Trevor Ng
If you're looking to replace the struts on your Volkswagen Golf Mk3, you've come to the right place. This job requires some special tools and a fair bit of elbow grease, but with the right guidance, it can be a rewarding DIY project. The struts are an essential part of your vehicle's suspension system, and when they wear out, you'll notice a decline in ride quality and handling. In this step-by-step guide, we'll cover everything from inspecting your struts to disassembling and replacing them, ensuring your Golf Mk3 drives like new again.
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What You'll Learn
Removing the dust shield, clip, and bump stop
To remove the dust shield, clip, and bump stop from the struts of a Volkswagen Golf GTI MK4 (1999-2005 model), follow these steps:
First, jack up the car and remove the front wheels. Disconnect the brake pad wear sensor from the harness, which should be marked with a red arrow. Next, unclip the wire from the holders on the strut, marked with a yellow arrow. Leave the brake line attached to the caliper and hard line, but remove the rubber flexible line from the holder on the strut, as indicated by the red and yellow arrows, respectively.
Now, use a 16mm socket to remove the bolt connecting the sway bar link to the lower control arm, as shown by the red arrow in Figure 3. There should be an 18mm nut and bolt "pinching" the strut into the top of the housing. Use two wrenches or sockets to remove this nut, then slide the bolt out from the housing. With the bolt removed, spray the area between the strut and housing with penetrating oil. You can use a special tool made by Volkswagen, or a 3/8 to 1/4 step down bit or a 7mm Allen to insert in the lower part of the housing and turn to spread it open.
With the car safely supported, push the suspension down until the strut releases from the housing. Now, you can remove the dust shield/boot, clip, and bump stop, marked with red, green, and yellow arrows, respectively. If you are using factory replacement struts, check these components for damage and replace them if needed. If they are still in good condition, you can transfer them to the new strut.
Remember, the installation of the new strut is just the reverse of this removal process. Don't forget to replace the hardware with new single-use nuts and bolts.
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Disconnecting the brake pad wear sensor
Firstly, locate the brake pad wear sensor. It is usually attached to the harness and clipped to the strut via a wire. This wire needs to be carefully unclipped from the holders on the strut. Make sure you are only dealing with the brake pad wear sensor and not the ABS sensor, as they are two separate components. It is important not to cut the ABS sensor wire.
Once you have identified the correct sensor, you can begin the disconnection process. You will need to detach the sensor from the harness. This may involve unclipping or unscrewing the sensor, depending on your specific model. Be cautious when handling the sensor to avoid causing any damage. If the sensor or its connector is corroded, proceed with extra care as corrosion can make the process more challenging.
After detaching the sensor from the harness, you will need to address the wiring. Cut and splice the wire that leads to the brake pad. This step ensures that the circuit is complete, preventing the warning light from illuminating. You can use various methods to splice the wires, such as soldering or crimp fittings. Ensure that you are only splicing the wire connected to the brake pad and not any other components.
Before reconnecting the sensor, it is essential to clean and inspect the contact points. Use a suitable cleaning agent to remove any dirt or corrosion buildup. Verify that the sensor itself is not damaged and is functioning correctly. If the sensor is faulty, you may need to replace it with a new one.
Finally, when you are ready to reassemble the struts, reconnect the brake pad wear sensor by plugging it back into the harness. Ensure that the wire is securely clipped to the holders on the strut. Test the sensor to ensure it is functioning properly and that there are no warning lights illuminated on your dashboard.
By following these steps, you can successfully disconnect and reconnect the brake pad wear sensor when disassembling and reassembling the struts on your Mk3 Golf. Remember to work carefully and consult a professional mechanic if you encounter any issues or complications during the process.
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Removing the drop link
First, it is important to safely raise and support the vehicle. This ensures stability and prevents any accidental movements that could cause injury. Remove the front tires for easier access to the drop link. The stabilizer bar is not under stress or pressure, so there is no need to worry about any sudden movements when removing the drop link.
Next, locate the drop link and the components attached to it. The drop link connects the sway bar to a bracket on the strut. To remove the drop link, you will need to use an 18mm socket or wrench to loosen the nut that secures it to the bracket. If the joint starts turning with the wrench, use a 6mm triple square to hold the bolt and turn the nut with a wrench instead.
Once the nut is removed, you may need to use a bar to lever the sway bar down to completely detach the drop link from the strut. After removing the drop link, you can inspect the bushings for any signs of wear or damage. Look for cracks in the bushings, as well as any rips in the boot or grease leakage, which would indicate the need for replacement.
The process of removing the drop link is now complete. Remember to follow safety protocols and wear appropriate protective gear throughout the procedure. It is important to handle the components with care to avoid any damage to the vehicle or injury to yourself.
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Undoing the ball joint
To undo the ball joint of a strut on a Mk3 Golf, you will need some basic tools and safety gear. It is important to wear safety glasses at all times when working with tools and automotive fluids. Always use a hydraulic jack and safety stands when lifting or getting under a vehicle. If you are unsure about where to safety lift your vehicle, refer to its owner's guide.
Before undoing the ball joint, you will need to jack up the side you will be working on and remove the road wheel. The next step is to remove the drop link to the anti-roll bar. You will need an 18mm socket and an 18mm spanner on the other side to stop it from rotating. Once the nut is removed, use a bar to lever the anti-roll bar down a bit to remove the link from the strut.
Now, you can remove the wires attached to the strut. The rubber grommets should just pull off, and you can then unbolt the bracket holding the brake line. With the brake line still attached to the caliper and hard line, remove the rubber flexible line from the holder on the strut.
At this point, you can put a trolley jack under the steering arm ball joint and jack up the suspension just enough to stop the ball joint from spinning when you try to undo the nut. You can now undo the nut on the steering arm ball joint.
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Replacing nuts and bolts
When replacing the nuts and bolts on your Volkswagen Golf GTI Mk 4 or 5, it is recommended to purchase all new hardware, as Volkswagen microencapsulates their hardware with a binding agent. While some people clean up the threads, apply blue Loctite, and reuse the bolts, this is not advised.
To replace the nuts and bolts, you will first need to jack up the car and remove the front wheels. You should always refer to an up-to-date guide for your specific model, but the following steps are likely to be required.
First, disconnect the brake pad wear sensor from the harness and unclip the wire from the holders on the strut. Leave the brake line attached to the caliper and hard line, but remove the rubber flexible line from the holder on the strut. Next, remove the drop link to the anti-roll bar using an 18mm socket and spanner. You will then need to remove the wires attached to the strut. The rubber grommets should just pull off, and you can then unbolt the bracket holding the brake line.
Now, you can begin to remove the nuts and bolts. There is an 18mm nut and bolt that pinch the strut into the top of the housing. Use two wrenches or sockets and remove the nut, then slide the bolt out from the housing. With the bolt removed, spray the area between the strut and housing with penetrating oil.
You may also need to remove the three 16mm bolts on the bottom of the knuckle to create more room to remove the strut. Additionally, you can remove the 27mm nut that holds the axle to the housing.
When installing the new nuts and bolts, remember that they are single-use only and should be tightened securely.
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