VW Amarok Customer complaint: clacking noises from leaf spring

Repair instructions: Installation of a 0.9mm thick packing in 2+1 or 3+2 leaf spring
Installation of a 0.9mm thick packing in 2+1 or 3+2 leaf spring
1. Lift the vehicle and secure it against falling down with tensioning belts.
2. Remove the rear wheels.
3. Position the engine and gearbox jack -V.A.G 1383 A- centrally under the rear
differential and support it with a square length of wood at the front, see photo:
4. Remove the shock absorber bolt -1- on the rear axle (both sides)
TPI 2030221 - page 2
5. Remove the nuts -1- from the spring clamps -2- and -
3-.
6. Take off the spring clamp and the spring clamping
plate.
7. Lower the axle a little with the engine and gearbox
jack -V.A.G 1383 A- and turn the jack to make the
centre bolt of the leaf spring accessible, see photos:
Note!
The brake hoses must not be
under tension or kinked.
Installation of a 0.9mm thick packing in 2+1 or 3+2 leaf spring
TPI 2030221 - page 3
8. Loosen the attachment of the centre bolt of the leaf spring and remove the bolt.
9. a.) 2+1 leaf spring: Remove the lower spring packing (2.0mm thick) between lower
and central leaf spring. b) 3+2 leaf spring: Remove the lower spring packing (2.0mm
thick) between the third and fourth layer.
Installation of a 0.9mm thick packing in 2+1 or 3+2 leaf spring
TPI 2030221 - page 4
8. Clean the space before inserting the new plate.
9. Fit the new spring packing 2H0.511.160 (thickness 0.9mm) from the repair kit
2H0.598.160.
The repair kit 2H0.598,160 consists of these components:
Part number Designation Quantity
2H0 511 160 Spring packing 2
WHT 005 772 Hex. nut M10x10.5 2
WHT 005 779 Centre bolt M10x1.5x52 2 for 2+1 spring (not needed for 3+2
spring)
WHT 005 780 Centre bolt M10x1,5x68 2 for 3+2 spring (is with 2+1 spring not
needed)
10. A clamp or pliers can be used to install the centre
bolt. The surface of the leaf spring must not get
damaged in the process (e.g. protect length of
wood, see photo).
Installation of a 0.9mm thick packing in 2+1 or 3+2 leaf spring
TPI 2030221 - page 5
11. Align the plates parallel to the leaf springs.
12. Position the individual leaf spring layers centrally in the fanned-out arrangement.
13. Tighten the new centre bolt with the new nut. Tightening torque CNM.
14. The installation takes place in reverse order, note the following points:
Fanned-out arrangement
View from
front View from rear
Installation of a 0.9mm thick packing in 2+1 or 3+2 leaf spring
- Make sure that the guide pins of the leaf spring reach into the hole of the axle.
- Tighten the clamps equally to achieve the same excess lengths of the thread.
- Rubber metal mountings have a limited turning range. Therefore tighten the screwed
connections on the shock absorbers only when the rear axle is lifted (unladen
weight position).
Note
TPI 2030221 - page 6
Installation of a 0.9mm thick packing in 2+1 or 3+2 leaf spring
Bolt tightening torques:
Component Tightening torque
Spring clamp bolts on the spring clamping plate. 150 Nm + 180
Shock absorber on the axle tube 90 Nm + 180
Leaf spring centre bol t 45 Nm
Always replace the packing on both sides.
One repair kit 2H0.598.160 needed for the repair of one vehicle.
With the listed attachments new nuts and bolts must be used according to the parts
catalogue/ELSA (4x spring clamps, 8x spring clamp nuts, 2x shock absorber bolts
and 2x shock absorber nuts).
TPI 2030221 - page 7