Your system specialist RUVILLE also offers a broad product range for the chassis of VW Transporter V (T5) 2.5 TDI, 96 KW which has been practically rounded off with the introduction of suspension springs for the front and rear axle. Please always comply with the general and specific procedures for the respective compo-nents when carrying out repairs.

Vehicle-specific installation instructions:

Specific installation instructions have to be heeded for some chassis com-ponents in VW T5 2.5 TDI, 96 KW. These are described in greater detail below. The corresponding articles are marked in grey in the table.

Basic installation instructions:

When fitting waxed parts, the contact surfaces must be cleaned. Contact surfaces must be free of wax and grease

No welding or straightening work is permitted to structural or wheel suspension parts

Vehicles must not be moved without the drive shaft as this would otherwise damage the wheel bearing

Rubber/metal bearings have a limited swivelling range. Before fixing axle parts with rubber/metal bearings, they must therefore be brought into a position corresponding to the driving position (empty weight position)

Always replace self-locking nuts Always replace corroded bolts/nuts

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Every new model or series entails new installation specifications for the chassis. RUVILLE passes on all the latest know-how to the garages. You can find out more about our training courses at www.ruville.de or directly from our technical instructor Remo Schönsee on e-mail: rschoensee@ruville.de

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gEnERaL InsTRUCTIons aLL RUVILLE ChassIs CoMPonEnTs FoR ThE VW T5 2.5 TDI, 96 KW

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➜ VW T5 2.5 TDI, 96 KW ChassIs

InsTRUCTIons FoR sPECIFIC CoMPonEnTs

VW Transporter V 2.5 TDI, 96 KW

article no. Description

755438 Bellows set, drive shaft

815406 Dust cap set, shock absorber

825409 Strut mounting

825409S Repair set, strut mounting

825410 Strut mounting

835422 Buffer mounting, suspension

845404 Cover/bellows, shock absorber

865403 Roller bearing, strut mounting

895456 Chassis spring

895496 Chassis spring

925492 Tie rod

925493 Tie rod

925494 Tie-rod end

925495 Tie-rod end

925496 Axial joint, tie rod

925497 Supporting/guide joint

925498 Supporting/guide joint

925499 Rod/strut, stabiliser

985451 Bearing, steering

985452 Bushing, stabiliser

985456 Bearing, steering

5462 Wheel bearing set

VW T5 2.5 TDI, 96 KW

ChassIs

Use the new Ruville detector card for the generations of wheel bearings with integrated wheel hub and multi-pole code ring:

The detector card has a cut-out for also checking the wheel bearing with integrated wheel hub and for diagnosis of the magnetic multi-pole code ring. Damage to the wheel revs sensor ring is quickly and easily detected simply by holding the card in position.

Article: 5462 | Wheel bearing set

This wheel bearing belongs to the 2.1 generation of wheel bearings. A special tool must always be used for dismantling and installation. The wheel bearing can be replaced with a normal press. Please always use the special tool in this case as otherwise considerable damage will be caused to the bearing with premature failure as a foregone conclusion. This is because of the design. The wheel hub and bearing are only connected via the bearing inner ring through the pre-tension of the orbitally formed shoulder. If the bearing is fitted without using a special tool, it will be auto-matically forced against the bearing inner ring which will cause pressure marks on the raceways and roller bodies.

Caution, damage to the vehicle: Do not loosen the central bolt of the drive shaft when the vehicle is standing on its wheels. When the bolt is loosened, the vehicle can be damaged by the dead weight of the vehicle. Dismantling and fitting:Apply the tools as shown in the picture (Fig. 1): Screw the grips (3) to the wheel hub (1) with wheel bolts. The wheel bolts (2) must not protrude at the back of the grips as otherwise the wheel bearing cannot be pressed in completely. apply the tools as shown in the drawing: 1 Threaded rod 2 Threaded nut3 Pressure head 4 Hydraulic cylinder 5 Bell6 Grips 7 Threaded rod8 Threaded nut 9 Pressure piece

Extract the wheel hub with wheel bearing, holding the jig tight

Apply the tools as shown in the drawing: Use a larger guide piece (9) for installation

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VW T5 2.5 TDI, 96 KW

ChassIs

Article: 755438 | Bellows set, drive shaft 815406 | Dust cap set, shock absorber 825409 | Strut mounting 825409S | Repair set, strut mounting 825410 | Strut mounting 835422 | Buffer mountings, suspension 845404 | Cover/bellows, shock absorber 865403 | Roller bearing, strut mounting 895456 | Chassis spring 895496 | Chassis spring

Repairs to the strut To remove the left strut:For vehicles with 5-speed manual transmission

Unscrew drive shaft from transmissionFor vehicles with 6-speed transmission and vehicles with 4-wheel drive

Press the drive shaft out of the wheel bearing housing

Caution: To prevent stretching the protective collar of the intermediate steering shaft and the hydraulic lines, unscrew the steering gear from the unit support and press the left side approx. 40 mm upwards. Place a wooden wedge or similar under the steering gear.

To remove the right strut: For vehicles with 5-speed manual transmission

Unscrew the drive shaft from the transmissionFor vehicles with 6-speed manual transmission

Unscrew the mounting from the bracket and remove the drive shaft from the transmission.

For vehicles with 4-wheel drive Press the drive shaft out of the wheel bearing housing.

The rear fastening bolt of the unit carrier must be unscrewed completely on both sides of the vehicle. Now screw this bolt in again through 5 turns. Then loosen the front fastening bolt until the washer is loose. Turn the wheel hub so that one of the holes of the wheel bolts is at the top. Fit holder -T10149- to the wheel hub with the wheel bolt. To do so, the wheel bearing housing must be supported with an engine and transmission hoist.

Unscrew the strut from the wheel bearing housing and spread the wheel bearing housing (1) open with spreader 3424. Now lower the wheel bear-ing housing until it is separated from the strut and swivel it in the drive di-rection. You can then remove and dismantle the strut.

Note: When lowering the wheel bearing housing, always make sure that the drive shaft has sufficient clearance.

Article: 925492 | Tie rod 925493 | Tie rod 925494 | Tie-rod end 925495 | Tie-rod end 925496 | Axial joint, tie rod

Installation: Caution! The gear rack of the steering gear must be greased before fitting the tie rod. Please only use the grease specified by the manufacturer. To distribute the grease, turn the steering alternately to both sides as far as it will go. Grease the gear rack on the gearing and pressure piece side. Then turn the steering to straight-on position. Screw the tie rod (2) into the gear rack of the steering gear (5). Tighten the tie rod (2) using the open-end wrench (SW 38). There is no need to hold the gear rack. Comply with the tightening torques of the tie rod!

Fasten the bellows (4) to the steering gear (5) using a new clamp (3). To do so, please use the gripper for Phaeton steering gear or hose clip pliers. Make sure that the bellows are not twisted. Then screw the tie-rod end (1) to the steering lever of the wheel bearing housing using a new nut. Always align the vehicle.