Installing Rough Road Suspension - Rear

[MOGolf]

Installing the Rough Road suspension rear shocks and springs.

These parts are for the RR package, but the process is the same for any rear shock/spring replacement.

The complete shock parts are shown below.

Starting from top of shock (quantity two for job unless specified):
Nut N 103 041 02 (always replace, tighten to 25Nm)
Mount 3B0 513 353
Mount bolts N 907 583 01 or N 907 583 02 (two each side - four total, tighten to 45Nm)
Jounce bumper 3B0 512 131 H
BOOT 4B0 512 137 B
cap 1H0 513 268 D
shocks 4B0 511 115 DD
Bolt N 104 110 01 (always replace, tighten to 50Nm plus 1/4 turn)
Nut N 102 861 02 (always replace)

Installation steps:

Raise and safely support the car.

Remove wheel.

Use a jack to lift the axle to the point that it just starts to lift the vehicle off the support. I used a bottle jack pressing on a block of wood under the spring seat.

Remove the two upper bolts. (13mm socket required)

Remove the lower bolt and nut. (16mm socket/wrenches requied)

Remove the shock from the car. (BTW, that yellow paint mark is an identifying mark for the shock. Different shocks have different colors.)

You raised the axle so that there is no weight pulling down on the shock as you removed it. The same must be done when you install it.

Assemble the new shock to the upper mount and jounce bumper. If reusing the mount and old bumper, remove the old shock first. Install the cap on the shock, assemble the boot to the jounce bumper, push those into the mount, then attach the mount to the rod. The new, larger diameter boot is required because these shocks are larger in diameter compared to the originals. Put a drop of a liquid soap on your finger, spread it on the ball end of the bumper, and then work the bumper into the boot.

Tools required: 16mm socket/wrench, counterholding tool for the shock. Here is the 3079 counterholding tool and special cutaway socket.

The old shocks have a mystery part. It protects the threads on the shock. I transferred it from old to new.

If you're going to replace the springs, now is the time to do it. I found it necessary to insert a pry bar in the axle tube where the lower nut is located and press down in order to remove/install the spring. I suggest replacing the spring plates (4B0 512 149) since they will be worn. They just slip over "posts" that keep them, and the spring, centered in place.

The springs shown (three white and one orange) are p/n 4B0 511 115 DD. Springs appropriate for a sedan, or without going up any weight range will/may be different.

Be sure to install the springs so that the ends of them are parallel to the line of the axle across the body of the car.

Install the shock to the rear axle, but leave the bolt loose. Raise the axle to position the shock and make sure there is now weight pulling down on it when you install the upper bolts. Tighten them, then tighten the lower bolt.

Reinstall the wheel. Lower the car (unless it is on a lift).

Repeat the process for the other side. Lower the car. Clean up.

For the curious, the shocks and springs had to come from Europe. They are not standard North Amerian parts.

Coming in another thread: The front struts.

 

[Heli wrench]

thanks for that well written informative post!!

 

[Radman]

As a side note you do not have to remove the wheels to do this. It is actually easier with the wheel in place as the weight of the wheel will help pull down the axel. The axel will raise itself automatically during re-install as you lower the car. It takes about 20 mins to do the rear suspension on the B5.5 and MKIV cars.

 

[MOGolf]

You do not want the weight of the axle pulling down on the shock during removal nor install. Also, I don't have a torque wrench that can get in there to the upper bolts with the wheel in place. Getting the wheel out of the way is a simple thing to do.

The weight of the wheel might help with spring removal, but I'm not putting in on just for that.

 

[Radman]

Ill rephrase my statement. You have to remove the lower shock bolt before you raise the car. Thus no stress on shock. As for torque wrench you are correct. It will probably not fit up there. I use my impact on lowest setting when re-installing bolts. This is my preferred method. I have found with the wheel removed it is more difficult to do as you have to raise the axel into place. Removing the wheel is no big deal however as you mention.
Regardless of method MOGolf's method is the correct instructed way. Thanks for sharing with all whom may have feared attempting this themselves. It is an easy procedure. The front on the other hand is more complicated.

 

[Growler]

The front on the other hand is EXTREMELY more complicated.

fixed that for you..

perhaps MOGolf will enlighten us as to the troubles he had to go thru to compress his rough road springs enough.... when he gets it finished.. was quite the scene at his place on Sunday when he had the first one apart and we were trying (and failed) to get the spring compressed enough...

 

[Tolianych]

Folks, need advice on the springs. Planning to do a similar project - got an 01 Passat 4Motion GLX wagon. My local dealer (MD) can likely get the following springs:

4B0 511 115 G - 1 blue
4B0 511 115 H - 2 blue
4B0 511 115 J - 3 blue
4B0 511 115 K - 2 violet
4B0 511 115 L - 3 violet
3B0 511 115 AG - 1 orange 1 blue
3B0 511 115 AH - 1 orange 2 blue
3B0 511 115 AJ - 1 orange 3 blue
3B0 511 115 AK - 1 white 1 blue
3B0 511 115 AL - 1 white 2 blue

Which one(s) are the closest in size and stiffness to the one used by MOGolf for his project (1 orange, 3 white marks)? Thanks!

T

 

[oilhammer]

Just an update, the rear springs 4B0-511-115-DD are NLA from Volkswagen (they do not even show that as being a good number anymore).

This would be for a FWD wagon.

 

[NHV10]

I just got front and rear rough road springs from Frans in Holland (as well as a 5-speed manual transmission kit) for a second 05 wagon. I have put 30K miles on the first wagon, with the rough road springs and Bilstein HD shocks, plus takeoff wheels/tires from a Tiguan, and it has been a very nice ride.

Am holding off on tire size for th new wagon until I get a feel for the gearing of the new tranny. it is noticeably slower off the line with the stock auto, and bigger tires, but perfectly acceptable, and cruises nicely at high speeds.

 

[deming]

Just read this thread.

We have two 2005 Passat Wagons. One has some miles on the clock (165k) and I think the rear shocks or springs may be worn out.
In the warm weather months we frequently haul stuff in the back on road trips and it sags. I do not want to do the Air Lift air bag thing.

I am strongly considering the HD Bilstein front and rear shocks from Bora and new springs.

I could however use some advice on replacement coil springs.

Can you tell me about these special front and rear "rough road" springs from Frans ?
I do not want the car looking like a lifted truck and I do not want to lose my stock looking ride height.
Going up a little bit (maybe 1.00" is OK). Down / lowered is not OK. Advice ?