This car is going to fight me all the way!
What I thought was going to be a simple task has turned into a nightmare of a project. My hopes of simply pulling the wheel speed sensor and cleaning it have turned into completely disassembling the front suspension.
On paper is simple. Reality is something different. What I thought was an easy task has escalated into something out of my control.
Like I said in my previous post http://www.etechautoworks.com/abs-traction-control-brake-pad-warning-light-on/ you should be able to remove the wheel speed sensor by hand. That is of course if it is possible to remove by it by hand. In my case it was so rusted and seized that I had only one choice – completely destroy it.
Which in some cases is recommened, but not in this one.
To compound issues even more not only was the wheel speed sensor seized, so was the upper control arm thru-bolt.
Okay, let’s take a few steps back. The wheel speed sensor is located on the steering knuckle. The steering knuckle is held together by the upper and lower control arms and the steering rod end. Take an even further step back. The Passat B5 has a four-point independent suspension system. Two upper control arms – two lower control arms.
It’s a great setup if maintained regularly, but if not it can be as time-consuming and costly as this one is.
Bearing Bracket
The upper control arms have one single thru-bolt securing them to the steering knuckle. If you have ever done any suspension work most jobs can be accomplished with just a hammer, ball joint spreader, and or punch. But not with this vehicle. Everything is so rusted and seized that a lot more force is required.
Volkswagen-SnapOn does make a specific tool for this application for reference.
VAS6085
It’s basically a press. That presses the bolt out. Instead of hammering it out it. Which is what I did and in most cases is possible but it did not quite work out. Instead, the bolt just folded.
Here’s what’s left of the bolt after the head sheared off and I cut what was left of the threaded stud off.
Just for reference and if at this point you are as frustrated as I am I found this guy on YouTube and it was the most relaxing video I have ever watched. https://www.youtube.com/watch?v=ZjX6Dbo4u8E
Anyways, now that the bolt is stuck I have no choice but to remove the whole assembly in one piece. Which requires removing the bearing bracket.
The bearing bracket is held on by three bolts. Which are accessible through the engine bay. Attached to the bearing bracket are the upper control arms and shock strut. It is possible to remove one of the control arms without removing the bracket but the forward control arm is not possible. Thanks, Volkswagen.
It’s too close to the structure. The aft one. No problem.
And I thought it was going to get easier from there.
This has been the most frustrating experience that I have ever had. I guess what I am most frustrated with is something that should have taken me 10 minutes maximum has turned into who knows when it’s going to get done.
Not only is the thru-bolt stuck just to add injury to insult the bearing bracket bolts are stripped and I sheared the aft lower control arm ball joint.
After everything is said and done here is the damage count.
Aft Lower Control Arm
Bearing Bracket
Sheared bolt. Cracked bracket.
Here’s what’s left of the speed sensor for the most part.
Wheel Speed Sensor
