op py
cedure ⇒ page 74 .
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote
Note
AG.
Do only measure wheel bearing play with outer slotted nut -3-!
– Secure outer slotted nut -3- with locking plate -2-.

– Coat contact surfaces of new hub cap with sealant ⇒ Elec‐
Note
Due to the air-tight conditions and the metal contact, the sealant
starts to cure immediately after the installation of the hub cap to
the wheel bearing housing ⇒ Electronic Parts Catalogue (ETKA) .

Specified torques
5.8 Removing and installing outer tapered

roller bearing, Crafter 4MOTION with

Crafter 2006 ➤
♦ Extractor hook - T20143-
♦ -2- Splitter - KUKKO 18-2-

♦ -3- Splitter - KUKKO 17-2-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
♦ Press tool - VW 412- ut
hor eo
a ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Thrust piece - T50018-

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
♦ Drift - 3138-

Removing
– Remove wheel hub ⇒ page 69 .
– Pull tapered roller bearing -1- off wheel hub -2- using splitterag-en AG. Volkswagen AG do
KUKKO 18-2- , splitter - KUKKO 17-2- and press tool -VoVW lksw es n
ot g
412- . sed by ua
ran
ri tee
ho
– Lever out seal using extractor hook - T20143/2-
au .
t or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Drive tapered roller bearing outer race -1- out of wheel bearing
housing -2- using drift - 3138- .
rrectness of i
– Remove any dirt in wheel bearing housing.
l purpos
Installing
nform
ercia

m
at
om
io
Caution
n
c
in t
or
his
te

a
do
riv

p
cum
for
en
ng
t.
yi Co
Cop py
– Clean wheel hub, check it for damage and renew if necessary.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
– Place tapered roller bearing -2- onto wheel hub -3-. Prote AG.

Crafter 2006 ➤
– Drive tapered roller bearing -2- into wheel hub -3- to stop
-arrow- using thrust piece - T50018- -1-.
Caution
The force for pressing in the tapered roller bearing must only
be applied on inner race!
– Apply sufficient universal grease ⇒ Electronic Parts Catalogue

(ETKA) on tapered roller bearing.
– Drive tapered roller bearing outer race -1- into wheel bearing
housing -2- using a commercially available plastic head ham‐
mer and a commercially available copper drift.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– Drive radial shaft seal -1- flush into wheel bearing housing
h re
-2- using a commercially available plastic head hammer and
ole,
spec
thrust piece - T50018- .
t to the co
Caution
rrectne
Do not damage or soil radial shaft seal during installation.
ss o
cial p
f inform
Note
mer
atio
om
Renew inner tapered roller bearing if necessary ⇒ page 78 .
n
c
i
or
n thi
te
sd
va
Install wheel hub ⇒ page 69 .

i
o
pr
cum
r
fo
Specified torques
en
ng
t.
yi Co
op py
♦ ⇒ “5.2 Assembly overview - wheel bearing unit, Crafter 4MO‐ . C rig
ht ht
rig by
copy Vo
by lksw
cted
agen
Prote AG.
5.9 Removing and installing inner tapered

roller bearing, Crafter 4MOTION with

Crafter 2006 ➤
♦ Extractor hook - T20143- AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
♦ Thrust piece - T10380-
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh
♦ Drift - 3138-
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Thrust piece - 2050-

Removing
– Remove wheel bearing housing ⇒ page 67 .
– Lever out radial shaft seal using extractor hook - T20143- .

Crafter 2006 ➤
– Drive tapered roller bearing -1- in -direction of arrow- out of

wheel bearing housing -2-.
– Drive tapered roller bearing outer race -1- out of wheel bearing
housing -2- using drift - 3138- .
– Remove any dirt in wheel bearing housing.
Installing
– Drive tapered roller bearing outer race -1- into wheel bearing
housing -2- to stop using a commercially available plastic head
hammer and thrust piece - 2050- .
– Apply sufficient universal greasewage
n A⇒G.Electronic Parts
Volkswagen AG do Catalogue
es n
(ETKA) on tapered roller y Vo bearing, and place it in wheel
lks obearing
t gu
housing. ir se
d b ara
nt ee
ho
aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
– Drive radial shaft seal -1- flush into wheel bearing housing
spec
-2- using thrust piece - T10380- .

t to the co
Caution
rrectne
Do not damage or soil radial shaft seal during installation.

ss o
cial p
– Install wheel bearing housing ⇒ page 67 .

inform
mer
Install wheel hub ⇒ page 69 .

atio
om
Specified torques
n
c
i
or
n thi
e

t
sd
va

i
o
pr
cum
r
fo
en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
6 Drive shaft
⇒ “6.1 Assembly overview - drive shaft, Crafter 4MOTION with
⇒ “6.2 Removing and installing drive shaft, Crafter 4MOTION with
⇒ “6.3 Dismantling and assembling drive shaft, Crafter 4MOTION
⇒ “6.4 Checking outer constant velocity joint, Crafter 4MOTION
with Achleitner four-wheel drive ”, page 90
AG. Volkswagen
6.1 Assembly overview - drive shaft, Crafter
Volks
wage4MOTION with
n AG do
esAchleitner
not four-
wheel drive by gu
d ara
e nte
ris
ho eo
aut ra
ss c
1 - Nut
ce
le
un
pt
an
d
itte
y li
moving
rm
ab
pe
ility
❑ Checking wheel bearing
ot
wit
play ⇒ page 72 .
, is n
h re
❑ Specified torque
hole
spec
⇒ page 63
es, in part or in w
t to the co
When bolt is loosened or tight‐
ened, vehicle must not be
standing on its wheels.
rrectness of i
2 - Outer constant velocity joint
l purpos
❑ Including ABS sensor

ring.
nform
ercia
❑ Renew only as com‐

m
plete unit
a
com
tion in
❑ Checking ⇒ page 90
r
te o
thi
❑ Removing ⇒ page 88 .
s
iva
do
r
rp
c
❑ Installing: drive onto
um
fo
shaft as far as stop us‐

en
ng
t.
yi
ing a plastic head ham‐
Co
Cop py
mer
t. rig
gh ht
pyri by
Vo
o
3 - Retaining ring
c by lksw
cted agen
Prote AG.
moving
❑ Insert in groove in shaft
4 - Clamp
moving
❑ Tightening ⇒ page 90
5 - Boot
❑ Check for splits and
chafing
❑ Material: Hytrel (polyester elastomer)
6 - Clamp
6. Drive shaft 81
Crafter 2006 ➤
7 - Drive shaft
8 - Multi-point socket head bolt
❑ Always renew after removing n AG. Volkswagen AG do
lkswage es n
❑ Initial torque specification: 10 Nm byV
o ot g
ua
d ran
❑ 76 Nm ir se tee
tho
u or
a ac
9 - Locking plate ss
ce
le
un
pt
10 - Clamp
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
11 - Boot for constant velocity joint
h re
ole,
spec
❑ Material: Arnitel (polyester elastomer).
❑ Without breather hole
t to the co
❑ Check for splits and chafing
❑ Drive off constant velocity joint with a drift
rrectne
❑ Before installing to constant velocity joint, coat sealing surface with sealant ⇒ Electronic Parts Catalogue
(ETKA) .
ss o
cial p
12 - Clamp
f inform
mer
atio
om
n
c
i
or
n
13 - Inner constant velocity joint
thi
te
sd
a
❑ Renew only as complete unit

iv
o
pr
cum
r
❑ Pressing off ⇒ page 89

fo
en
ng
t.
yi
❑ Pressing on ⇒ page 89
Co
Cop py
t. rig
gh
14 - Retaining ring
ht
pyri by
Vo
co lksw
by
❑ Remove and install with circlip pliers - VW 161 A- Prote
cted AG.
agen
15 - Cover
❑ Pressing off ⇒ page 89
6.2 Removing and installing drive shaft,

wheel drive

Crafter 2006 ➤

Removing
Note
olkswagen AG
en AG. V
Bonded rubber bushes olks
wagcan be twisted onlydoto
es na limited extent.
ot g
Therefore, tighten
ed by V the bolted connections of components ua
ran with
bonded rubber
horis bushes only when the wheel bearing housing tee has
been raised
sa
ut (unladen position) ⇒ page 2 . or
ac
s
ce
e
nl
pt

du
an
itte
y li
erm
ab
ility
WARNING
ot p
wit
, is n
h re
hole
spec
platform.
es, in part or in w
t to the co

rrectness of i
l purpos
Note
nf
ercia

rm
m
atio
m

o
n in
c

or
thi
te
sd
iva
o
r
rp
cu

o
m
f

en
ng
t.
yi Co
electronic components and their locations ABS/TCS/ESP . . Cop py
rig
ht ht
rig by
opy Vo
by c lksw
cted agen
Prote AG.
- mechanism .
6. Drive shaft 83
Crafter 2006 ➤
Note

renewed.
n AG. Volkswagen A age G do
ksw es n
y Vol ot g
– Release outer slotted nut -1- by bending locking
ed
b plate ua
ran
-arrow- back. oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove outer slotted nut -3- and locking plate -2-.
l purpos
– Unscrew slotted nut -1-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
– Unscrew bolts -arrows- of upper swivel joint -1-.
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Loosen multi-point socket head bolts -arrows- (right or left) on

final drive -1-.
– Turn steering wheel to right or left in order to free more space
for working.
– Pull drive shaft out of wheel bearing housing and remove it.
lkswage es n
o ot g
Note byV ua
d ran
ir se tee
tho
or
If necessary, screw on slotted nut and drivesout
s au
constant velocity ac
joint by carefully knocking constant velocity joint using a com‐
ce
le
un
mercially available plastic head hammer.
pt
an
d
itte
y li
erm
ab
ility
ot p
Caution
wit
is n
h re
ole,
Wheel bearings must not be subjected to load after bolt secur‐
spec
ing drive shaft to wheel hub has been loosened.
t to the co
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
rrectne
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle
s
nevertheless has to be moved, comply with the following:
s o
cial p
f
• Install an outer joint instead of the drive shaft.
inform
mer
atio
om
Installing
n
c
i
or
n thi
e

t
sd
iva
o
pr
cum
r
fo
en
ng
Caution
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– In case of soiling or damage on wheel bearing housing

⇒ Item 1 (page 63) , radial shaft seal ⇒ Item 4 (page 63) or
wheel hub ⇒ Item 8 (page 64) , clean parts or renew them.
– Insert drive shaft and guide outer constant velocity joint into
wheel bearing.
6. Drive shaft 85
Crafter 2006 ➤
– Tighten the two inner bolts -arrows- of upper swivel joint -1-
first hand-tight and then to specified torque.
Note
Check that dust caps are undamaged and correctly seated.

AG. Volkswagen AG d
agen oes
lksw not
– Tighten multi-point socketdheadby
V bolts first hand-tight and then
o gu
ara
to specified torque. oris e nte
h eo
ut ra
– Secure track rod ball
ss a joint ⇒ page 189 . c
ce
e
nl
– Install front right speed sensor - G45- or front left speed sensor
pt
du
an
- G47- ⇒ Brake system; Rep. gr. 45 ; Electrical and electronic
itte
y li
components and their locations ABS/TCS/ESP .
erm
ab
ility
ot p
– Check and adjust wheel bearing play ⇒ page 72 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Specified torques
l purpos
♦ ⇒ “6.1 Assembly overview - drive shaft, Crafter 4MOTION with

nform
ercia

m

at
om
ion
c

in t
or
his
ate
do
riv
6.3 Dismantling and assembling drive shaft, Crafter 4MOTION with Achleitner
p
cum
for
en
g
four-wheel drive
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤

equipment required
♦ Thrust plate - VW 401-
♦ Press tool - VW 408 A-
♦ Support sleeve - VW 522-
♦ Tensioner - 40 - 204 A-
♦ Special pliers - V.A.G 1682-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
. rig
♦ Multi-purpose tool - VW 771-
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Drive shaft 87
Crafter 2006 ➤
♦ Puller - T10382-
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
Removing outer constant velocity risedjoint nte
ho eo
ut
– Clamp drive shaft in vice
ss ausing protective jaw covers. ra
c
ce
le
– Fold back boot.

un
pt
an
d
itte
y li
– Set puller - T10382- up so that smooth side of puller plate -

rm
ab
T10382/1- points to spindles - T10382/2- .

pe
ility
ot
wit
, is n
– Assemble puller - T10382- complete with multi-purpose tool -

h re
VW 771- .
hole
spec
– Pull constant velocity joint from drive shaft with puller -

es, in part or in w
t to the co
T10382- and multi-purpose tool - VW 771- .

1- Puller plate - T10382/1-
rrectness of i
2- Spindles - T10382/2-
l purpos
Driving on outer constant velocity joint:

– Install new retaining ring.
nform
ercia
– If necessary, push new joint boot onto drive shaft.

m
a
com
tio
– Knock onto shaft with plastic hammer until circlip engages.

n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
olksw not
Driving off cover for inner d byjoint
V gu
ara
rise nte
– Remove retaining ut ring.
ho eo
ra
s a c
s
– Remove both clamps and slide boot towards outer joint.
ce
le
un
pt
an
– Drive off boot with drift.
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Pressing off inner constant velocity joint
rrectne
Assembling
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Pressing on inner constant velocity joint
co Vo
by lksw
cted agen
Prote AG.
– Press joint on to stop.
– Install retaining ring.
– Coat sealing surface of cover with sealant ⇒ Electronic Parts

Catalogue (ETKA) .
– Apply an unbroken bead of sealant of 2…3 mm in diameter
onto clean surface of cover in area of inner holes -arrow-.
6. Drive shaft 89
Crafter 2006 ➤
. Volkswagen AG
a gen AG does
– Using bolts -arrows-, align new cover in relation
Vol
ksw to bolt holes. not
gu
by ara
d
The alignment must be very accurate, because
oris
e
no further align‐ nte
eo
ment is possible once the part has been
auth
hammered on. ra
ss c
– Drive on cover using a plastic hammer.
ce
e
nl
pt
du
an
– Wipe off surplus sealant.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Tighten clamp on outer joint
rrectness of i
– Position clamp tensioner - V.A.G 1682- as shown in diagram.
l purpos
Ensure jaws of tensioner lie in corners -arrows B- of ears on

O-type clip.
nf
ercia
– Tighten clamp by turning spindle with a torque wrench (do not
or
cant pliers).
m
m
atio
om
n in
or c
thi
Note
te
sd
iva
o
r
rp
cu
♦ Due to the hard material of the protective boot (compared to
o
m
f
en
ng
rubber) and the necessity of using a stainless steel clamp, it

t.
yi Co
op
is only possible to tension the clamp with clamp tensioner - C py
t. rig
V.A.G 1682- .
gh ht
pyri by
Vo
co lksw
by
♦ Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g. cted agen
Prote AG.
torque wrench - V.A.G 1331- ).
♦ Make sure thread of spindle -A- on pliers moves freely. Lubri‐
cate with MoS2 grease if necessary.
♦ If the thread is tight (e.g. due to dirt), the required clamping
force for the clamp will not be attained although the specified
tightening torque is applied.
Tightening clamp on small diameter

Specified torque
Clamp 25 Nm
6.4 Checking outer constant velocity joint,

wheel drive
The joint is to be dismantled to renew the grease if it is heavily
soiled, or to check the running surfaces of the balls for wear and
damage.

Crafter 2006 ➤
Removing
– Before dismantling, mark position of ball hub in relation to ball
cage and joint body with an electric scriber or oil stone.
– Swing ball hub and ball cage.
– Remove balls one at a time.
– Turn cage until the two rectangular windows -arrow- lie on joint
body.
– Take out cage with hub.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
– Swing segment of hub into square cage window.
y li
erm
ab
ility
– Tip hub out of cage.
ot p
wit
, is n
The six balls for each joint belong to a tolerance group. Check
h re
hole
stub axle, hub, cage and balls for small indentations (pitting) and
spec
traces of seizing. Too much circumferential backlash in the joint
es, in part or in w
t to the co
becomes noticeable during load change jolts; in such cases, the
joint must be renewed. Smoothing and traces of wear of the balls
are no reason to change the joint.
rrectness of i
Installing
l purpos

– Pack half the total quantity of grease into the joint body.
nf
ercia
orm
– Fit cage with hub into joint body.

m
atio
om
– Press in opposing balls one after the other; the original position
n in
or c
of the hub relative to the cage and joint body must be restored.
thi
te
sd
iva
– Fit new retaining ring into hub.

r
rp
cu
o
m
f
en
ng
– Distribute remaining grease in boot.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Drive shaft 91
Crafter 2006 ➤
42 – Rear suspension
1 Rear axle
⇒ “1.1 Assembly overview - rear axle”, page 92
⇒ “1.2 Assembly overview - rear axle, vehicles with twin wheels”,
page 95
⇒ “1.3 Measuring length on U-bolt”, page 97
⇒ “1.4 Removing and installing leaf spring stop buffer”,
page 98
⇒ “1.5 Removing and installing leaf spring”, page 98 n AG. Volkswagen A
age G do
ksw es n
⇒ “1.6 Removing and installing leaf spring, vehicles
by Vol with twin ot g
ua
wheels”, page 100 rised ran
te
tho eo
⇒ “1.7 Renewing leaf spring rubbersbush”,
sa
u
page 102 ra
c
ce
le
⇒ “1.8 Renewing leaf spring rubber bush”, page 104

un
pt
an
d
itte
y li
⇒ “1.9 Removing and installing shackle, vehicles with twin
erm
ab
wheels”, page 106
ility
ot p
wit
⇒ “1.10 Renewing shackle rubber bush, vehicles with twin
is n
h re
wheels”, page 107
ole,
spec
⇒ “1.11 Removing and installing spring bracket”, page 109
t to the co
⇒ “1.12 Removing and installing rear axle shaft”, page 110
⇒ “1.13 Removing and installing rear axle shaft, vehicles with twin
rrectne
wheels”, page 112
⇒ “1.14 Renewing shrink ring, vehicles with twin wheels”,
ss
page 113
o
cial p
f inform
1.1 Assembly overview - rear axle
mer
atio
om
n
c
i
or
WARNING
thi
te
sd
iva
o
r
♦ It is not permitted to carry out welding and straightening

p
cum
r
fo
operations on load-bearing or wheel-guiding suspension

en
ng
t.
yi
components.
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
♦ Always renew corroded nuts and bolts.
cted agen
Prote AG.
Caution

bonded rubber bushes only when the axle beam is raised or
when the vehicle is standing on its wheels (in the unladen po‐
sition) ⇒ page 2 .
92 Rep. gr.42 - Rear suspension

Crafter 2006 ➤
1 - Bolt
❑ M14 × 1.5 × 110
2 - Spring bracket
❑ Installed in certain vehi‐
cles, e.g. drop-side ve‐
hicles
⇒ page 109 .
3 - Nut
moving
❑ M14 × 1.5: 172 Nm
4 - Nut
❑ M12 × 1.5: 60 Nm +
180°
❑ M16 × 1.5: 240 Nm
5 - Bolt
❑ M14 × 1.5 × 50: 172 Nm
6 - Bolt
7 - Bump stop
Parts Catalogue “ET‐ Volkswa
KA” . swa
gen AG
. gen AG
does
k not
Vol gu
d by ara
Note
oris
e nte
eo
th
au ra
ss The stop buffer for the Crafter 4MO‐ c
ce
le
TION with Achleitner four-wheel

un
pt
drive is bigger in size, but the re‐

an
d
itte
y li
moval and installation procedure is

rm
ab
identical.
pe
ility
ot
wit
, is n

h re
hole
spec
8 - U bolt
es, in part or in w
t to the co
❑ Different sizes. To allocate correctly, length must be measured ⇒ page 97

❑ Allocation ⇒ Electronic Parts Catalogue “ETKA” .
rrectness of i
Note
l purpos
The U bolt for the Crafter 4MOTION

with Achleitner four-wheel drive is
nform
ercia
bigger in size, but the removal and

installation procedure is identical.
m
a
com
tion in
r
9 - Saddle plate
te o
thi
s
iva

do
r
rp
cum
fo
10 - Nut
en
ng
t.
yi Co
Cop py
t. rig
gh
❑ M12 × 1.5: 70 Nm + 180°
ht
pyri by
Vo
co lksw
by
❑ M16 × 1.5: 240 Nm Prote
cted AG.
agen
1. Rear axle 93
Crafter 2006 ➤
11 - Bolt
12 - Self-locking nut
❑ M12 × 1.5: 70 Nm + 180°
❑ M16 × 1.5: 240 Nm
❑ Renewing ⇒ page 104 . wage
es n
olks ot g
14 - Bolt byV ua
d ran
ir se tee
❑ Always renew after
uth removing
o
or
a ac
ss
15 - Shackle
ce
e
nl
pt
❑ Before installing leaf spring, secure to leaf spring in installation position (must be positioned vertically to
du
an
itte
leaf spring)
y li
erm
ab
ility
16 - Rear axle
ot p
wit
, is n
❑ With rear axle shafts and wheel bearings
h re
hole
❑ Removing and installing ⇒ Rep. gr. 39 ; rear axle
spec
es, in part or in w
❑ Removing and installing final drive ⇒ Rep. gr. 39 ; Final drive
t to the co
17 - Nut
rrectness of i
❑ M14 × 1.5: 160 Nm
l purpos
18 - Brake caliper
❑ Removing and installing ⇒ Rep. gr. 46 ; Repairing rear brakes
nform
ercia
19 - Bolt
m
at
om
io

n
c
in t
or
his
e
20 - Nut
at
do
riv

p
cum
for
en
g
❑ 105 Nm
n
t.
yi Co
Cop py
21 - Bolt
t. rig
gh ht
yri by
❑ Always renew after removing cop Vo
by lksw
cted agen
❑ M14 × 1.5 × 110: 106 Nm
Prote AG.
❑ M14 × 1.5 × 160: 135 Nm

22 - Shock absorber
23 - Propshaft
❑ Before removing, mark position relative to final drive flange.
24 - Bolt
❑ Specified torque: ⇒ Rep. gr. 39 ; propshaft
25 - Leaf spring
26 - Bump stop
❑ Can be removed from or pushed onto leaf spring support position
27 - Damper weight
❑ Pressed onto leaf spring
❑ Not available as replacement part

Crafter 2006 ➤
1.2 Assembly overview - rear axle, vehicles

with twin wheels
WARNING
♦ It is not permitted to carry out welding and straightening

operations on load-bearing or wheel-guiding suspension
components.
♦ Always renew corroded nuts and bolts.
AG. Volkswagen AG d
Caution lksw
agen oes
not
Vo gu
d by ara
Bonded rubber bushes can be twisted only tohoarislimited extent.
e nte
eo
Therefore, tighten the bolted connections sofautcomponents with ra
c
bonded rubber bushes only when the axle s beam is raised or
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
1 - Bump stop
hole
spec
es, in part or in w
t to the co
KA” .
rrectness of i
Note
l purpos
The stop buffer for the Crafter 4MO‐

TION with Achleitner four-wheel
drive is bigger in size, but the re‐
nf
ercia
o
moval and installation procedure is
rm
m
identical.
atio
om
n in
or c

thi
te
⇒ page 98 sd
iva
o
r
rp
cu
2 - U bolt
o
m
f
en
ng
t.
yi
❑ Different sizes. To allo‐
Co
op py
cate correctly, length
t. C rig
gh ht
yri
must be measured p by
o Vo
by c
⇒ page 97
lksw
cted agen
Prote AG.
KA” .
Note
The U bolt for the Crafter 4MOTION

with Achleitner four-wheel drive is
bigger in size, but the removal and
installation procedure is identical.
3 - Nut
moving
❑ M12 × 1.5: 90 Nm
❑ M16 × 1.5: 185 Nm
1. Rear axle 95
Crafter 2006 ➤
4 - Shackle
❑ Removing and installing ⇒ page 106 AG. Volkswagen AG d
agen oes
lksw not
5 - Rubber bush for shackle by
Vo gu
ara
ed
❑ Renewing ⇒ page 107 . horis nte
eo
aut ra
6 - Bolt ss c
ce
e
nl
pt
du
an
itte
y li
7 - Nut
erm
ab
ility
ot p
wit
, is n
❑ M12 × 1.5: 85 Nm
h re
hole
❑ M16 × 1.5: 185 Nm
spec
es, in part or in w
8 - Bolt
t to the co
9 - Rubber bush for leaf spring
rrectness of i
l purpos
10 - Leaf spring
nf
ercia
orm
m
atio
om
n in
11 - Saddle plate
or c
thi
e

t
sd
iva
o
r
rp
cu
12 - Nut
o
m
f
en
ng

t.
yi Co
Cop py
❑ 106 Nm
t. rig
gh ht
pyri by
Vo
o
13 - Coupling rod by c lksw
cted agen
Prote AG.
Note
The coupling rods must have the

same length on both sides.
❑ Removing and installing, Crafter 4MOTION with Achleitner four-wheel drive ⇒ page 118 .
14 - Bolt
❑ M10 × 1.5: 60 Nm
❑ M12 × 1.5: 120 Nm
15 - Bolt
16 - Clamp
17 - Anti-roll bar
19 - Nut
❑ 160 Nm
20 - Bolt

Crafter 2006 ➤
21 - Nut
❑ M12 × 1.5: 106 Nm
❑ M14 × 1.5: 135 Nm
22 - Shock absorber
23 - Bolt
❑ M14 × 1.5 × 110: 106 Nm
❑ M14 × 1.5 × 160: 135 Nm
24 - Propshaft
❑ Before removing, mark position relative to final drive flange.
❑ Removing and installing ⇒ Rep. gr. 39 ; propshaft
25 - Rear axle
❑ Removing and installing ⇒ Rep. gr. 39 ; rear axle
❑ Removing and installing final drive ⇒ Rep. gr. 39 ; Final drive
26 - Bolt
27 - Nut
AG. Volkswagen AG d
agen oes
❑ 185 Nm V olksw not
g by ua
ed ran
28 - Damper weight
ho
ris tee
ut or
❑ Pressed
ss onto leaf spring
a ac
❑ Not available as replacement part

ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
1.3 Measuring length on U-bolt

wit
, is n
h re
To allocate U-bolt in ⇒ Electronic parts catalogue “ETKA” , length

hole
spec
of U-bolt must be measured.

es, in part or in w
t to the co
• U-bolt removed
– Place U-bolt upwards on a level surface.
rrectness of i
– Measure dimension -a- between inner radius and level sur‐

l purpos
face.
– Used measured dimension -a- to allocate U-bolt in ⇒ Elec‐
nf
ercia
tronic parts catalogue “ETKA” .

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Rear axle 97
Crafter 2006 ➤
1.4 Removing and installing leaf spring stop

buffer
Removing
– Position screwdriver -B- along side between bump stop -A-
and mounting on chassis.
– Push bump stop -A- in direction of -arrow- and remove from
mounting on chassis.
Installing
– Insert bump stop -5- into mounting on chassis.
– Compress base of bump stop -A- together, in direction of
-arrow- using a screwdriver -B-, and lock it into mounting.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
1.5 Removing and installing leaf spring ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se
tho tee
or Crafter 2006 ➤
u
ss
a
Running gear, ac
axles, steering - Edition 12.2015
ce
le
un
pt
Removing
an
d
itte
y li
rm
ab
– Undo nut -arrow- from bolt -1-.
pe
ility
ot
wit
– Remove bolt -1- with vehicle standing on its wheels.
, is n
h re
hole
– Loosen flange nuts -2- approx. 2 turns. Unscrew bolt -3- for
spec
parking brake cable retainer.
es, in part or in w
t to the co
rrectness of i
WARNING
l purpos
platform.
nform
mercia
a
com
tion in
– Insert support -4- from trolley jack in engine and gearbox jack
r
te o
- V.A.G 1383 A- .
thi
s
iva
do
r
– Position engine and gearbox jack - V.A.G 1383 A- under rear

rp
cum
fo
axle and slightly take up the weight of the rear axle.
en
ng
t.
yi Co
op
– Unscrew flange nuts from spring U-bolts. C py
t. rig
gh ht
yri by
– Remove U-bolts and saddle plate from leaf spring -1-. cop Vo
by lksw
cted agen
Prote
– Lower axle beam -3- to dimension -a- ≈ 20 mm.
AG.
Note
♦ Leaf spring bolt -arrow- must slide out of hole in axle beam;
lever out if necessary.
♦ The brake hose -2- must not be twisted.
– Unbolt leaf spring from mounting points on frame.
Note
In certain vehicles, cover cap -arrow- must be removed to enable

removal of rear securing bolt for leaf spring -A-.
1. Rear axle 99
Crafter 2006 ➤
– Then turn leaf spring -1- 180° and remove to rear.

Installing
Note
Install larger mounting eye forwards.
Caution

when the vehicle is standing on its wheels (in unladen position)
⇒ page 2 .
– The spring bolt of the leaf spring must be inserted into the
aperture in the axle beam.
Specified torques
♦ ⇒ “1.1 Assembly overview - rear axle”, page 92
1.6 Removing and installing leaf spring, ve‐

hicles with twin wheels
AG. Volkswagen AG d
agen
♦ Engine and gearbox jack - V.A.G 1383 A- olksw
oes
not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
Removing
Note
If components with bonded rubber bushes are renewed or nuts

or bolts on these components are loosened, the unladen position
must be measured before starting work ⇒ page 2 .
– Remove nut -arrow- from shock absorber bolt -1-.

swage es n
– Remove bolt -1- with vehicle standing on its wheels. byV
olk ot g
ua
d ran
ir se
– Loosen nuts -2- approx. 2 turns. tho tee
or
au ac
– Loosen wheel nuts. ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
WARNING
ot
wit
, is n
h re
hole
spec
platform.
es, in part or in w
t to the co
– Remove wheel.
rrectness of i
– Remove brake caliper ⇒ Brake system; Rep. gr. 46 .
l purpos
– Unscrew upper nut -4- and remove coupling rod -1- from
bracket -5-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
- V.A.G 1383 A- .
axle beam -3- and exert slight counter pressure.
– Remove nuts from U-bolts.
– Remove bolt -1- from shackle -5-.
– Remove U-bolts and saddle plate from leaf spring -4-.
1. Rear axle 101

Crafter 2006 ➤
– Remove front bolt -1- from leaf spring -2-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Lower axle beam until leaf spring -1- can be turned 180°.
es, in part or in w
t to the co
– Remove leaf spring rearwards.
Installing
rrectness of i
l purpos
Caution
nf
ercia
orm
m
atio
m

o
n in
c

or
thi
e
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
If the springs eyes differ in size, the larger spring eye must always
point forwards in direction of travel.
– Install brake caliper ⇒ Brake system; Rep. gr. 46 .
– Fit wheel ⇒ page 135 .
Specified torques
♦ ⇒ “1.2 Assembly overview - rear axle, vehicles with twin
wheels”, page 95
1.7 Renewing leaf spring rubber bush

Crafter 2006 ➤

equipment required
♦ Sleeve - 3144-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Remove rear leaf spring ⇒ page 98 .

t to the co
– Press out rubber bush.

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Rear axle 103

Crafter 2006 ➤
Before pressing in new rubber bush, coat it with acid-free lubri‐

cant, e.g. soft soap.
– Press rubber bush in until shoulders project evenly on both
sides.
– Install rear leaf spring ⇒ page 98 .
AG. Volkswagen AG d
agen oes
Specified torques olksw not
y V gu
d b ara
e
♦ ⇒ “1.1 Assembly overview - rear axle”, pageho92ris nte
eo
ut ra
s a c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
1.8 Renewing leaf spring rubber bush
ot p
wit
is n
h re
ole,
spec
equipment required
t to the co
rrectne
♦ Tube - VW 415 A-
ss o
♦ Removing and installing
cial p
f in
tool - VW 459/2-
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove rear leaf spring ⇒ page 100 .

Crafter 2006 ➤
Renewing large rubber bush:


– Press in rubber bush until shoulders project evenly on both
sides.
Renewing small rubber bush:

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt

du
an
itte
y li
erm

ab
ility
sides.
ot p
wit
, is n
– Install rear leaf spring ⇒ page 100 .

h re
hole
spec
Specified torques
es, in part or in w
t to the co

wheels”, page 95
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
105
cop Vo
by lksw
Prote
cted AG.
agen 1. Rear axle
Crafter 2006 ➤
1.9 Removing and installing shackle, vehi‐

cles with twin wheels
Removing
Note

– Remove nut -arrow- from shock absorber bolt -1-.

– Remove bolt -1- with vehicle standing on its wheels.
– Loosen wheel nuts.
WARNING
platform.
– Remove wheel.
– Remove brake caliper ⇒ Brake system; Rep. gr. 46 .
– Unscrew upper nut -4- and remove coupling rod -1- from
bracket -5-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
- V.A.G 1383 A- .
axle beam -3- and exert slight counter pressure.
– Remove bolt -1- from shackle -5-.
– Lower axle beam -3- together with leaf spring -4-.
– Unscrew upper bolt from shackle and remove shackle.
Installing
Caution

– Install brake caliper ⇒ Brake system; Rep. gr. 46 .
Specified torques
♦ ⇒ “1.2 Assembly overview - rear
agaxle,
en AG. vehicles with
Volkswagen AG dtwin
oes
wheels”, page 95 olksw not
yV g b ua
ed ran
♦ ⇒ “1.1 Specified torque
ho
ris for wheel bolts”, page 135 tee
t or
au ac
ss
1.10 Renewing shackle rubber bush, vehicles with twin wheels
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Rear axle 107

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
Crafter 2006 ➤ horis
eo
ut
Running gear, axles, steeringss - Edition 12.2015
a ra
c
ce
e
nl
pt
du
an
itte
equipment required
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
♦ Tube - VW 415 A-
es, in part or in w
t to the co
♦ Drift sleeve - 40-20-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Remove shackle ⇒ page 106 .


Crafter 2006 ➤

Volkswagen AG
agen
AG. does
ksw
sides. by
Vol not
gu
ara
ed nte
– Install shackle ⇒ page 106 . oris eo
th
au ra
c
Specified torques ss
ce
e
nl
pt
du
an
itte
y li
wheels”, page 95
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
1.11 Removing and installing spring bracket
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
Removing
– Remove lower securing bolt for shock absorber ⇒ page 99 .
WARNING
platform.
– Insert support from trolley jack in engine and gearbox jack -

V.A.G 1383 A- ⇒ page 99 .
axle beam and exert slight counter pressure.
1. Rear axle 109

Crafter 2006 ➤
– Unscrew nut -1- from bolt -2-.

– Then lower axle beam with leaf spring -3- using engine and
gearbox jack - V.A.G 1383 A- until bolt -2- can be pulled out.
– Remove bolts -4-; counterhold at nuts to do this.
– Unscrew last bolt -arrow- and remove spring bracket -A-.

Installing
Caution

Note
Always renew self-locking nuts and bolts. AG. Volkswagen AG d

agen oes
olksw not
y V gu
Specified torques ise
d b ara
nte
or eo
h
♦ ⇒ “1.1 Assembly overview - rear axle”, page 92 s aut ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
1.12 Removing and installing rear axle shaft
ab
ility
ot p
wit
, is n
h re
hole

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
Removing
WARNING
platform.
– Remove wheel -1-.

– Release speed sensor wiring -2- from axle beam.
– Remove brake caliper complete with brake Gcarrier
. Volksw-3-
agenand se‐
cure it to body ⇒ Brake systems; Rep.
lkswaggr.
en A 46 ; Front wheel
AG do
es n
brake; Removing and installingbybrake
Vo caliper . ot g
ua
ed ran
ris tee
tho or
au ac
Note ss
ce
e
nl
pt
du
an
When doing this ensure that the electrical wiring for the brake
itte
y li
wear indicator -4- is not damaged.

erm
ab
ility
ot p
wit
, is n
– Remove brake disc and brake shoes for handbrake ⇒ Braking

h re
system; Rep. gr. 46 ; Rear brake; Removing and installing

hole
spec
brake shoes .
es, in part or in w
t to the co
– Remove bolts -arrows-.

rrectness of i
– Place a drip tray for workshop hoist - VAS 6208- under area
l purpos
of rear axle shaft and pull rear axle shaft out of axle beam.
– Remove brake disc splash plate -A- from axle beam.
nform
mercia
at
om
io
Note
n
c
in t
or
his
ate
Clean oil drain channel -B- before re-installing rear axle shaft.
do
priv
cum
for
en
g
Installing
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Rear axle 111

Crafter 2006 ➤ AG. Volkswagen AG d
Running gear, axles, steering - Edition 12.2015 agen oes
olksw not
byV gu
ara
ed
is nte
– Position brake disc splash plate -A- on axle beam. hor eo
aut ra
c
– Install rear axle shaft in axle beam. ss
ce
e
nl
pt
du
– Tighten new bolts -arrows- diagonally.
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
♦ When installing rear axle shaft, oil drain channel -B- must be
spec
guided through splash plate for brake disc. Oil drain channel
es, in part or in w
t to the co
points downwards.
♦ After installing shaft in rear axle beam, check oil level in rear
final drive and replenish as necessary ⇒ Rep. gr. 39 ; Axle
rrectness of i
oil; Checking axle oil level .
l purpos
Specified torques
nform
ercia

page 126
m
at
om
ion
c
in t
or
his
ate
do
riv
1.13 Removing and installing rear axle shaft,

p
cum
for
en
vehicles with twin wheels
ng
t.
yi Co
Cop py
ht. rig
Special tools and workshop equipment required opy
rig by
Vo
ht
c lksw
by
cted agen
Prote AG.
Removing
WARNING
platform.

Crafter 2006 ➤
– Remove nuts -1-.

– Position dip tray under rear axle shaft area and pull rear axle
shaft -2- out of axle beam.
Installing
Note

♦ After installing shaft in rear axle beam, check oil level in rear
final drive and replenish as necessary ⇒ Transmission; Rep.
gr. 39 ; Checking oil in rear final drive .
– Coat sealing surface of rear axle shaft with sealant ⇒ Elec‐

– Install rear axle shaft -2- and tighten new nuts -1- diagonally.
Specified torques n AG. Volkswagen AG do
lkswage es n
o ot g
yV ua
♦ ⇒ “4.2 Assembly overview - wheel bearing unit, vehicles
ir se
d b
with ran
twin wheels”, page 127 utho tee
or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
1.14 Renewing shrink ring, vehicles with twin
hole
spec
wheels
es, in part or in w
t to the co
♦ Thrust washer - VW 447 i-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
♦ -3- Splitter - Kukko 17/2-
co Vo
by lksw
cted agen
Prote AG.
1. Rear axle 113

Crafter 2006 ➤
♦ -2- Puller - Kukko 18/2-

– Remove brake shoes for handbrake ⇒ Brakes - mechanism;
Rep. gr. 46 ; Removing and installing brake shoes for hand‐
brake .
– Remove rear wheel hub ⇒ page 131 .
Position separator - Kukko 17/2- and puller - Kukko 18/2- as il‐
lustrated and pull shrink ring -1- off axle tube -2-.
– Heat new shrink ring to approx. 80 °C and push onto axle tube
to stop.
– Install brake shoes for handbrake ⇒ Brakes - mechanism;
Rep. gr. 46 ; Removing and installing brake shoes for hand‐
brake .
– Install rear wheel hub ⇒ page 131 .
Specified torques
♦ ⇒ “4.2 Assembly overview - wheel bearing unit, vehicles with
twin wheels”, page 127
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
2 Anti-roll bar
⇒ “2.1 Assembly overview - anti-roll bar”, page 115
⇒ “2.2 Assembly overview - anti-roll bar, vehicles with twin
wheels”, page 116
⇒ “2.3 Removing and installing anti-roll bar”, page 116
⇒ “2.4 Removing and installing anti-roll bar, vehicles with twin
wheels”, page 117
⇒ “2.5 Removing and installing coupling rods, Crafter 4MOTION
⇒ “2.6 Renewing anti-roll bar bushes, vehicles with twin wheels”,
page 120
⇒ “2.7 Renewing coupling rod bushes, vehicles with twin wheels”,
page 122
2.1 Assembly overview - anti-roll bar
1 - Bolt
moving n AG. Volkswagen AG do
swage es n
❑ 106 Nm yV
olk ot g
ua
d b ran
2 - Coupling rod ir se tee
tho
u or
a ac
ss
Note
ce
le
un
pt
an
d
itte
Coupling rods are adjustable. They y li

rm
must have the same length on both ab

pe
ility
sides.
ot
wit
, is n
h re

hole
spec
⇒ page 116
es, in part or in w
t to the co
❑ Removing and instal‐

ling, only Crafter 4MO‐
TION with Achleitner
rrectness of i
four-wheel drive
⇒ page 118 .
l purpos
3 - Nut
nform
ercia
moving
m
❑ 106 Nm
com
tion in
r
4 - Bolt
te o
thi
s
iva
do
5 - Bolt
r
rp
cum
fo

en
ng
t.
yi
moving
Co
Cop py
. rig
❑ M10: 60 Nm
t
gh ht
pyri by
Vo
o
❑ M12: 120 Nm
c by lksw
cted agen
Prote AG.
6 - Clamp
7 - Anti-roll bar
⇒ page 116
8 - Rubber mounting
9 - Rear axle
2. Anti-roll bar 115

Crafter 2006 ➤
2.2 Assembly overview - anti-roll bar, vehicles with twin wheels
1 - Bracket for coupling rod

❑ Welded to vehicle
frame.
2 - Nut
moving
❑ 106 Nm
3 - Bolt
4 - Clamp
5 - Bolt
moving
❑ M10: 60 Nm
❑ M12: 120 Nm agen
AG. Volkswagen AG d
oes
olksw not
6 - Coupling rod byV gu
ara
ed
ris nte
❑ Renewing rubber bush ut
ho eo
ra
⇒ page 122 ss a c
ce
le

un
pt
an
⇒ page 117
d
itte
y li
erm
ab
7 - Anti-roll bar
ility
ot p
❑ Renewing rubber bush
wit
is n
h re
⇒ page 120
ole,
spec
⇒ page 117
t to the co
8 - Rubber mounting
9 - Rear axle
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
2.3 Removing and installing anti-roll bar

thi
te
sd
iva
o
r
Removing
p
cum
r
fo
en
ng
t.
yi Co
Cop py
Note ht. rig
rig ht
py by
co Vo
by lksw
♦ Renew anti-roll bar if corrosion protective layer is damaged.
cted agen
Prote AG.
♦ If components with bonded rubber bushes are renewed or nuts

or bolts on these components are loosened, the unladen po‐
sition must be measured before starting work ⇒ page 2 .
WARNING
platform.

Crafter 2006 ➤
– Remove bolt -1-.

– Unscrew nut -2-.
3 - Coupling rod
– Swing anti-roll bar -5- together with coupling rod -1- down‐
wards until lower bolt -2- can be pulled out (past spring -6-).
– Remove clamp -4- and rubber bush -5-.
– Remove anti-roll bar downwards.
Installing
Caution

Therefore, tighten the bolted connections
wage
n AG. of
Volcomponents
kswagen AG
doewith
bonded rubber bushes only ywhen Volks
the axle beam is raiseds norot g
when the vehicle is standing
ir se on its wheels (in the unladen po‐
db ua
ran
sition) ⇒ page 2 . utho tee
or
a ac
ss
ce
e
nl
pt
du
– Centre anti-roll bar before tightening clamps. The anti-roll bar

an
itte
must be aligned at 90° to contact surface and installed.

y li
erm
ab
ility
– Then connect the anti-roll bar to the coupling rod.

ot p
wit
, is n
Specified torques
h re
hole
spec
♦ ⇒ “2.1 Assembly overview - anti-roll bar”, page 115

es, in part or in w
t to the co
2.4 Removing and installing anti-roll bar, ve‐

rrectness of i
l purpos
Removing
nform
ercia
Note
m
at
om
io

n
c
in t
r

o
his
te

a
do
priv
cum
for
en
g

n
t.
yi Co
Cop py
t. rig
gh ht
yri
WARNING p by
co Vo
by lksw
cted agen
Prote AG.
platform.

Crafter 2006 ➤
– Unscrew nuts -4-.

– Remove upper bolt from coupling rod bracket -5- and swing
anti-roll bar -2- together with coupling rod -1- downwards until
lower bolt can be pulled out (past spring -3-).

– Take off clamp -1- and rubber bush -3-.
– Remove anti-roll bar from below.
Installing
Caution

– Centre anti-roll bar before tightening clamps. The anti-roll bar

must be aligned at 90° to contact surface and installed. AG. Volkswagen AG d
agen oes
ksw
– Then connect the anti-roll bar to the coupling rod. byV
ol not
gu
d ara
ise nte
or eo
h
aut ra
Note ss c ce
le
un
pt
The coupling rods are adjustable, they must have the same length
an
d
itte
y li
on both sides.
erm
ab
ility
ot p
wit
Specified torques
is n
h re
ole,
♦ ⇒ “2.2 Assembly overview - anti-roll bar, vehicles with twin

spec
wheels”, page 116

t to the co
2.5 Removing and installing coupling rods,

rrectne

wheel drive
ss o
cial p
f inform
Note
mer
atio
om
♦ Coupling rods are adjustable. They must have the same length
n
c
i
or
on both sides.
thi
te
sd
va
♦ Renew anti-roll bar if corrosion protective layer is damaged.

i
o
pr
cum
r
fo
en
ng
♦ If components with bonded rubber bushes are renewed or nuts

t.
yi Co
or bolts on these components are loosened, the unladen po‐ Cop py
ht. rig
sition must be measured before starting work ⇒ page 2 . rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Removing
t to the co
Note
rrectne
The following procedure is for the left side of the vehicle. The
s
procedure for the right side is identical.

s o
cial p
f inform

mer
atio
om
n
c
WARNING
i
or
n thi
te
sd
va
i
o
pr
cum
r
platform.
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Remove bolt -1-.

– Unscrew nut -3-.
– Remove coupling rod -2-. AG. Volkswagen AG d
agen oes
lksw not
Installing d by Vo gu
ara
rise nte
Install in reverse order. Note the uthfollowing
o points: eo
ra
s a c
s
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
♦ Check that dust caps are undamaged and correctly seated.
ility
ot p
wit
is n
♦ Tapered pin must be free of oil and grease.
h re
ole,
spec
♦ If necessary, clean with a dry cloth but do not use cleaning
solutions.
t to the co
Caution
rrectne
ss
o
cial p
f
inform
mer
atio
om
n
c
i
or
n thi
te
– Fit coupling rod -2-, insert bolt -1- and tighten nut first hand-
sd
iva
o
r
tight and then to specified torque.

p
cum
r
fo
en
ng
t.
yi Co
– Insert coupling rod -2- into anti-roll bar and tighten nut -3- first t. Cop py
hand-tight and then to specified torque.
rig
gh ht
pyri by
Vo
co
Specified torques
by lksw
cted agen
Prote AG.
Components Specified torque

Upper bolt with nut -1- on coupling rod 106 Nm
♦ Use new nut
♦ When loosening and tightening, counterhold nut.
Coupling rod nut -3- 106 Nm

♦ Use new nut
2.6 Renewing anti-roll bar bushes, vehicles with twin wheels

Crafter 2006 ➤

equipment required
♦ Tube - 2040-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
– Remove anti-roll bar ⇒ page 117 .

erm
ab
ility
ot p

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
AG. Volkswagen
Before pressing in new rubber bush, coat itlkswith
wageacid-free lubri‐ does n
n AG
cant, e.g. soft soap. db
y Vo ot g
ua
e ran
ris tee
– Press in rubber bush until shoulders
ut
ho project evenly on both or
sides. ss
a ac
ce
le
– Install anti-roll bar ⇒ page 117 .
un
pt
an
d
itte
y li
Specified torques
erm
ab
ility
ot p
wit
is n
wheels”, page 116
h re
ole,
spec
t to the co
2.7 Renewing coupling rod bushes, vehicles with twin wheels
rrectne
ss
equipment required
o
cial p
f inform
mer
atio
om
n
c
i
or
n
♦ Tube - 2040-
thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove coupling rod ⇒ page 117 .

Crafter 2006 ➤

sides.
– Install coupling rod ⇒ page 117 .
Specified torques
wheels”, page 116 olks
wage es n
o
yV t gu
db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
3 Suspension strut, shock absorber,

spring
⇒ “3.1 Removing and installing shock absorbers”, page 124
3.1 Removing and installing shock absorb‐

ers
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
Removing horis nte
eo
aut ra
– Raise vehicle and strap it down ⇒ Maintenance
ss ; Booklet 10.2 . c
ce
le
un
pt
an
d
itte
WARNING
y li
rm
ab
pe
ility
ot
wit
, is n
platform.
h re
hole
spec
es, in part or in w
t to the co
– Raise rear axle slightly using engine and gearbox jack - V.A.G
1383 A- to relieve shock absorber
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
124
op Vo
by c lksw
Rep. gr.42 - Rear suspension Prote
cted AG.
agen
Crafter 2006 ➤
– Unscrew bolt -2- and remove shock absorber from mounting.

– Unscrew bolt -1- from longitudinal member and remove shock
absorber -3- from vehicle.
Installing
Specified torques agen
AG. Volkswagen AG d
oes
olksw not
V gu
♦ ⇒ “1.1 Assembly overview
d by - rear axle”, page 92 ara
rise nte
o eo
♦ ⇒ “1.2 Assembly
aut overview - rear axle, vehicles with twin
h
ra
wheels”, page
s 95
s c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Suspension strut, shock absorber, spring 125

Crafter 2006 ➤
4 Wheel bearing assembly, trailing arm

⇒ “4.1 Assembly overview - wheel bearing assembly”,
page 126
⇒ “4.2 Assembly overview - wheel bearing unit, vehicles with twin
wheels”, page 127
⇒ “4.3 Removing and installing wheel bearing unit, vehicles with
⇒ “4.4 Removing and installing wheel hub, vehicles with twin
wheels”, page 131
⇒ “4.5 Adjusting wheel bearing play, vehicles with twin wheels”,
page 132
4.1 Assembly overview - wheel bearing assembly
1 - Rear axle shaft

❑ With wheel bearing/
wheel bearing unit
❑ ABS sensor ring is in‐
stalled in wheel bearing.
⇒ page 110 .
2 - Splash plate for brakes
3 - Rear axle
4 - Bolt
moving
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Tighten bolts in stages in the sequence shown:

com
tion in
r
te o
stage Bolts Specified torque/turning further angle

thi
s
iva
do
1. -4- 30 Nm
r
rp
cum
fo
2. -4- 100 Nm
en
ng
t.
yi Co
op
3. -4- Loosening bolt
C py
t. rig
gh ht
pyri by
Vo
o
126
by c lksw
cted
Rep. gr.42 - Rear suspension
agen
Prote AG.
Crafter 2006 ➤
stage Bolts Specified torque/turning further angle

4. -4- 30 Nm
5. -4- Tighten further to 45°.
4.2 Assembly overview - wheel bearing unit, vehicles with twin wheels
1 - Rear axle
2 - Shrink ring
❑ Check for scoring.
⇒ page 113
3 - Rotor for speed sensor
⇒ page 128
4 - Sealing ring
5 - Shielding ring n AG. Volkswagen AG do
lkswage es n
o ot g
yV
6 - Inner wheel bearing ir se
d b ua
ran
o tee
❑ Renewing ⇒ pagea128 uth . or
ac
ss
7 - Wheel hub
ce
le
un
pt
an
d
itte
y li
⇒ page 131
rm
ab
pe
ility
8 - Brake disc
ot
wit
, is n

h re
hole
⇒ Brake systems; Rep.

gr. 46 . spec
es, in part or in w
t to the co
9 - Flange
rrectness of i
⇒ page 135
l purpos
10 - Bolt
moving
nform
ercia
❑ 80 Nm +40°
m
a
com
tio
11 - Stud
n in
r
te o
thi
12 - Wheel bolt
s
iva
do
r
rp

cum
fo
en
ng
t.
13 - Wheel nut
yi Co
Cop py
❑ Specified torque: ⇒ page 135
t. rig
gh ht
pyri by
Vo
o
14 - Outer wheel bearing
c by lksw
cted agen
Prote AG.
15 - Thrust washer
16 - Inner slotted nut
❑ Chamfer points outwards
❑ Setting wheel bearing play ⇒ page 132 .
17 - Locking plate
18 - Outer slotted nut
❑ Chamfer points inwards
4. Wheel bearing assembly, trailing arm 127

AG. Volkswagen AG d
agen oes
Crafter 2006 ➤ Volksw not
gu
y
Running gear, axles, steering - Edition 12.2015 rise
d b ara
nte
tho eo
u
❑ Setting wheel bearing play ⇒ page 132 . ss a ra
c
❑ 250 Nm
ce
le
un
pt
an
d
itte
19 - Rear axle shaft
y li
erm
ab
ility
ot p
wit
is n
20 - Self-locking nut
h re
ole,
spec
❑ 70 Nm
t to the co
rrectne
4.3 Removing and installing wheel bearing unit, vehicles with twin wheels
ss o
Special tools and workshop cial p
f in
equipment required
form
mer
atio
om
n
c
i
or
n thi
te
sd
a
♦ Support - VW 441-
iv
o
pr
cum
r
fo
♦ Thrust piece - VW 442-
en
ng
t.
yi Co
op
♦ Removing and installing C py
t. rig
tool - VW 459/1-
gh ht
pyri by
Vo
co lksw
by
♦ Assembly tool - 3253/1- cted agen
Prote AG.

Crafter 2006 ➤
♦ Special wrench - T10202-
♦ Assembly tool - T10214/3-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove rear wheel hub ⇒ page 131 .
– Insert suitable punch in both holes -arrows- of wheel hub.
rrectness of i
– Drive rotor -1- out of wheel hub -2-.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
– Prize sealing ring -1- out of wheel hub using a screwdriver out copy Vo
by lksw
of wheel hub -2-. cted agen
Prote AG.

Crafter 2006 ➤
– Remove shielding ring -1- and inner wheel bearing -2- from
wheel hub -3-.
– Drive outer race of inner wheel bearing -1- and outer wheel
bearing -3- with a copper drift outAof wheel
G. V hub
olkswagen A -2-.
agen G do
es n
ksw
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Press in new outer race for inner wheel bearing. t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
– Press in new outer race for outer wheel bearing.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Before installing, grease new wheel bearing with universal

grease ⇒ Electronic Parts Catalogue (ETKA) .
– Fit new wheel bearing -2- and shielding ring -1-.
Renew shielding ring if damaged.
– Press in new sealing ring.
– Press in new rotor.

– Install rear wheel hub ⇒ page 131 .
Specified torques
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
4.4 Removing and installing wheel hub, ve‐

du
an
itte
y li

erm
ab
ility
ot p
wit

, is n
h re
hole

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
Removing
o
m
f
en
ng
t.
– Remove rear axle shaft ⇒ page 112
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
131
cted agen
Prote AG.
4. Wheel bearing assembly, trailing arm
Crafter 2006 ➤
– Remove wheel.
– Remove brake caliper together with brake carrier, and secure
it with wire so that weight of brake caliper does not stress or
damage brake hose ⇒ brake systems; Rep. gr. 46 .
– Remove brake disc ⇒ Brake systems; Rep. gr. 46 .
n AG. Volkswagen A ge G do
swa es
– Release outer nut -1- by bbending
yV
olk locking plate -arrow- back.
not
gu
a
ed ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew outer slotted nut with special wrench - T50017- .
rrectness of i
– Remove locking plate.
l purpos
– Unscrew inner slotted nut with special wrench - T50017- .
nform
ercia
– Remove thrust plate and outer tapered roller bearing from axle
tube.
m
at
om
io
– Pull wheel hub off axle tube.
n
c
in t
or
his
e
Installing
at
do
priv

um
for
en
ng
t.
yi Co
Cop py
t. rig
Note
gh ht
pyri by
Vo
co lksw
by
cted agen
Always use a new locking plate for the outer slotted nut. Prote AG.

– Installing rear axle shaft ⇒ page 112 .
– If fitted, install wheel flange ⇒ page 135 .
– Install brake disc ⇒ Brake systems; Rep. gr. 46 .
– Install brake carrier and brake caliper ⇒ Brake systems; Rep.
gr. 46 .
– Fitting wheel ⇒ page 135 .
Specified torques
4.5 Adjusting wheel bearing play, vehicles with twin wheels

Crafter 2006 ➤

equipment required
♦ Universal dial gauge holder
- VW 387-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
– Remove rear axle shaft ⇒ page 112 .

or
n thi
te
sd
a
– Loosen outer slotted nut and remove locking plate

iv
o
pr
⇒ page 131 .
um
r
fo
en
ng
t.
yi
1- Tighten inner slotted nut to 300 Nm using special wrench -
Co
op py
T50017- (when doing this, turn wheel hub so that wheel
t. C rig
gh ht
yri
bearing does not become jammed). p by
o Vo
by c lksw
cted agen
2- Loosen inner slotted nut 1/2 turn with wrench - T50017-
Prote AG.
(when doing this, turn wheel hub so that wheel bearing does
not become jammed).
– Tighten inner slotted nut with special wrench - T50017- by
hand until it rests against thrust plate (now wheel bearing has
zero play).
– Loosen inner slotted nut 1/8 turn.
– Fit new locking plate.

– Fit outer slotted nut and tighten it.
Outer slotted nut 250 Nm

Crafter 2006 ➤
– Secure dial gauge - VAS 6079- with universal dial gauge hold‐
er - VW 387- to wheel hub.
– Create 2 mm preload on dial gauge and set adjuster ring to
“0”.
– Measure wheel bearing play by firmly moving wheel hub back‐
wards and forwards in axial direction.
– Set wheel bearing play to 0.02 ... 0.04 mm by turning inner
slotted nut.
Note
AG. Volkswagen AG d
agen oes
ksw
When measuring the wheel by
V bearing play, ensure that the
ol not
gouter
ua
slotted nut is tightened rised
to specified torque! ran
tee
tho
u or
a ac
ss
– Bend down locking plate -arrow-.
ce
le
un
pt
an
d
itte
1 - Outer slotted nut

y li
rm
ab
pe
ility
– Installing rear axle shaft ⇒ page 112

ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
44 – Wheels, tyres, vehicle geometry

1 Wheels, tyres
⇒ “1.1 Specified torque for wheel bolts”, page 135
⇒ “1.2 Renewing wheel bolts, vehicles with twin wheels”,
page 135
1.1 Specified torque for wheel bolts

When installing wheel, adhere to the following assembly se‐
quence under all circumstances, as imbalance may otherwise
occur in the vehicle.
1- Position wheel
2- Install wheel bolts or wheel nuts.
3- To centre, pre-tighten wheel bolts or wheel nuts diagonally
by hand.
4- Tighten wheel bolts or wheel nuts diagonally.
Specified torque
Wheel bolt to wheel hub for 240 Nm
steel wheels
Wheel bolt to wheel hub for al‐ 180 Nm
loy wheels
Wheel nuts to wheel bolts/studs 180 Nm
WARNING
After the vehicle has been driven 50 km, the wheel nuts or bolts
must be retightened. G. Volkswage nA n AG d
wage oes
Volks not
gu
by ara
ed
1.2 Renewing wheel bolts, vehicles with twin wheels thoris nte
eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
135
copy Vo
by lksw
cted agen 1. Wheels, tyres
Prote AG.
Crafter 2006 ➤

equipment required
♦ Removing and installing
tool - VW 459/2-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
– Loosen wheel nuts.

y li
erm
ab
ility

ot p
wit
, is n
h re
hole
WARNING
spec
es, in part or in w
t to the co
platform.
rrectness of i
– Remove wheel.
l purpos
– Unscrew bolts -3- and remove wheel flange -2-.

nf
ercia
Rear axle
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
136 Rep. gr.44 - Wheels, tyres, vehicle geometry

Crafter 2006 ➤
– Unscrew bolts -2- and remove flange -1-.

– Drive out wheel bolts -1-, e.g. using an aluminium hammer.
– Press in wheel bolts. AG. Volkswagen AG d

agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
When pressing in, ensure that milled side of wheel bolt comes
into contact with wheel flange edge -arrow-.
rrectne
A - Wheel flange
B - Wheel bolt ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
– Tighten new bolts -3-. C py
t. rig
gh ht
yri by
Rear axle cop Vo
by lksw
cted agen
Prote AG.
1. Wheels, tyres 137

Crafter 2006 ➤
– Tighten new bolts -2-.

Specified torques
page 61
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
2 Tyre pressure monitoring system

⇒ “2.1 Assembly overview - tyre pressure sensor”, page 139
⇒ “2.2 Removing and installing tyre pressure sensor G222 /
G223 / G224 / G225 ”, page 141
⇒ “2.3 Changing wheels on vehicles with Tyre Pressure Monitor‐
ing System”, page 144
⇒ “2.4 Changing tyres on vehicles with tyre pressure monitoring
system”, page 145
2.1 Assembly overview - tyre pressure sen‐

sor
⇒ “2.1.1 Assembly overview - tyre pressure sensor, Schrader”,
page 139
⇒ “2.1.2 Assembly overview - tyre pressure sensor, Siemens”,
page 141
2.1.1 Assembly overview - tyre pressure sensor, Schrader
Note
The nominal pressures are stored in the tyre pressure monitor control unit - J502- and only require changing
on switching tyre dimensions, e.g. in the case of different summer and winter tyres. New or different tyre pres‐
sure sensors are automatically taught-in by the system.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Tyre pressure monitoring system 139

Crafter 2006 ➤
1 - Tyre pressure sensor

❑ Front left tyre pressure
sensor. - G222-
❑ Front right tyre pressure
AG. Volkswagen AG d
sensor - G223- ksw
agen oes
not
Vol
❑ Rear left tyre pressure
d by gu
ara
sensor - G224- rise nte
tho eo
u ra
❑ Rear rightsstyre
a pressure c
sensor - G225-
ce
le
un
pt
❑ With metal valve
an
d
itte
y li
erm
ab
ility
⇒ page 141 .
ot p
wit
is n
2 - Valve core
h re
ole,
spec
❑ Always renew when
changing tyre
t to the co
3 - Rim
4 - Union nut
rrectne
❑ 6 Nm
ss
♦ In the union nut is a micro-
o
cial p
f
encapsulation with locking
inform
fluid that is activated when
mer
tightening the nut. This du‐
atio
m
rably locks the union nut to

o
n
c
the metal valve.

i
or
n thi
te
sd
a
♦ The union nut must be re‐

iv
o
pr
placed after loosening from

um
r
fo
en
ng
the metal valve. yi

t.
Co
op
C py
t. rig
gh
moving.
ht
pyri by
Vo
co lksw
by
5 - Valve cap
cted agen
Prote AG.

Crafter 2006 ➤
2.1.2 Assembly overview - tyre pressure sensor, Siemens

AG. Volkswagen AG d
agen oes
olksw not
V gu
1 - Tyre pressure sensor d by ara
ise nte
or
❑ Front left tyre pressure aut
h eo
ra
sensor. - G222- ss c
ce
le
❑ Front right tyre pressure
un
pt
an
d
sensor - G223-
itte
y li
erm
ab
❑ Rear left tyre pressure
ility
ot p
sensor - G224-
wit
is n
❑ Rear right tyre pressure
h re
ole,
sensor - G225-
spec
t to the co
⇒ page 142 .
2 - Bolt
rrectne
❑ Square-head bolt with
flat head
ss
❑ Is supplied as a replace‐
o
cial p
f
ment part complete with
inform
the tyre pressure sensor
mer
⇒ Electronic Parts
atio
m
Catalogue “ETKA”
o
n
c
i
or
n thi
3 - Metal valve
te
sd
va
❑ Is supplied as a replace‐
i
o
pr
cum
r
ment part complete with

fo
en
ng
the tyre pressure sensor

t.
yi Co
op
⇒ Electronic Parts
C py
t. rig
gh
Catalogue “ETKA”
ht
pyri by
Vo
o
by c lksw
4 - Valve core
cted agen
Prote AG.
❑ Always renew when
changing tyre
5 - Rim
6 - Union nut
❑ 6 Nm
♦ When tightening, do not
use metal valve as a coun‐
terhold.
♦ The result of a disc being placed in the union nut is that the metal valve is first screwed onto the tyre pressure
sensor when the nut is tightened. The tyre pressure sensor is screwed onto the rim after the disc breaks.
❑ Always renew after removing.
7 - Valve cap
2.2 Removing and installing tyre pressure

sensor -G222- / -G223- / -G224- / -
G225-
⇒ “2.2.1 Removing and installing tyre pressure sensor, Schrader”,
page 141
⇒ “2.2.2 Removing and installing tyre pressure sensor, Siemens”,
page 142
2.2.1 Removing and installing tyre pressure

sensor, Schrader

Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
Removing ss a ra
c
ce
le
– Remove tyre from rim ⇒ page 139 .

un
pt
an
d
itte
y li
– Turn nut -1- anti-clockwise until tyre pressure sensor -2- can
erm
ab
be removed.
ility
ot p
wit
is n
Installing
h re
ole,
spec
Caution
t to the co
♦ Before installing tyre pressure sensor , clean valve hole.
rrectne
– Insert metal valve into valve hole in rim.
ss o
cial p
f in
Caution
form
mer
atio
♦ In the union nut is a micro-encapsulation with locking fluid

om
that is activated when tightening the nut. This durably

c
i
or
n thi
locks the union nut to the metal valve.

te
sd
iva
o
r
♦ The union nut must be replaced after loosening from the

p
cum
r
fo
metal valve.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Tighten new union nut to specified torque. op Vo
by c lksw
cted agen
Prote
– Install tyre on rim ⇒ page 139 .
AG.
Specified torques
♦ ⇒ “2.1.1 Assembly overview - tyre pressure sensor, Schrader”,
page 139
2.2.2 Removing and installing tyre pressure

sensor, Siemens

Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Removing
t to the co
– Remove tyre from rim ⇒ page 139 .
rrectness of i
– Turn nut -1- anti-clockwise until tyre pressure sensor -2- can
be removed.
l purpos
Note
nf
ercia
orm
m
atio
When the nut -1- is turned, the valve turns as well.
om
n in
or c
thi
e
Installing
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
Caution t. C rig
gh ht
pyri by
Vo
o
by c lksw
♦ Always completely renew tyre pressure sensor and metal Prote
cted agen
valve
AG.
♦ Before installing tyre pressure sensor , clean valve hole.

Crafter 2006 ➤
– The metal valve -3- is bolted to the tyre pressure sensor using
bolt -5-.
Note
When doing this, ensure the metal valve is not bolted tight on the
sensor.
– Insert metal valve into valve hole in rim.
Caution
♦ When tightening, do not use metal valve as a counterhold.

♦ The result of a washer being placed in the union nut -2- is
that the metal valve is first screwed onto the tyre pressure
sensor when the nut is tightened. The tyre pressure sen‐
sor is screwed onto the rim after the disc breaks.
– Tighten new union nut until the rupture disc breaks

– Tighten new union nut to specified torque.
– Install tyre on rim ⇒ page 139 .
Specified torques
♦ ⇒ “2.1.2 Assembly overview - tyre pressure sensor, Siemens”,
page 141
wage
2.3 Changing wheels on vehicles with Tyre lks es n
o ot g
byV ua
d ran
Pressure Monitoring System tho
ir se tee
or
au ac
If the wheels are changed (e.g. switch from summer to winter
ss
ce
e
tyres), the tyre pressure sensors transmit data as soon as the

nl
pt
du
an
speed of the new wheels exceeds 25 km/h. The ID numbers of

itte
y li
the new tyre pressure sensors are automatically detected and

erm
ab
entered by the control unit.

ility
ot p
wit
, is n
The tyre pressure monitoring control unit - J502- must first switch
h re
to learning mode before it can automatically train the tyre pres‐

hole
spec
sure sensors.
es, in part or in w
t to the co
To do this, the vehicle must remain stationary for 20 minutes.

Following the detection of a flat tyre, this time is 5 minutes.
rrectness of i
If the stationary time is not maintained and the control unit con‐
sequently does not switch to learning mode, the system detects
l purpos
interference in transmission and will learn the tyre pressure sen‐

sors automatically only after a stationary period of 20 minutes.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
Note
♦ When changing wheels, note that only Volkswagen-approved

wheel and tyre combinations with the tyre inflation pressure
specified in the tank flap may be installed.
♦ If unapproved wheel and tyre combinations are installed, they
must possess a certificate from the responsible technical in‐
spection authority (in Germany, TÜV) for the respective vehi‐
cle, and a second wheel set must be learned via the ⇒ Vehicle
. Volkswagen AG
diagnostic tester ⇒ page 145 . swa
gen AG does
olk not
yV gu
♦ Learning is also necessary if the tyre inflation
ise
d b pressure devi‐ ara
nte
ates from the tyre inflation pressure specified
ho
r in the tank flap eo
ut
⇒ page 145 . ss
a ra
c
ce
le
un
pt
Tyre sets with other specified tyre inflation pressures
an
d
itte
y li
erm
ab
If a vehicle is fitted with tyres requiring nominal tyre inflation pres‐
ility
ot p
sures other than those specified on the tank flap sticker, these
wit
tyres (second wheel set) can also be monitored with the TPM
is n
h re
system.
ole,
spec
Nominal tyre inflation pressures for the second wheel set must be
t to the co
specified to the system with the ⇒ Vehicle diagnostic tester.
The tyre pressure sensors for the wheels of the second wheel set
are not automatically detected and trained by the TPM system
rrectne
(unlike the tyre pressure sensors for the wheel set with Volkswa‐
gen-approved wheel and tyre combinations).
ss o
The following work has to be performed to switch to the second
cial p
f in
wheel set:
form
mer
♦ Read ID numbers (IDs) of the tyre pressure sensors prior to
atio
m
installation.
o
n
c
i
or
n thi
e
♦ Switch the TPM to wheel set 2.

t
sd
iva
o
pr
c
♦ Enter the necessary nominal tyre pressures and the IDs of the
um
r
fo
en
ng
tyre pressure sensors in the system.

t.
yi Co
op py
2.4 Changing tyres on vehicles with tyre
t. C rig
gh ht
pyri by
pressure monitoring system
co Vo
by lksw
cted agen
Prote AG.
Pressing tyre off wheel rim
Caution
♦ Comply with the notes on safety and conditions

⇒ page 1
– Remove air from tyre by screwing out the nickel-plate valve

element.

Crafter 2006 ➤
– When pressing off a tyre using tyre fitting equipment with a

press-off plate, always ensure that the tyre valve/ tyre pres‐
sure sensor -arrow- is directly opposite the bead breaker -1-.
The bead breaker must be positioned no more than 2 cm from
wheel rim flange.
Volkswa
– Remove balancing weights and sdirt
wagefrom wheel rim. does
n AG. gen AG
olk not
yV gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
– Press both tyre beads off all round and liberally coat tyre and
ot p
wheel rim flange with tyre assembly paste -arrow-.
wit
, is n
h re
hole
Removing tyre from wheel rim
spec
es, in part or in w
t to the co
Caution
♦ Comply with the notes on safety and conditions
rrectness of i
⇒ page 1
l purpos
♦ The assembly head must never be within area -a- of tyre

valve/tyre pressure sensor, or the assembly head will
nform
ercia
damage the tyre pressure sensor .

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

wage es n
yV
olks ot g Crafter 2006 ➤
b ua
ir se
d Running gear, axles, steering ran - Edition 12.2015
tee
ho
aut or
ac
– Position wheel on tyre assembly
ss unit so that the tyre valve/
tyre pressure sensor is located in front of assembly head.
ce
le
un
pt
an
d
itte
– Position assembly head near tyre valve/ tyre pressure sensor
y li
erm
ab
so that an assembly lever can be inserted approx. 30° next to
ility
ot p
the tyre valve/ tyre pressure sensor .
wit
is n
h re
– Lever tyre bead over assembly finger on assembly head using
ole,
assembly lever then remove assembly lever.
spec
t to the co
– Run tyre fitting unit clockwise until upper bead lies completely
above wheel rim flange.
– Position wheel on tyre assembly unit so that the tyre valve/
rrectne
tyre pressure sensor is located in front of assembly head.
ss o
cial p
f
Note
inform
mer
If the tyre pressure sensor is damaged or loose, then replace the
atio
m
complete item ⇒ page 141 .

o
n
c
i
or
n thi
te
sd
a
Fitting tyres
iv
o
pr
cum
r
fo
en
ng
t.
Caution
yi Co
Cop py
t. rig
gh ht
yri
♦ Comply with the notes on safety and conditions p by
co Vo
⇒ page 1
by lksw
cted agen
Prote AG.
Note
If the tyre pressure sensor is damaged or loose, then replace the

complete item ⇒ page 141 .
– Liberally apply tyre assembly paste to wheel rim flanges, tyre

beads and inner side of the upper tyre beads.
The inside of the tyre must be fitted first.

Crafter 2006 ➤
– Turn rim on tyre fitting unit so that tyre valve with tyre
wage
pressure
n AG. Volkswagen AG
does
sensor -arrow- is directly opposite assembly yV
o head.
lks not
gu b ara
ed
– Press tyre into drop centre in -direction
ris of arrow- between tyre nte
tho e
valve with tyre pressure sensor sand
au assembly head. or
ac
s
– Allow the tyre fitting unit to turn in a clockwise direction.
ce
le
un
pt
an
d
itte
– Stop the fitting of lower bead before reaching tyre valve/ tyre
y li
erm
ab
pressure sensor to prevent damage to tyre pressure sensor .
ility
ot p
wit
The tyre bead will now slide over the wheel rim flange. The wheel
is n
h re
rim may be turned only until the assembly head is just before the
ole,
tyre valve/ tyre pressure sensor .
spec
t to the co
– Check to ensure that tyre bead is seated correctly on assembly
head and run tyre fitting machine clockwise.
– Stop the fitting of upper bead before reaching tyre valve/ tyre
rrectne
pressure sensor to prevent damage to tyre pressure sensor .
The tyre bead will now slide over the wheel rim flange. The wheel
ss o
rim may be turned only until the assembly head is just before the
cial p
f i
tyre valve/ tyre pressure sensor .
nform
mer
– Fill tyres to a maximum tyre pressure of 3.3 bar (bead seating
atio
m
pressure).
o
n
c
i
or
n thi
te
sd
a
Caution
iv
o
pr
cum
r
fo
en
ng
Never increase the inflation pressure when the tyre bead does
t.
yi Co
op
not lie completely against the wheel rim flange. C py
t. rig
gh ht
yri by
This would lead to prior damage to the tyre and/or the wheel cop Vo
by lksw
rim. cted agen
Prote AG.
– When the tyre bead does not lie completely against the wheel
rim flange: deflate the tyre, press tyre bead off wheel rim flange
and generously coat again with tyre assembly paste.
– Fill tyres to a maximum tyre pressure of 3.3 bar (bead seating
pressure).
– If the tyre beads seat perfectly against the shoulder of the
wheel rim, increase inflation pressure to 4 bar to »seat« the
tyre.
– Screw in new nickel-plated valve core and fill tyre to the pre‐
scribed tyre pressure.
– Then, balance the wheel.
– Fit wheel.
Specified torques

Crafter 2006 ➤
3 Wheel alignment
AG. Volkswagen AG d
⇒ “3.1 Notes for wheel alignment”, page 149 agen oes
olksw not
y V gu
b ara
⇒ “3.2 Necessity of wheel alignment”, page 150 rise
d
nte
tho eo
⇒ “3.3 Test preparations”, page 151 ss au ra
c
ce
le
⇒ “3.4 Test prerequisites”, page 152
un
pt
an
d
itte
y li
⇒ “3.5 Determining ride height”, page 152
erm
ab
ility
ot p
⇒ “3.6 Specified values for wheel alignment”, page 153
wit
is n
h re
⇒ “3.7 Specified values for wheel alignment”, page 157
ole,
spec
⇒ “3.8 Adjusting camber on front axle”, page 157
t to the co
⇒ “3.9 Adjusting toe on front axle”, page 158
⇒ “3.10 Adjusting caster on front axle”, page 159
rrectne
3.1 Notes for wheel alignment
ss
o
cial p
f inform
♦ Wheel alignment computer - V.A.G 1813- or VW/Audi-ap‐
mer
proved wheel alignment units
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Brake pedal depressor - V.A.G 1869/2-
Wheel alignment must be performed only using a VW/AUDI-ap‐

proved wheel alignment unit!
Whenever wheels are aligned, both the front and rear axles must
be measured.
Otherwise, the steering rack may not be centred!
– Carry out alignment with the wheel alignment computer.
All the information required to perform alignment can be found in
the wheel alignment computer.
⇒ VW Service Net; Systems; Software wheel alignment comput‐
er; Beissbarth
3. Wheel alignment 149

Crafter 2006 ➤
. Volkswage AG n AG d
agen oes
olksw not
⇒ VW Service Net; Systems; Software d b wheel alignment
yV comput‐ gu
ara
er; Hunter rise nte
ho eo
ut ra
⇒ VW Service Net; Systems; sSoftware
sa wheel alignment comput‐ c
er; Corghi
ce
le
un
pt
an
d
⇒ VW Service Net; Systems; Software wheel alignment comput‐
itte
y li
rm
er; John Bean
ab
pe
ility
ot
3.2 Necessity of wheel alignment
wit
, is n
h re
hole
♦ The vehicle does not handle properly.
spec
es, in part or in w
t to the co
♦ Vehicle has been involved in an accident and components
have been renewed.
♦ Axle components are removed or renewed.
rrectness of i
♦ Tyres are worn more on one side.
l purpos
Front axle component was renewed. Alignment necessary
nform
ercia
Yes No
m
a
Lower suspension link X
com
tion in
Wheel bearing housing X
r
te o
thi
s
Track rod/track rod ball joint X
iva
do
r
rp
cum
Steering rack X
fo
en
ng
t.
yi
Subframe X
Co
Cop py
t. rig
Front shock absorber opyri
gh by
Vo X ht
Anti-roll bar X
c by lksw
cted agen
Prote AG.
Front leaf spring X
Front axle component removed and reinstalled Alignment necessary

Yes No
Steering rack X
Subframe X
Front shock absorber X
Anti-roll bar X
Rear axle
All camber and toe values on the rear axle are prescribed by the
design. If measured values exceed tolerances, they can only be
corrected/restored by replacing defective/damaged components.
(Crafter 4MOTION with Achleitner four-wheel drive)
♦ The vehicle does not handle properly.
♦ Vehicle has been involved in an accident and components
have been renewed.
♦ Axle components are removed or renewed.
♦ Tyres are worn more on one side.

Crafter 2006 ➤
Front axle component was renewed. Alignment necessary

Yes No
Wheel bearing housing AG.X
Volkswagen AG
agen does
ksw
Track rod/track rod ball joint byV
ol X not
gu
d ara
e
Steering rack horis X nte
eo
ut ra
Subframe ss a X c
ce
le
un
pt
an
d
itte
Anti-roll bar X
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
Front axle component removed and reinstalled Alignment necessary
spec
Yes No
t to the co
rrectne
Steering rack X
ss o
cial p
Subframe X
f inform
mer
atio
Anti-roll bar X
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
Rear axle
um
r
fo
en
ng
t.
yi
All camber and toe values on the rear axle are prescribed by the
Co
op py
design. If measured values exceed tolerances, they can only be
. C rig
ht ht
rig
corrected/restored by replacing defective/damaged components. py by
co Vo
by lksw
cted agen
3.3 Test preparations
Prote AG.

♦ Brake pedal depressor - V.A.G 1869/2-
The existing lateral runout of the wheel must be compensated for,

otherwise the result will be falsified.
If runout compensation is not performed, it is not possible to adjust
toe-in correctly!
Observe information provided by the manufacturer of the wheel
alignment unit:
• Carry out wheel runout compensation.
• Fit brake pedal depressor - V.A.G 1869/2-
• Use brake pedal depressor to depress brake pedal

Crafter 2006 ➤
3.4 Test prerequisites

• Measuring equipment correctly adjusted
• Tyres inflated to correct pressures.
• Vehicle accurately aligned, suspension bounced and rocked
several times
• Suspension, steering and steering linkage checked for exces‐
sive play and damage
• Tread depth difference does not exceed 2 mm on one axle.
• The vehicle ride height at the front and rear has a great influ‐ AG. Volkswagen AG d
ence on the test and adjustment figures. Therefore always agen oes
olksw not
measure vehicle ride height before starting measurements. ed byV gu
ara
ris nte
• When performing adjustment operations, aim as closely asaut
ho eo
ra
possible to the respective specified values. ss c
ce
le
un
• It is not a good practice to perform vehicle alignment until the
pt
an
d
itte
vehicle has been driven 1000 - 2000 km for only then are the
y li
rm
ab
settling operations completed.
pe
ility
ot
• When checking wheel alignment, ensure that sliding plates
wit
, is n
h re
and turntables are not touching end stop.
hole
spec
Please note:
es, in part or in w
t to the co
• The test equipment must be properly adjusted and attached
to the vehicle; observe device manufacturer's operating in‐
structions.
rrectness of i
If necessary, contact the manufacturer for familiarisation with the
l purpos
proper use of the wheel alignment equipment.

Wheel alignment platforms and wheel alignment units and com‐
nform
ercia
puters can lose their calibration over a period of time.

m
a
Wheel alignment platforms and alignment units and computers
com
tion in
should be checked and adjusted as necessary during inspection
r
te o
thi
and maintenance at least once per year!
s
iva
do
r
– Treat these highly sensitive units carefully and conscientious‐

rp
cum
fo
ly!
en
ng
t.
yi Co
op
3.5 Determining ride height
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ The vehicle ride height at the front and rear has a great influ‐
ence on the test and adjustment figures. Therefore always
measure vehicle ride height before starting vehicle alignment
measurements.
♦ Measure both versions of vehicle ride height when calculating
vehicle specification data.
♦ The more exact the vehicle ride height is calculated, the more
exact the vehicle can be located in the specifications tables.

Crafter 2006 ➤
Measuring vehicle ridewheight

gen AGwith wheeln A
. Volkswage housing
G do
es n edge as a ref‐
s a
erence point: y Volk ot g
u b ara
ed n
– Measurethovehicle
ris ride height between centre of wheeltee(meas‐
or
ured on au wheel hub with no wheel cover fitted) -1- and edgeac of
ss
wheel housing -2-.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
3.6 Specified values for wheel alignment
atio
om
n in
or c
⇒ “3.6.1 Specifications tables for front axle of 3.0 t and 3.5 t ve‐
thi
te
hicles (max. permitted front axle loading 1,650 kg)”, page 153
sd
iva
o
r
rp
cu
⇒ “3.6.2 Specification tables for front axle of 3.5 t and 3.88 t ve‐
o
m
f
en
ng
hicles (max. permitted front axle loading 1800 kg)”, page 154
t.
yi Co
Cop py
⇒ “3.6.3 Specification tables for front axle of 4.6 t and 5.0 t vehi‐
ht. rig
rig ht
by
cles (max. permitted front axle loading 1,850 kg)”, page 155 copy Vo
by lksw
cted agen
Prote
⇒ “3.6.4 Specification tables for front axle of 4.6 t and 5.0 t vehi‐
AG.
cles (max. permitted front axle loading 2,000 kg)”, page 155
⇒ “3.6.5 Specification table for rear axle, vehicles from 3.0 t to
3.88 t”, page 156
⇒ “3.6.6 Specification table for rear axle, vehicles from 4.6 t to
5.0 t”, page 156
3.6.1 Specifications tables for front axle of 3.0 t and 3.5 t vehicles (max. permitted
front axle loading 1,650 kg)
Note
These specification tables are only valid for these vehicles.
• Compare the measured height of wheel housing edge -h- to

values in specification table. Measure ride height
⇒ page 152
• Then, select specifications or adjustment figures for the re‐
spective vehicle, and adjust vehicle to these figures.
Height of wheel Toe-in per wheel Camber Caster angel Toe-out on turns with
housing edge steering angle of in‐
-h- in mm ner wheel of 20°
⇒ page 153
460.2 00°02' 00°00' 05°04' 01°36'
465.0 00°04' 00°07' 05°01' 01°32'
469.8 00°06' 00°14' 04°59' 01°28'
474.6 00°08' 00°22' 04°56' 01°24'
479.4 00°10' 00°29' 04°54' 01°20'
484.2 00°12' 00°37' 04°51' 01°16'

Crafter 2006 ➤
⇒ page 153
489.1 00°14' 00°46' 04°49' 01°12'
493.9 00°16' 00°54' 04°46' 01°09'
498.7 00°18' 01°03' 04°44' 01°06'
503.5 00°19' 01°12' 04°42' 01°02'
Tolerances:
Toe-in per wheel Individual figures +/- 5' Permissible deviation le/ri +/- 10'
Camber Individual figures +/- 35' Permissible deviation le/ri +/- 60'
Caster angel Individual figures +/- 30' Permissible deviation le/ri +/- 30'
3.6.2 Specification tables for front axle of 3.5 t and 3.88 t vehicles (max. permitted
front axle loading 1800 kg)
Note AG. Volkswagen AG d

agen oes
olksw not
yV g
These specification tables
ised are only valid for these vehicles. uara
b
nte
r
ho eo
aut ra
• Compare thesmeasured height of wheel housing edge -h- to
s c
ce
e
nl
pt
du
⇒ page 152
an
itte
y li
erm
ab

ility
ot p

wit
, is n
h re
hole
spec

es, in part or in w

t to the co
⇒ page 153
464.7 00°02' 00°00' 05°02' 01°36'
rrectness of i
468.9 00°04' 00°06' 04°59' 01°32'

l purpos
473.0 00°06' 00°12' 04°57' 01°29'

477.2 00°07' 00°19' 04°55' 01°25'
nf
ercia
481.3 00°09' 00°25' 04°53' 01°22'

orm
m
atio
485.5 00°11' 00°32' 04°51' 01°19'

om
n in
c
489.6 00°13' 00°39' 04°48' 01°15'

or
thi
te
sd
493.8 00°14' 00°46' 04°46' 01°12'

iva
o
r
rp
cu
498.0 00°16' 00°53' 04°44' 01°09'

o
m
f
en
ng
t.
yi
502.1 00°17' 01°01' 04°42' 01°06'
Co
Cop py
ht. rig
506.3 00°19' 01°08' 04°40' 01°03'
rig ht
py by
co Vo
510.4 00°20' 01°16' 04°38' 01°01'
by lksw
cted agen
Prote AG.
514.6 00°22' 01°24' 04°37' 00°58'
Tolerances:

Crafter 2006 ➤
Caster angel Individual figures

agen
A+/-
G. V30'
olkswagPermissible
en AG
do deviation le/ri +/- 30'
w es n
olks ot g
byV ua
ed ran
ris tee
tho or
3.6.3 Specification tables for front axle of 4.6 t and 5.0 t vehicles (max. permitted ss
au ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Note ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
⇒ page 152
rrectness of i
l purpos
nform
ercia

m
at
om
⇒ page 153
ion
c
in t
r
482.5 00°02' 00°00' 04°52' 01°38'

o
his
ate
do
riv
486.7 00°03' 00°07' 04°50' 01°36'

p
cum
or
490.8 00°04' 00°14' 04°48' 01°33'

f
en
ng
t.
yi Co
495.0 00°05' 00°21' 04°46' 01°31'
Cop py
t. rig
gh ht
499.1 00°07' yri
00°29' 04°44' 01°29'
p by
co Vo
by lksw
503.3 00°08' 00°37'
cted
04°42' 01°27'
agen
Prote AG.
507.4 00°09' 00°44' 04°40' 01°25'
511.6 00°09' 00°52' 04°38' 01°23'
515.8 00°10' 01°01' 04°36' 01°22'
519.9 00°11' 01°09' 04°34' 01°20'
524.1 00°12' 01°17' 04°32' 01°19'
528.2 00°13' 01°26' 04°31' 01°18'
Tolerances:
3.6.4 Specification tables for front axle of 4.6 t and 5.0 t vehicles (max. permitted
Note

⇒ page 152

Crafter 2006 ➤
⇒ page 153
482.5 00°02' 00°00' 04°52' 01°38'
486.4 00°03' 00°07' 04°50' 01°36'
490.3 00°04' 00°13' 04°48' 01°33'
494.2 00°05' 00°20' 04°46' 01°31'
498.1 00°06' 00°27' 04°44' 01°29'
502.0 00°07' 00°34' 04°42' 01°27'
505.9 00°08' 00°41' 04°41' 01°26'
509.8 00°09' 00°49' 04°39' 01°24'
513.6 00°10' 00°56' 04°37' 01°23'
517.5 00°11' 01°04' 04°35' 01°21'
521.4 00°11' 01°12' 04°34' 01°20'
525.3 00°12' 01°20' 04°32' 01°19'
529.2 00°13' 01°28' 04°33' 01°18'
533.1 00°13' 01°36' 04°29' 01°17'
537.0 00°14' 01°45' 04°27' 01°16'
Tolerances:
AG. Volkswagen AG d
agen oes
lksw not
3.6.5 Specification table for rear axle, vehicles from 3.0 t to 3.88 t Vo gu
by ara
d
rise nte
tho eo
au ra
ss c
Note
ce
e
nl
pt
du
an
itte

y li
erm
ab
ility
ot p
wit
Permitted vehicle gross weight in Toe-in/total toe Camber

, is n
h re
(kg)
hole
spec
Up to 3,500 0°07.5' ± 15' -0°35'+ 5'

es, in part or in w
t to the co
3.6.6 Specification table for rear axle, vehicles from 4.6 t to 5.0 t
rrectness of i
l purpos
Note
nf
ercia
orm

m
atio
om
n in
or c
Permitted vehicle gross weight in Toe-in/total toe Camber

thi
te
sd
a
(kg)
iv
o
r
rp
cu
Up to 5000
o
0°00'± 15' -0°35'+ 5'

m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
3.7 Specified values for wheel alignment

Crafter 4MOTION with Achleitner four-wheel drive
Note
Wheelbase (mm) 3250 3665 4325

Wheel angle / opposite an‐ 33.4° / 30.5°
gle
Min. turning circle (m) 15.5 17.0 19.4
Toe-in 0° 0' ± 10'
Camber 0° 25' ± 15'
Caster 2° 15' ± 20'
Steering knuckle pivot in‐ 6°olkswagen AG
en AG. V
clination ksw
ag does
not
y Vol gu
b
Steering arm (mm) ris
ed 137 ara
nte
ho eo
Steering wheel diameter au
t 390 ra
c
(mm) ss
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
♦ The castor and the camber cannot be adjusted on front axle.
h re
ole,
spec
♦ However, castor or camber must be measured when checking
total running gear geometry and figures checked in respective
t to the co
specifications table.
rrectne
3.8 Adjusting camber on front axle
ss o
cial p
f
Setting on Crafter 4MOTION
inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
sd
The camber can not be adjusted on Crafter 4MOTION with

iva
o
r
Achleitner four-wheel drive.

p
cum
r
fo
en
ng
t.
yi Co
Setting on Crafter Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
Note
agen
Prote AG.
♦ For repairs, adjustment of camber is possible using replace‐

ment part eccentric bolt.
♦ Always measure vehicle ride height before starting camber
measurements and select respective specifications table ac‐
cording to figures measured. Measuring ride height:
⇒ page 152
– Remove bolt -A- and replace it with a new eccentric bolt ⇒

Electronic Parts Catalogue “ETKA” .

Crafter 2006 ➤
Note
But do not fully tighten eccentric bolt.
– Unscrew nut from bolt -B- and renew it ⇒ Electronic Parts

Catalogue “ETKA” .
Note
Tighten nut for bolt -B- slightly.
• Always carry out the steps below in the sequence as listed

here.
– Look up the camber value in the respective specifications table
⇒ page 153 and set this value using bolt -A-.
– Tighten nuts of bolt -B- to specified torque.
– Tighten nuts of bolt -A- to specified torque.
Note
AG. Volkswagen AG d
agen oes
Bolt -A- must not turn when
yV
olksthe nuts are tightened!
w not
gu
b ara
ed nte
oris
– Check adjusted
au
t camber
h value and repeat procedure if neces‐ eo
ra
sary ⇒ pagess 157 . c
ce
le
un
pt
– Check front axle toe and adjust if necessary ⇒ page 158 .

an
d
itte
y li
Specified torques
erm
ab
ility
ot p

wit
is n
page 61
h re
ole,
spec
3.9 Adjusting toe on front axle

t to the co
– Set steering rack to central position, until marks -1- and -2-
align over one another.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Loosen lock nut -A- on left and right track rods and hold track
rod ball joint with an open-end spanner.
– Turn both track rods until specification is attained.
Note
AG. Volkswagen AG d
The steering rack must remain in the centre position. lksw
agen oes
not
Vo gu
by ara
d
ise nte
– Tighten left and right track rod lock nuts to prescribed
thor torque. eo
au ra
ss c
ce
le
un
Note
pt
an
d
itte
y li
rm
ab
♦ After completing adjustments, ensure track rod boots are not
pe
ility
twisted. Twisted boots have a shorter service life.
ot
wit
, is n
h re
♦ If steering wheel is not in centre position on completion of track
hole
spec
rod adjustments, reposition it in “straight” position on steering
es, in part or in w
tube. Removing and installing steering wheel ⇒ page 164 .
t to the co
Specified torques
rrectness of i
l purpos
3.10 Adjusting caster on front axle
nform
mercia
a
Note
com
tion in
r
te o
thi
♦ Caster on front axle cannot be adjusted.
s
iva
do
r
♦ However, caster must be measured when checking total run‐

rp
cum
fo
ning gear geometry and figures checked in respective speci‐
en
ng
t.
yi
fications table.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
4 Front camera for driver assist sys‐ . Volkswag

tems
AG en AG
agen does
olksw not
V g y ua
db ran
⇒ “4.1 Calibrating front camera for driver assistrissystems”,
e
tee
page 160 utho or
a ac
ss
4.1 Calibrating front camera for driver assist
ce
e
nl
pt
du
an
systems
itte
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
The following situations can cause the camera function to be im‐
es, in part or in w
t to the co
paired by sustained poor visibility of the lane marker lines:
♦ The field of view of the camera is soiled or iced over. In this
rrectness of i
case, clean the affected area.
l purpos
♦ The field of view of the camera is fogged over.

The camera’s viewing window must be cleaned manually if there
nform
ercia
is heavy soiling on the inside of the windscreen in the field of view

of the camera. To do this, the control unit and lens hood must be
m
at
om
removed and the windscreen cleaned using cleaning solution.
ion
c
Remove control unit and lens hood ⇒ Electrical system; Rep. gr.
in t
or
his
e
96 ; Front camera for driver assist systems .

at
do
priv
c
Correct calibration is a basic precondition for the front camera for
um
for
driver assist systems - R242- to function without faults.
en
ng
t.
yi Co
op py
The front camera for driver assist systems - R242- must be reca‐ t. C rig
gh ht
librated if: yri
p by
co Vo
by lksw
cted
♦ “No or incorrect basic setting/adaptation” entry is stored in the
agen
Prote AG.
event memory.
♦ The front camera for driver assist systems - R242- was re‐
newed.
♦ Windscreen has been renewed or removed.
♦ Modifications having an effect on the body height have been
made to the car's running gear.
Note
♦ Before calibrating the front camera for driver assist systems,

read out event memory and rectify faults as necessary.
♦ Calibration of the driver assistant system's front camera is
permitted only with the setting device - VAS 6430- !

Crafter 2006 ➤
agen
AG. Volkswagen AG d
oes Running gear, axles, steering - Edition 12.2015
olksw not
y V gua
b
♦ Setting device ris - VAS 6430-
ed ran
tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Calibration board for lane departure warning - VAS 6430/11-
l purpos
♦ ⇒ Vehicle diagnostic tester
nform
ercia
Note
m
at
om
ion
c
in t
r
♦ The front camera for driver assist systems - R242- must be

o
his
e
correctly located in the holder.

at
do
priv
cum
or
♦ The field of view of the camera must be clean and clear.

f
en
ng
t.
yi Co
♦ The distance between the setting device - VAS 6430- and the Cop py
centre point of the hub of the front wheels must be 1,800 mm
t. rig
gh ht
yri by
± 25 mm. op Vo
by c lksw
cted agen
Prote
♦ The calibration board must be positioned centrally on the set‐
AG.
ting device.
♦ Choose a light area with neutral background for calibration,
e.g. headlight adjusting station or wheel alignment station.
♦ During the calibration procedure, make sure that all the car
doors remain closed and that the car's exterior lighting is
switched off.
♦ Setting device - VAS 6430- is not allowed to be moved on
alignment beam.
– Move front wheels to straight-ahead position.

– Turn setting device - VAS 6430- upwards so that alignment
beam is parallel to middle of measurement transducers on
front wheels, in order to perform a correct measurement with
distance measuring unit -1-.
1- Distance measuring unit with tape measure and socket pin
– Position setting device - VAS 6430- at distance -a- of 1,800
mm ± 25 mm from centre point of hub of front wheels to beam
of setting device - VAS 6430- .
Caution
♦ Distance -a- of 1,800 mm ± 25 mm must be measured on

both sides of vehicle and setting device - VAS 6430- must
then be aligned.
♦ Distance -a- must be same on both sides of car.
4. Front camera for driver assist systems 161

Crafter 2006 ➤
– Move setting device - VAS 6430- sideways -arrows B- until

device is located centrally in vehicle longitudinal axis.
– Screw down adjuster screws -2- and -3- slightly to secure set‐
ting device - VAS 6430- against rolling away.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Use adjuster screw -1- to level spirit level -A-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Use adjuster screws -2- and -3- to level spirit level -B-.
– Attach calibrating board for lane departure warning - VAS

6430/11- -1- centrally to setting device - VAS 6430- .
– Position calibrating board for lane departure warning - VAS
6430/11- -1- with a spacing -a- of 1700 mm.
– To do this, adjust height of setting device - VAS 6430- until
dimension -a- of 1700 mm is reached from ground up to cross-
hairs.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
– If vehicle is on a wheel alignment platform,riseheight -b- between
d
nte
surface on which setting device - VASut 6430- stands and sur‐
ho eo
ra
face on which vehicle stands on wheelss a
alignment platform c
must be determined. Calculated value must be added to height
ce
le
un
pt
of calibration board for lane departure warning - VAS 6430/11-

an
d
itte
of 1700 mm.
y li
rm
ab
pe
ility
– Connect battery charger ⇒ Electrical system; General infor‐

ot
wit
mation; Rep. gr. 27 ; Charging battery .

, is n
h re
hole
Concluding work is carried out via ⇒ Vehicle diagnostic tester.

spec
es, in part or in w
– Switch on ignition.
t to the co
– On ⇒ Vehicle diagnostic tester, select “Guided Fault Finding”.

rrectness of i
Body (Rep. Gr. 01;27;50...97)

l purpos
General body repairs
01-Self-diagnosis capable systems

nform
mercia
0087 - Lane departure warning control unit -

a
com
tio
MMPC906
n in
r
te o
thi
0087 - Functions
s
iva
do
r
rp
cum
0087 - Control unit - Calibrated

fo
en
ng
t.
Follow instructions on screen to perform calibration.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Front camera for driver assist systems 163

Crafter 2006 ➤
48 – Steering
1 Steering wheel AG. Volkswagen AG d
agen oes
lksw not
⇒ “1.1 Removing and installing steering wheel”,d page
by
V 164
o gu
ara
ise nte
r
1.1 Removing and installing steering wheel ho eo
aut ra
ss c
Removing
ce
le
un
pt
an
d
itte
– Remove airbag unit on driver side ⇒ General body repairs,
y li
erm
ab
exterior; Rep. gr. 69 ; Passenger protection; Driver side air‐
ility
ot p
bag .
wit
is n
h re
– Turn steering wheel to centre position (wheels in straight-
ole,
ahead position).
spec
– Unscrew bolt -1- and pull steering wheel off steering column.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Guide connectors for airbag unit -2- through aperture in steer‐

ing wheel.
Installing
164 Rep. gr.48 - Steering

Crafter 2006 ➤
lkswage es n
o ot g
– Guide connectors for airbag -2-ethrough
d byV aperture in steering ua
ran
wheel. horis tee
ut or
a ac
– Put steering wheel onto steering
ss column.
ce
e
nl
– Centre markings of steering wheel and steering column
pt
du
an
itte
-arrows- must align.
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Secure steering wheel with bolt -1-.

– Mark bolt with a centre punch mark.
The bolt may be used 5 times.
Specified torque
Bolt for steering wheel 80 Nm
1. Steering wheel 165

Crafter 2006 ➤
2 Steering column
⇒ “2.1 Assembly overview - steering column”, page 166
⇒ “2.2 Removing and installing steering column”, page 167
⇒ “2.3 Removing and installing control unit for electronic steering
column lock J764 ”, page 168
2.1 Assembly overview - steering column
1 - Steering column
⇒ page 167 .
2 - Nuts
moving
❑ Qty. 4
❑ 21 Nm
3 - Eccentric bolt
4 - Intermediate steering shaft
⇒ page 167 .
5 - Bolt AG. Volkswagen AG d
agen
❑ 28 Nm olksw
oes
not
byV gu
ara
d
6 - Nut orise nte
eo
h
ut
❑ Always renew after sre‐
s a ra
c
moving
ce
e
nl
pt
du
❑ 21 Nm
an
itte
y li
erm
ab
7 - Nuts
ility
ot p
❑ Qty. 4
wit
, is n
h re
❑ 8 Nm
hole
spec
8 - Control unit for electronic

es, in part or in w
t to the co
steering column lock - J764-

⇒ page 168 .
rrectness of i
9 - Fastening bolts
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
2.2 Removing and installing steering col‐

umn
Removing
WARNING
The following conditions must be met before starting work on

the electrical system and removing the steering wheel:
♦ Disconnect earth strap from battery ⇒ Electrical system;
Rep. gr. 27 ; Disconnecting and reconnecting battery .
♦ Wheels must be in straight-ahead position.
Failure to comply with these precautions may lead to subse‐
quent failure of the airbag system!
– Note or request radio code on vehicles with coded radio if

AG. Volkswagen AG d
necessary. olkswagen oes
no
V t gu
by
– Turn wheels to straight-ahead
ris
ed position. ara
nte
tho eo
– Remove ignition skey
au with steering wheel in centre position. ra
c
s
ce
e
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

nl
pt
du
necting and reconnecting battery .
an
itte
y li
erm
ab
– Remove nut -arrow- from universal joint behind ABS unit -1-
ility
ot p
and remove bolt.
wit
, is n
h re
– Pull intermediate shaft -2- out of universal joint.
hole
spec
– Remove steering wheel ⇒ page 164 .
es, in part or in w
t to the co
– Remove steering column switch ⇒ Electrical system; Rep. gr.
94 .
rrectness of i
– Remove driver footwell cover ⇒ General body repairs, interior;

Rep. gr. 70 .
l purpos
– Remove steering column trim ⇒ General body repairs, interior;

Rep. gr. 70 .
nform
mercia
at
om
– Remove nuts -arrows- securing steering column -1- from ple‐

on
c
num chamber bulkhead.

in t
or
his
ate
– Disconnect connector of electric steering column lock.

do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Steering column 167

Crafter 2006 ➤
– Remove nuts -arrows-.

– Pull steering column out of guides.
– Turn steering column 180° so that electronic steering column
lock points upwards.
– Remove steering column from vehicle.
Installing
Specified torques
♦ ⇒ “2.1 Assembly overview - steering column”, page 166
2.3 Removing and installing control unit for

electronic steering column lock - J764-
Removing
• Battery voltage at least 11.5 V
– Switch off ignition.
Note
. Volkswagen AG
gen AG does
Switch off ignition only. Ignition key must remain in ignition lock.
Vol
ksw
a
not
gu
by ara
ed nte
ris
– Remove cover in footwell on driver side ⇒ Generalth body
o re‐ eo
au ra
pairs, interior; Rep. gr. 70 . ss c ce
e
nl
– Remove front left footwell vent ⇒ Heater, air conditioning sys‐

pt
du
an
tem; Rep. gr. 80 ; Air duct; Removing and installing footwell

itte
y li
erm
vent on driver side .

ab
ility
ot p
– Turn pin -2- in direction of -arrow A-.

wit
, is n
h re
– Hold electronic steering column lock control unit - J764- -3-

hole
spec
tightly and pull pin -2- out.

es, in part or in w
t to the co
– Lower electronic steering column lock control unit - J764- -3-

in direction of -arrow B- and remove.
rrectness of i
– Disconnect connector -1-.

l purpos
Installing
nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
e
If electronic steering column lock/ electronic steering column lock

t
sd
iva
control unit - J764- has been replaced, new component must be

o
r
rp
cu
adapted/coded using ⇒ Vehicle diagnostic tester.

o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
3 Steering rack
⇒ “3.1 Assembly overview - steering rack”, page 169
⇒ “3.2 Repairing steering rack”, page 172
⇒ “3.3 Adjusting steering rack”, page 173
⇒ “3.4 Removing and installing steering rack”, page 178
⇒ “3.5 Removing and installing steering stop limit, Crafter 4MO‐
⇒ “3.6 Removing and installing track rod”, page 185
⇒ “3.7 Removing and installing track rod ball joint”, page 189
⇒ “3.8 Removing and installing boot”, page 191
3.1 Assembly overview - steering rack

⇒ “3.1.1 Assembly overview - steering rack, Crafter”, page 169
⇒ “3.1.2 Assembly overview - steering rack, Crafter 4MOTION
3.1.1 Assembly overview - steering rack, Crafter
1 - Subframe
2 - Nut
moving
3 - Bolt
❑ 28 Nm lkswage es n
o ot g
byV ua
d ran
4 - Universal joint o
ir se tee
th or
u
5 - Steering rack ss
a ac
ce
le
❑ Note scope of delivery.

un
pt
an
d
itte

y li
rm
ab
⇒ page 178
pe
ility
ot
6 - Bolt
wit
, is n
h re
❑ 20 Nm
hole
spec
es, in part or in w
7 - Pressure line
t to the co
8 - Return line
9 - Bolt
rrectness of i

l purpos
moving
❑ Initial torque specifica‐
nform
ercia
tion: 25 Nm
❑ 80 Nm +90°
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Steering rack 169

Crafter 2006 ➤
3.1.2 Assembly overview - steering rack, Crafter 4MOTION with Achleitner all-
wheel drive

❑ Right.
are undamaged and
correctly seated.
❑ Tapered pin must be
⇒ page 189
ks wage es n
2 - Nut Vol ot g
d by ua
ran
❑ Counterhold on track orise tee
rod ball joint with a span‐
au
th or
ac
ner when loosening s or
s
ce
e
tightening nut.
nl
pt
du
an
❑ 65 Nm
itte
y li
erm
ab
3 - Spring-type clip
ility
ot p
wit
, is n
h re
moving
hole
spec
4 - Boot
es, in part or in w
t to the co
❑ Check for damage
❑ Must not be twisted after
toe setting has been ad‐
rrectness of i
justed.
l purpos

⇒ page 191
nform
ercia
5 - Clamp
m
at

om
io
moving
n
c
in t
or
his
e
❑ Secure new hose clip

at
do
riv
using locking pliers for

p
cum
Phaeton steering rack - VAS 6199- .

for
en
ng
t.
yi Co
6 - Track rod t. Cop py
rig
❑ Right.
gh ht
pyri by
Vo
co
❑ 115 Nm
by lksw
cted agen
Prote AG.
7 - Steering stop limit
❑ The right steering stop limit must be bonded on with adhesive sealant ⇒ Electronic Parts Catalogue
(ETKA) .
8 - Steering rack housing
Checking and adjusting steering rack ⇒ page 173 .
9 - Nut
❑ 50 Nm +60°
❑ Tapered hole must be free of oil and grease.

Crafter 2006 ➤
11 - Thrust piece
12 - Spring
13 - Adjustment bolt AG. Volkswagen AG d
agen oes
ksw
Checking and adjusting steering rackby⇒ V page 173 .
ol not
gu
ara
d
rise nte
14 - Track rod ball joint utho eo
ra
a c
❑ Left. ss
ce
le
un
❑ Check that dust caps are undamaged and correctly seated.
pt
an
d
itte
y li
❑ Tapered pin must be free of oil and grease.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
15 - Track rod
❑ Left.
t to the co
❑ 115 Nm
rrectne
16 - Sealing plug set
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
3.2 Repairing steering rack

❑ Right.
are undamaged and
correctly seated.
❑ Tapered pin must be
❑ Removing and installing n AG. Volkswagen AG do
⇒ page 189 olks
wage es n
o V t gu
by ara
2 - Nut ris
ed nte
ho eo
❑ Counterholdauon track
t ra
c
rod ball joint
ss with a span‐
ce
le
ner when loosening or

un
pt
an
tightening nut.
d
itte
y li
rm
ab
❑ 65 Nm
pe
ility
ot
wit
, is n
h re
hole
4 - Boot
spec
es, in part or in w
❑ Check for damage

❑ Must not be twisted after t to the co
toe setting has been ad‐
justed.
rrectness of i

l purpos
⇒ page 191
5 - Clamp
nform
ercia

m
moving
a
com
tion in
❑ Secure new hose clip

r
te o
using locking pliers for

thi
s
iva
Phaeton steering rack -

do
r
rp
VAS 6199- .
um
fo
en
ng
t.
yi
6 - Track rod
Co
Cop py
.
❑ Right.
ht rig
rig ht
py by
Vo
❑ The hexagon on the track rod has been changed from AF 41 to AF 40. The series parts, replacement
co lksw
by
cted agen
parts and parts in repair kits are the same. The axial joints are compatible amongst each other, and AF
Prote AG.
41 joints are replaced by AF 40 joints.
❑ 115 Nm
7 - Steering rack housing
8 - Nut
❑ 50 Nm +60°
10 - Thrust piece
11 - Adjustment bolt

Crafter 2006 ➤
12 - Spring
❑ Left.
❑ Check that dust caps are undamaged and correctly seated.
❑ Tapered pin must be free of oil and grease.
14 - Track rod
❑ Left.
❑ The hexagon on the track rod has been changed from AF 41 to AF 40. The series parts, replacement
parts and parts in repair kits are the same. The axial joints are compatible amongst each other, and AF
41 joints are replaced by AF 40 joints.
❑ 115 Nm
15 - Sealing plug set agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
ho eo
3.3 Adjusting steering rack ss aut ra
c
ce
le
un
pt
an
d
itte
y li
erm
ab
equipment required
ility
ot p
♦ Measuring bridge - VW
wit
is n
h re
382/7-
ole,
spec
♦ Measuring needle - VW
382/10-
t to the co
♦ Torque wrench - V.A.G
1331-
rrectne
♦ Open-end socket wrench -
V.A.G 1331/11-
ss o
cial p
f
inform
mer
♦ Dial gauge extension, 30

atio
mm - VAS 6341/3-
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
Procedure
olkswagen AG
en AG. V
– Raise vehicle and strap it down
olks⇒ Maintenance ; Booklet s10.2
wag doe
no .
yV t gu
db ara
rise nte
WARNING au
tho eo
ra
ss c
ce
e
nl
pt
du
platform.
an
itte
y li
erm
ab
ility
ot p
• Wheels in straight-ahead position and not subject to load.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Open clamp -arrow- and pull boot -1- from left track rod.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
– Pull sealing plug -1- off adjuster screw -2- of steering rack.
Co
Cop py
ht. rig
ht
Determine test value:
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Insert dial gauge - VAS 6080- together with dial gauge exten‐
sion, 30 mm - VAS 6341/3- into measuring device - VW 382- .

Crafter 2006 ➤
– Fit dial gauge - VAS 6080- together with measuring tool - VW

382- on steering rack.
– Push dial gauge - VAS 6080- into measuring device - VW 382-
until the measuring pin touches the thrust piece.
Volkswa AG. gen AG
agen does
– Set dial gaugeV-olVAS
ksw 6080- to »zero«. not
gu
y
db ara
rise nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– Fit torque wrench - V.A.G 1331- together with extension and
h re
ole,
open-end socket wrench - V.A.G 1331/11- to swivel joint.
spec
– Apply a torque of 22 Nm when turning left. Read value on
t to the co
gauge - VAS 6080- .
– Apply a torque of 22 Nm when turning right. Read value on
rrectne
gauge - VAS 6080- .
– Calculate test value from sum of the two values shown.
ss o
cial p
Example:
f inform
mer
1st value shown 0.03 mm

atio
m
+ 2nd value shown 0.04 mm

o
n
c
i
or
= Test value 0.07 mm

thi
te
sd
iva
o
pr
– The following table indicates what action has to be taken.

cum
r
fo
en
ng
t.
yi
Test value Action
Co
Cop py
t. rig
Less than 0.04 mm Adjust steering rack
gh ht
pyri by
⇒ page 175 .
co Vo
by lksw
cted agen
Prote AG.
0.04 … 0.08 mm No adjustment necessary
0.09 … 0.30 mm Adjust steering rack
⇒ page 175 .
0.31 … 0.60 mm Renew thrust piece
⇒ page 176 .
Greater than 0.60 mm Renew steering rack
⇒ page 178 .
Adjusting steering rack
• Test value determined ⇒ page 174
• Test value less than 0.04 mm or between 0.09 and 0.30 mm
Note
Steering racks that have already been adjusted are marked with
3 punch marks -arrows-. It is not permissible to adjust marked
steering racks again.
Procedure
– Tighten adjuster screw -2-.
Adjustment bolt 60 Nm

Crafter 2006 ➤
– Loosen adjuster screw 45°.

– Determine test value ⇒ page 174 .
– Adjust steering rack by turning adjuster screw.
Setting: 0.04…0.08 mm
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Insert new sealing plug -1-.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
– Mark adjusting screw by making 3 centre punch marks

n in
r
te o
-arrows-.
thi
s
iva
do

r
rp
cum
fo

en
ng
t.
yi Co
op
– Carry out a road test. C py
t. rig
gh ht
yri
– The power steering must independently return to the straight-
p by
co Vo
by lksw
ahead position after manoeuvring or cornering, without catch‐ Prote
cted AG.
agen
ing.
Renew thrust piece
• Test value determined ⇒ page 174
• Test value between 0.3 and 0.60 mm
Procedure

Crafter 2006 ➤
– Undo and remove adjusting screw -2-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
– Pull out spring -1- and thrust
ss piece -2-.
a ac
ce
le
– Clean seat of thrust piece.

un
pt
an
d
itte
y li
– Grease new thrust piece and insert it into steering rack.
erm
ab
ility
ot p
wit
is n
h re
Note
ole,
spec
The repair kit contains grease.
t to the co
– Insert new spring into thrust piece.
rrectne
– Tighten adjuster screw -1-.
s
s o
cial p
f
Adjustment bolt 60 Nm
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen adjuster screw 45°.

– Determine test value ⇒ page 174 .
– Adjust steering rack by turning adjuster screw.
Setting: 0.040.08 mm
– Insert new sealing plug -1-.
– Mark adjusting screw by making 3 centre punch marks
-arrows-.
– Carry out a road test.
– The power steering must independently return to the straight-
ahead position after manoeuvring or cornering, without catch‐
ing.

Crafter 2006 ➤ agen
AG. Volkswagen AG d
oes
ksw
Running gear, axles, steering
by
V - Edition 12.2015
ol not
gu
ara
ed nte
oris e
3.4 Removingssand installing steering rack th or
au ac
ce
e
nl
pt
du
an
itte
y li
♦ Hose clamps, up to 25 mm - 3094- erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Observe the following important points when working on the

steering rack:
♦ Absolute cleanliness is required when working on power steer‐
ing system
♦ Thoroughly clean all unions and the adjacent areas before
disconnecting
♦ After removal, place parts on a clean surface and cover them
over if repairs are not to be performed immediately
♦ Only use lint-free cloths
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components.
♦ Only unpack replacement parts immediately prior to fitting
♦ Only use genuine packed parts
♦ Do not work with compressed air if the system is open.
♦ Do not move the vehicle.
Removing
– Remove saddle plates ⇒ page 30 . Not installed in Crafter
4MOTION with Achleitner four-wheel drive.
WARNING
platform.

Crafter 2006 ➤

– Remove left track rod ball joint.
– Press right track rod ball joint off wheel bearing housing.
– Clamp off return line using hose clamp, up to 25 mm - 3094- .
olkswagen AG
en AG. V
– Clamp off pressure line using hose clamps,olksup to 25 mm -
wag does
not
3094- . d byV gu
ara
e nte
ris
– Turn steering wheel clockwise as
au
thfar
o
as it will go. eo
ra
ss c
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
Make sure that the steering wheel remains in this position during
ility
ot p
the assembly work. This ensures that the airbag coil connector
wit
, is n
and return ring with slip ring - F138- does not move/twist.
h re
hole
spec
es, in part or in w
t to the co
– Undo bolt -arrow- and remove it from universal joint.
rrectness of i
– Pull universal joint off steering rack.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Detach return line -1- from subframe -arrows-. p by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
– Undo bolt -A- and push plate -B- backwards on return line.
– Carefully pull pressure line out of steering rack.
– Catch escaping hydraulic fluid.
– Seal or cover open lines/connections.
– Unscrew bolts from steering rack -arrow-.
– Counter-hold nuts -arrows- using an open-end spanner when

removing bolts.
– Remove steering rack from subframe.
Installing
Note agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b
If the steering rack is new, riseremove the right track rod ball joint.
d ara
nte
tho eo
au ra
c
– Turn steering rack
s clockwise on steering pinion as far as it will
s
ce
le
go.
un
pt
an
d
itte
y li
– Insert steering rack into subframe.

erm
ab
ility
ot p
– Fit universal joint onto steering pinion.

wit
is n
h re
ole,
– Firmly bolt steering rack to subframe -arrows-, counterholding

spec
at nuts ⇒ page 180 .

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
180
cop Vo
by lksw
Rep. gr.48 - Steering Prote
cted AG.
agen
Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
lksw not
– Install and dtighten
by
Vo
bolt for universal joint -arrow-.
gu
ara
ise nte
r
– Renew ut seals on pressure line.
ho eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Carefully press pressure line into steering rack, fit plate -B-.
Tighten bolt -A- for pressure lines.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
– Attach return line -1- to subframe -arrow-.
by c lksw
cted agen
Prote AG.
– Install track rod ball joints.
– Remove hose clamps, up to 25 mm - 3094- from pressure line.
– Checking power steering fluid level ⇒ page 197
– Fit saddle plate ⇒ page 30 .
– Check wheel alignment ⇒ page 149 .
Specified torques
♦ ⇒ “2.1 Assembly overview - steering column”, page 166
♦ ⇒ page 170
♦ ⇒ “2.1 Assembly overview - subframe”, page 9
♦ ⇒ “2.1.2 Assembly overview - subframe, Crafter 4MOTION
3.5 Removing and installing steering stop

limit, Crafter 4MOTION with Achleitner
four-wheel drive

AG. Volkswagen AG d
agen oes
olksw not
yV gu
Crafter 2006 ➤ ed b ara
nte
ris
Running gear, axles, steering - Edition 12.2015 uth o eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Ball joint puller - 3287 A- l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Locking pliers for Phaeton steering rack - VAS 6199-
♦ Steering rack grease ⇒ Electronic Parts Catalogue (ETKA) .

♦ Adhesive sealant ⇒ Electronic Parts Catalogue (ETKA) .
Removing
– Turn steering wheel to straight-ahead position.
– Remove wheel.
– Clean outside of steering rack in vicinity of boot ⇒ Mainte‐
nance ; Booklet 10.2 .
Note
Dirt must be prevented from entering the steering rack.
– Unscrew track rod ball joint ⇒ page 189 .

– Loosen spring-type clip on boot and push onto track rod.

Crafter 2006 ➤
– Open clamp -arrow- and pull boot -1- off steering rack.
– Remove track rod ⇒ page 185 .
Note
♦ If the steering rack shows signs of corrosion, damage, wear or

soiling, renew the complete steering rack.
♦ Likewise, if there is no film of grease on the steering rack, the
steering rack must be renewed.
– Remove damaged or loose steering stop limit.

Installing (left side):
– Turn steering wheel to full right lock.
– Clean any grease or oil from steering rack of power-assisted
steering.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
– Slide steering stop limit -1- loosely onto shoulder -2- of steer‐
ing rack of steering rack -3-.
Note
The steering stop limit -1- will be secured when left track rod is
tightened.
Installing (right side):
Note
AG. Volkswagen AG d
agen o
Observe manufacturer's
yV
oinstructions
lksw enclosed in the packaging
es n
ot g
and minimum curing
isedperiod.
b ua
ran
r tee
ho
aut or
ac
– Turn steering
ss wheel to full “left” lock.
ce
e
nl
pt
– Clean any grease or oil from steering rack of power-assisted
du
an
itte
steering.
y li
erm
ab
ility
– Apply an adhesive bead of 2 to 3 mm thickness on the inside
ot p
of the steering stop limit.
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
Observe the safety data sheet for the adhesive sealant ⇒
Electronic Parts Catalogue (ETKA) .
rrectness of i
l purpos
– Slide steering stop limit -1- onto steering rack -3- of steering
rack until it is flush.
nf
ercia
– Spread adhesive sealant ⇒ Electronic Parts Catalogue (ET‐

rm
m
KA) -2-.
atio
om
n in
or c
thi
Caution
te
sd
iva
o
r
rp
cu
Adhesive sealant ⇒ Electronic Parts Catalogue (ETKA) is in‐

o
m
f
en
ng
flammable.
t.
yi Co
Cop py
.
Adhesive sealant ⇒ Electronic Parts Catalogue (ETKA) is
ht rig
rig ht
by
harmful by inhalation. copy Vo
by lksw
cted agen
Prote
Adhesive sealant ⇒ Electronic Parts Catalogue (ETKA) is irri‐
AG.
tating to eyes and skin.
The minimum curing period is the period between bonding in the

part and using the vehicle.
During the minimum curing period room and object temperature
must be at least +18 °C.

Crafter 2006 ➤
Bonding surfaces may not be loaded until at least 24 hours after

installation has elapsed.
WARNING
Vehicle is safe to use only after the curing period is completed.
Installation (both sides):

– Install track rod ⇒ page 185 .
Note
Before installation, steering rack must be coated with steering

rack grease ⇒ Electronic Parts Catalogue (ETKA) .
Caution
No other type of grease may be used. agen

AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
r
– Turn steering to full lock on each ut side in succession.
ho eo
ra
s a c
– Grease steering rack on toothed side using steering rack s
ce
e
nl
grease ⇒ Electronic Parts Catalogue (ETKA) .
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Position spring-type clip onto boot.
t to the co
– Slide boot -1- onto track rod and steering rack. Secure boot
with new clamp -arrow-. rrectness of i
l purpos

– Fit wheel.
nform
ercia
– Check wheel alignment ⇒ page 149 .

m
at
om
io
Specified torques
n
c
in t
or
his
e

at
do
priv

um
for
en
g

n
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted
3.6 Removing and installing track rod
agen
Prote AG.
Caution
The hexagon on the track rod has been changed from AF 41

to AF 40. The series parts, replacement parts and parts in re‐
pair kits are the same. The axial joints are compatible amongst
each other, and AF 41 joints are replaced by AF 40 joints.

Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
♦ Open-end spanner insert AF 41 - V.A.G 1332/13- s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Open-end spanner insert AF 40 - T50063-
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Locking pliers for Phaeton steering rack - VAS 6199-

Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
lksw not
♦ Torque wrench - V.A.Gd by
V 1332-
o gu
ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
nform
ercia
WARNING
m
a
com
ti
on in
platform.
r
te o
thi
s
iva
do
r
rp
cum
fo

en
ng
t.
yi Co
op
– Remove noise insulation ⇒ General body repairs, exterior; C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Loosen nut -A- on track rod ball joint but do not remove com‐ cted agen
Prote AG.
pletely.
Leave nut -A- screwed on a few turns on track rod ball joint
threads to protect threads.
– Pull track rod ball joint off wheel bearing housing using ball
joint puller - 3287 A- . Unscrew nut -A-.
Note
When pressing off track rod ball joint, do not damage rubber boot
or heat shield -B-.

Crafter 2006 ➤
– Open clamp -arrows-. Slide boot -1- down off steering rack.
– Loosen spring-type clamp on boot and push onto track rod.
AG. Volkswagen AG d
agen
Left track rod: Volksw
oes
not
gu
d by ara
– Turn steering rack
oris to right (as viewed when looking forwards)
e nte
eo
to stop. aut
h
ra
ss c
Right track rod:
ce
e
nl
pt
du
an
– Turn steering rack to left (as viewed when looking forwards)
itte
y li
erm
to stop.
ab
ility
ot p
Continuation for both sides
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
to AF 40. Select and use the appropriate open-end spanner
insert.
rrectness of i
l purpos
Vehicles with AF 41 track rod
nform
ercia
– Unscrew track rod from steering rack.

m
at
om
io
1- Open-end spanner insert AF 41 - V.A.G 1332/13-
n
c
in t
or
his
e
2- Torque wrench - V.A.G 1332-

at
do
priv

um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Unscrew track rod from steering rack.

1- Open-end spanner insert AF 40 - T50063-
Installing
Caution

to AF 40. Select and use the appropriate open-end spanner
insert.

Crafter 2006 ➤
– Tighten track rod on steering rack.

1- Open-end spanner insert AF 41 - V.A.G 1332/13-
– Tighten track rod on steering rack.

1- Open-end spanner insert AF 40 - T50063-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
– Slide boot -1- with new clamporis -arrow- onto steering rack hous‐
e nte
eo
ing. aut
h
ra
ss c
– Secure clamp using locking pliers for Phaeton steering rack -
ce
le
un
pt
VAS 6199- .
an
d
itte
y li
erm
– Fit spring-type clamp onto boot.

ab
ility
ot p
– Install track rod ball joint to wheel bearing housing (use new
wit
is n
nut).
h re
ole,
spec
t to the co
Note
If track rod ball joint has been removed from track rod, vehicle
rrectne
steering geometry must be checked after installing ⇒ page 149 .

ss
Specified torques
o
cial p
f in

form
mer

atio
om

n
c
i
or
n thi
e

t
sd
iva
o
pr
cum
r
fo
3.7 Removing and installing track rod ball

en
ng
t.
yi Co
op
joint
C py
t. rig
gh ht
pyri by
Vo
o
Special tools and workshop equipment required by c lksw
cted agen
Prote AG.

Crafter 2006 ➤ olkswagen AG
en AG. V
Running gear, axles, steering - Edition
olks
wag12.2015 does
no
yV t gu
db ara
♦ Ball joint puller - 3287 A- rise nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
nform
ercia
WARNING
m
a
com
tion in
r
te o
thi
platform.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
– Remove wheel.
Co
Cop py
t. rig
gh
– Loosen nut -1- on track rod ball joint but do not remove com‐
ht
pyri by
Vo
o
pletely.
c by lksw
cted agen
Prote AG.
joint puller - 3287 A- . Now unscrew nut -1-.
Note
When pressing off, do not damage rubber grommet or heat shield.
– Loosen lock nut -2-.

– Mark position of track rod ball joint on track rod.
– Unscrew track rod ball joint from track rod. Use at flattened
sides of track rod ball joint -arrow A- and track rod -arrow B-
for this.
Installing
– Screw track rod ball joint onto mark (made previously) on track
rod. Secure ball joint with lock nut.
– Bolt track rod ball joint with new nut.
– Install wheel and tighten to specified torque.
– Perform wheel alignment ⇒ page 149 .
Specified torques

Crafter 2006 ➤
3.8 Removing and installing boot

Removing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Note orise nte
eo
th
au ra
s c
If boot is defective, moisture and dirt will enter steering rack. s
ce
le
There must be a palpable film of grease in the area of the teeth
un
pt
an
d
on the steering rack. If there is no film of grease, the steering rack
itte
y li
must be renewed. Also renew steering rack if there are signs of
erm
ab
corrosion, damage or wear to the steering rack.
ility
ot p
wit
is n
h re
ole,
spec
– Remove wheel.
t to the co
– Clean outside of steering rack in vicinity of boot.
No dirt must be allowed to enter the steering rack through a de‐
rrectne
fective rubber boot during this operation.
– Remove track rod ball joint ⇒ page 189 .
ss o
cial p
f
– Loosen spring-type clip on boot and push onto track rod.
inform
mer
– Open clamp -arrow- and pull boot -1- from track rod.
atio
om
– Remove clamp and pull boot from steering rack housing.
n
c
i
or
n thi
e
– Turn track rod out of ball joint.

t
sd
iva
o
pr
cum
r
– Pull boot with spring-type clip off track rod.

fo
en
ng
t.
yi Co
Cop py
t. rig
Note
gh ht
pyri by
Vo
co lksw
by
cted agen
♦ If the steering rack shows signs of corrosion, damage, wear or
Prote AG.
soiling, renew the complete steering rack.

♦ Likewise, if there is no film of grease on the steering rack, the
steering rack must be renewed.
Installing
Caution
Only use grease supplied with repair kit.
To grease, turn steering to full lock on each side in succession.
– Coat steering rack with grease.


Crafter 2006 ➤
– Slide boot -1- onto track rod and steering rack. Secure boot
with new clamp -arrow-.
– Position spring-type clip onto boot.
Specified torques
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Crafter 2006 ➤
4 Hydraulic power steering

⇒ “4.1 Assembly overview - hydraulic lines, reservoir, 4-cylinder
diesel engine”, page 193
⇒ “4.2 Assembly overview - vane pump, 4-cylinder diesel engine”,
page 195
⇒ “4.3 Assembly overview - vane pump, 5-cylinder diesel engine”,
page 196
⇒ “4.4 Checking power steering fluid level”, page 197
⇒ “4.5 Bleeding steering system”, page 198
⇒ “4.6 Check steering for leaks”, page 198
⇒ “4.7 Checking vane pump delivery pressure, 4-cylinder diesel
engine”, page 199
⇒ “4.8 Checking vane pump delivery pressure, 5-cylinder diesel
engine”, page 201
⇒ “4.9 Removing and installing vane pump, 4-cylinder diesel en‐
gine”, page 204
⇒ “4.10 Removing and installing vane pump, 5-cylinder diesel
engine”, page 206
4.1 Assembly overview - hydraulic lines, reservoir, 4-cylinder diesel engine

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Hydraulic power steering 193

Crafter 2006 ➤
1 - Reservoir
2 - Sealing cover with dipstick
❑ Checking power steer‐
ing fluid level
⇒ page 197 .
3 - Bracket
❑ For reservoir
4 - Clamp
5 - Return hose
6 - Suction hose
7 - Clamp
8 - Bolt
❑ 9 Nm
9 - Bracket
❑ For engine control unit
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
4.2 Assembly overview - vane pump, 4-cyl‐

inder diesel engine
Note
♦ There is no provision for repairing the vane pump. If problems

are reported, determine the cause by means of a pressure test
and a leakage test. If a fault is found, the vane pump unit must
be renewed.
♦ Renew sealing rings.
♦ Always check steering system for leaks if fluid level in reservoir
is low.
♦ If leakage appears near pipe connections, first check lines and
connections for leaks, tighten connections as necessary and
wipe dry.
♦ Vane pumps taken from parts stock contain no fluid. Therefore
it is essential to fill vane pump with hydraulic fluid ⇒ Electronic
Parts Catalogue (ETKA) and to rotate pump by hand prior to
installation. Otherwise vane pump may be damaged or be
noisy during operation.
♦ Do not re-use hydraulic fluid which has been drained off.
1 - Bracket lkswage es n
o ot g
byV ua
d
2 - Bush o
ir se
ran
tee
th or
❑ Drive aubush back slightly ac
ss
when installing vane
ce
e
nl
pump.
pt
du
an
itte
y li
3 - Bolt
erm
ab
ility
❑ 24 Nm
ot p
wit
, is n
4 - Bolt
h re
hole
spec
❑ 9 Nm
es, in part or in w
t to the co
5 - Pressure line
Note
rrectness of i
When installing, press on to stop in

l purpos
vane pump.
nform
ercia
❑ Contains
m
at
om
io
6 - Suction hose
n
c
in t
or
❑ Note installation posi‐

his
ate
tion on vane pump:

do
priv
marking -arrow A- must

um
for
en
g
align with marking

n
t.
yi Co
-arrow B- on vane . Cop py
pump.
t rig
gh ht
pyri by
Vo
co
7 - Clamp
by lksw
cted agen
Prote AG.
❑ Install on marking on
suction hose.
8 - Sealing ring
moving

Crafter 2006 ➤
9 - Vane pump
❑ Fill with hydraulic fluid before installing.
10 - Belt pulley
11 - Bolt
❑ 23 Nm
12 - Bolt
❑ 24 Nm
4.3 Assembly overview - vane pump, 5-cyl‐

inder diesel engine
Note
♦ Renew sealing rings.

♦ Pumps taken from parts stock contain no fluid. Therefore it is
essential to fill vane pump with hydraulic fluid ⇒ Electronic
Parts Catalogue (ETKA) and to rotate pump by hand prior to
installation. Otherwise vane pump may be damaged or be
noisy during operation.
♦ There is no provision for repairing the vane pump. If com‐
plaints are received, determine cause with the help of pressure
test . If a fault in component exists, vane pump must be re‐
newed.
♦ Make sure to use new hydraulic fluid ⇒ Electronic Parts Cata‐
logue (ETKA) . AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
196
AG.
Rep. gr.48 - Steering
Crafter 2006 ➤
1 - Vane pump agen

AG. Volkswagen AG d
oes
lksw not
❑ Fill with hydraulic
by Vo fluid gu
ara
beforeriseinstalling.
d
nte
ho eo
❑ Checking
s aut
delivery pres‐ ra
c
sure
s ⇒ page 201
ce
e
nl
pt
du
an
itte
⇒ page 206 .
y li
erm
ab
ility
2 - Belt pulley
ot p
wit
, is n
3 - Bolt
h re
hole
spec
❑ 25 Nm
es, in part or in w
t to the co
4 - Bracket
5 - Bolt
rrectness of i
❑ 25 Nm
l purpos
6 - Banjo bolt
❑ 38 Nm
nform
ercia
7 - Sealing rings
m
at
om
io
moving
n
c
in t
or
his
e
8 - Pressure hose
at
do
priv
9 - Suction hose
um
for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.4 Checking power steering fluid level

Procedure
When fluid is cold: (approx. 20°C):
– Unscrew filler cap.
– Wipe dipstick with a clean, lint-free cloth.
– Screw filler cap on hand tight and unscrew again.
Note
The cap must be fully screwed on in order to obtain an accurate

fluid level reading.
– Check fluid level: fluid level should be in area -A-.

Crafter 2006 ➤
When fluid is at operating temperature (approx. 80 ℃):

– Unscrew filler cap.
– Wipe dipstick with a clean, lint-free cloth.
– Screw filler cap on hand tight and unscrew again.
Note
The cap must be fully screwed on in order to obtain an accurate

fluid level reading.
– Check fluid level: fluid level should be in area -B-.
Note
AG. Volkswagen AG d
agen oes
ksw
♦ If fluid level is above specified area, excess fluid mustbybe V ex‐
ol not
gu
tracted. rise
d ara
nte
tho eo
♦ If fluid is below specified range, hydraulic system
s a must be
u ra
c
checked for leaks. It is not sufficient just to top up with fluid.
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
4.5 Bleeding steering system
wit
, is n
h re
hole
spec
– Check hydraulic fluid level and top up if necessary.
es, in part or in w
t to the co
– Raise vehicle until front wheels are free.
– With engine switched off, turn steering wheel 10 times from
lock to lock.
rrectness of i
– Check hydraulic fluid level and top up if necessary.
l purpos
– Lower vehicle.
nf
ercia
– Start engine.
orm
m
atio
– Turn steering wheel 10 times from lock to lock.
om
n in
or c
– Check hydraulic fluid level and top up if necessary

thi
te
⇒ page 197 .
sd
iva
o
r
rp
cu
Any air remaining in steering system will dissipate by itself over

o
m
f
en
ng
the next 10 to 20 km driven.

t.
yi Co
Cop py
t. rig
4.6 Check steering for leaks
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
If hydraulic fluid level in reservoir is low after repairs are comple‐

ted, steering system must be checked for leaks.
– Start engine.
– Turn steering wheel left and right to lock and hold briefly.
This develops the maximum possible pressure.
In this position, the following components must be checked for
leaks:
♦ Steering rack: steering pinion on valve block, connection point
between valve and steering rack housing, housing
♦ All hose and pipe connections.

Crafter 2006 ➤
♦ Vane pump: shaft seal, all threaded connections, housing

♦ Reservoir
n AG. Volkswagen A
4.7 Checking vane pump Volks delivery pressure, s not g
wage
G do
e
4-cylinder diesel
ise engine
by ua
d ran
or te eo
h
ut
ss equipment required
a ra
c
ce
♦ Hose clamps, up to 25 mm - 3094- e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
♦ Power steering tester - V.A.G 1402-

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Adapter set - V.A.G 1402/6-
♦ Adapter - V.A.G 1402/18-

– Clamp off suction hose at vane pump with hose clamp to
25 mm - 3094- .
– Remove pressure line from vane pump.

Crafter 2006 ➤
– Fit special tools as shown in illustration.

1- Vane pump
2- Adapter - V.A.G 1402/18-1- 1)
3- Securing bolt of pressure line ⇒ Item 4 (page 195)

4- Hose from adapter set - V.A.G 1402/6-
5- Power steering tester - V.A.G 1402-
6- Pressure line
7- Adapter - V.A.G 1402/18-2-
1) If seal is leaking or damaged on adapter - V.A.G 1402/18-1- , replace with new
seal ⇒ Item 8 (page 195) ⇒ Electronic Parts Catalogue .
– Remove hose clamp, up to 25 mm - 3094- from suction hose.
Lever on power steering tester - V.A.G 1402- must be in position

-2-.
– Top up hydraulic fluid in reservoir if necessary ⇒ page 197 .
– Start engine.
– Turn steering wheel approx. 10 times from lock to lock.
– Check delivery pressure
AG. Volkswagen AG d
agen
Test prerequisites: Volksw
oes
not
gu
d by ara
• System must orisbe free of leaks
e nte
eo
h
ut ra
• Hoses and
ss a
lines must not be not kinked or restricted. c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Crafter 2006 ➤
– With engine idling, close shut-off valve on pressure gauge

(position -1-) for no longer than 5 seconds. Read pressure on
power steering tester - V.A.G 1402- .
Note
Ensure that the shut-off valve is not closed in position -1- for more
than 5 seconds to avoid damage to the vane pump.
Specification for delivery pressure:

110…120 bar
If specification is not attained, renew vane pump ⇒ page 204 .
– Remove pressure gauge and adapter.
– Bleed steering system ⇒ page 198 .
– Check hydraulic fluid level and top up with hydraulic fluid if
necessary ⇒ page 197 .
– Check steering system for leaks ⇒ page 198 .
Specified torques
♦ ⇒ “4.2 Assembly overview - vane pump, 4-cylinder diesel en‐
gine”, page 195 n AG. Volkswagen A age G do
ksw es n
y Vol ot g
4.8 Checking vane pump delivery pressure, 5-cylinder diesel engine
b ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
Crafter 2006 ➤ aut
h
ra
s c
Running gear, axles, steering - Edition 12.2015 s
ce
le
un
pt
an
d
itte
y li
erm
equipment required
ab
ility
ot p
♦
wit
is n
h re
ole,
♦ Hose clamp, up to 25 mm -
spec
3094-
t to the co
♦ Power steering tester -
V.A.G 1402-
rrectne
♦ Adapter - V.A.G 1402/2-
♦ Adapter set - V.A.G 1402/6-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Test prerequisites:
• Poly V-belt and poly V-belt tension OK.
• System must be free of leaks
• Hoses and lines must not be kinked or restricted
– Remove noise insulation below subframe ⇒ Rep. gr. 50 ;
Noise insulation; Assembly overview - noise insulation .
– Clamp off suction hose using hose clamps, up to 25 mm -
3094- .
– Unscrew pressure line from vane pump.

Crafter 2006 ➤
– Assemble adapter as shown in figure.

1 - Power steering tester - V.A.G 1402-
2 - Adapter - V.A.G 1402/2-
3 - Adapter from adapter set - V.A.G 1402/6-
4 - Adapter from adapter set - V.A.G 1402/6-
5 - Hose from adapter set - V.A.G 1402/6-
6 - Banjo bolt
7 - Sealing ring
– Remove hose clamp, up to 25 mm - 3094- from suction hose.
Lever on pressure gauge must be in position -2-.

– Start engine and if necessary replenish hydraulic fluid in res‐
ervoir.
– Turn steering wheel approx. 10 times from lock to lock.
– Now check delivery pressure.
Test prerequisites:
• System must be freeagof
enleaks
AG. Volkswagen AG d
oe w s no
olks t
• Hoses and elines
db
y V must not be kinked or restricted
gu
ara
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– With engine idling, close shut-off valve on pressure gauge

t to the co
(position -1-) for no longer than 5 seconds, and read pressure.

Specification for delivery pressure:
rrectness of i
120 bar
l purpos
If specification is not attained, renew vane pump ⇒ page 206 .

nform
ercia
– Remove pressure gauge and adapter.

m

at
om
ion
c
– Check hydraulic fluid level and top up if necessary

in t
or
his
e
⇒ page 197 .
at
do
priv

um
for
en
ng
t.
Specified torques
yi Co
Cop py
ht. rig
♦ ⇒ “4.3 Assembly overview - vane pump, 5-cylinder diesel en‐ rig ht
py by
gine”, page 196
co Vo
by lksw
cted agen
Prote AG.
Pressure line to vane pump 38 Nm

Crafter 2006 ➤
4.9 Removing and installing vane pump, 4-cylinder diesel engine

equipment required
- 3094-
♦ Torque wrench - V.A.G
1331-
♦ Pin wrench - 3212-
♦ Tool insert - T40087-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Removing
orm
m
atio
om
n in
WARNING
or c
thi
te
sd
a
Please note the following points during all assembly work, in

iv
o
r
rp
cu
particular in the engine compartment, due to the narrow instal‐

o
m
f
en
ng
lation conditions:
t.
yi Co
op py
♦ Route lines of all kinds (for example for fuel, hydraulic fluid,
t. C rig
gh ht
yri
activated charcoal filter system, coolant, refrigerant, brake p by
co Vo
fluid, vacuum) and electrical cables so that the original
by lksw
cted agen
Prote
line/cable routing is re-established.
AG.
♦ Make sure there is adequate clearance from all moving or

hot components.
– Remove air filter ⇒ Power unit; Rep. gr. 13 ; Fuel supply line;
Air filter .
– Remove poly V-belt ⇒ Power unit; Rep. gr. 13 ; Cylinder block,
pulley end; Removing and installing poly V-belt .

Crafter 2006 ➤
– Unscrew bolts -arrows-, counterhold poly V-belt pulley -1- with

pin wrench - 3212- for this.
– Clamp off suction hose using hose clamps, up to 25 mm -

3094- .
– Open spring-type clip -1- and pull suction hose off vane pump.
– Close off suction hose with a plastic bag and adhesive tape.
– Remove bolts -2- and pull pressure line out of vane pump.
– Close off pressure line with a plastic bag and adhesive tape.
– Remove bolts -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Remove bolt -arrow- and remove vane pump from retainer.

ot
wit
, is n
Installing
h re
hole
spec

es, in part or in w
t to the co
– Fill vane pump with hydraulic oil.

– Fill hydraulic oil in through inlet connection of vane pump.
rrectness of i
– Turn hub by hand until oil emerges from pressure side.

l purpos
– Install vane pump, initially tightening only front bolts.

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Crafter 2006 ➤
AG. Volkswagen AG d
agen oes
lksw not
– Install suction hose -1- so that marks by V-arrow A- and
o gu
ara
-arrow B- aline with one another. rise d
nte
ho eo
ut
– Mount clamp -2- on mark -arrow
ss a A-. ra
c
ce
e
– Install poly V-belt ⇒ Power unit; Rep. gr. 13 ; Cylinder block,
nl
pt
du
an
itte
y li
erm
ab
– Install air filter ⇒ Power unit; Rep. gr. 13 ; Fuel supply line;
ility
ot p
Air filter .
wit
, is n
h re
hole
spec
es, in part or in w
– Check hydraulic fluid level ⇒ page 197 .
t to the co
Specified torques
rrectness of i
♦ ⇒ “4.2 Assembly overview - vane pump, 4-cylinder diesel en‐
l purpos
gine”, page 195
nform
ercia
4.10 Removing and installing vane pump, 5-

m
at
cylinder diesel engine
om
ion
c
in t
or
Removing
his
ate
do
riv
– Loosen pulley bolts -1-.

p
cum
for
en
g
– Unscrew expansion hose from vane pump.

n
t.
yi Co
Cop py
– Catch escaping hydraulic fluid. ht. rig
rig ht
py by
o Vo
– Unscrew return line from vane pump.
by c lksw
cted agen
Prote AG.
– Remove poly V-belt ⇒ Power unit; Rep. gr. 13 ; Cylinder block,
– Unscrew pulley bolts -1- from vane pump and remove pulley.
– Unscrew bolts -3- and -4- and remove vane pump from brack‐
et.
Installing
– Insert vane pump into bracket.

Crafter 2006 ➤
– Tighten bolts -3- and -4-.

– Install pulley -2- on vane pump and tighten bolts -1-.
– Screw expansion hose to vane pump.
– Screw return line to vane pump.
– Install poly V-belt ⇒ Power unit; Rep. gr. 13 ; Cylinder block,
– Make sure to use new hydraulic fluid ⇒ Electronic Parts Cata‐
logue (ETKA) .
Observe oil level in reservoir after filling with hydraulic fluid and
starting engine. The oil level must sink.
If this is not the case, switch off engine, disconnect expansion
hose from steering rack, and wait until hydraulic fluid escapes.
– Catch escaping hydraulic fluid and screw line on again.
– Start engine and if necessary replenish fluid in reservoir.
Check hose connections for leaks.
– Switch engine off and check fluid level of power steering
⇒ page 197 .
Specified torques AG. Volkswagen AG d
agen oes
lksw no
♦ ⇒ “4.3 Assembly overview - vane by V pump, 5-cylinder diesel en‐ t gua
o
gine”, page 196 ris
ed ran
tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

SM 22

Uploaded by

Copyright:

Available Formats

SM 22

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM 22

Uploaded by

Copyright:

Available Formats

Service AG.

Running gear, axles, steering

Service Department. Technical Information

No reproduction without prior agreement from publisher.

Copyright © 2016 Volkswagen AG, Wolfsburg K0059031220

3 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.1 Checklist for evaluating running gear on accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Removing and installing subframe with steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.4 Removing and installing coupling rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.5 Removing and installing saddle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.6 Removing and installing leaf spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3 Suspension strut, upper suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

2 Tyre pressure monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

2.1 Assembly overview - tyre pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

3 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

3.1 Notes for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

3.2 Necessity of wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

3.3 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

3.8 Adjusting camber on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

3.6 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

3.7 Removing and installing track rod ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

1.1 General notes on tyre pressure indicator

2.1 Raising wheel suspension to unladen position

♦ Tensioning strap - T10038-

2 Rep. gr.00 - Technical data

– Before starting work, measure distance -a- from centre of

All bolts on running gear components with bonded rubber

brought to a position equivalent to the operating (unladen) posi‐

1383 A- and support - T10149- .

– Attach support - T10149- with a wheel bolt -A-.

– Raise wheel bearing housing using engine and gearbox jack

♦ Do not lift or lower vehicle while engine and gearbox jack

– Tighten respective nuts and bolts.

4 Rep. gr.00 - Technical data

3 Evaluating accident vehicles

3.1 Checklist for evaluating running gear on

♦ Check of steering rack and lines for secure seating.

must turn with a constant force without resistance.

Visual and functional examination of running gear

• Adhere to the sequence of the following inspection steps!

♦ Check for true running and imbalance ⇒ VW ServiceNet;

Technical information; Reference guides; Wheel and Tyre

Guide; General; Imbalance due to wheels and tyres .

blows ⇒ VW ServiceNet; Technical information; Reference

3. Evaluating accident vehicles 5

messages using the ⇒ Vehicle diagnostic tester. If faults are

uals in ELSA. Following repairs, read event memories of the

6 Rep. gr.00 - Technical data

40 – Front suspension olksw

lower suspension link, swivel

wheel bearing assembly”,

suspension strut, upper sus‐

8 Rep. gr.40 - Front suspension

2.1 Assembly overview - subframe

❑ Removing and installing

❑ Can only be renewed

with subframe removed.