2022-2025 Volkswagen Amarok Truck Chassis User Manual
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Chassis for Your Volkswagen Amarok Truck Second Generation (2022-2025)

2 Chassis  
2.1 Running gear suspension  
Warning note  
Do not alter, drill, cut or weld any suspension  
components, especially the steering rack, subframe or  
anti-roll bars, springs or shock absorbers, including  
mounting brackets.  
The rear leaf springs are preloaded at the time of  
manufacture and should not be altered in any way in  
terms of spring rate or height during vehicle  
conversions. The addition or removal of leaves may  
result in spring failure or reduced function, as well as  
other vehicle-related problems for which Volkswagen  
Commercial Vehicles cannot be held responsible.  
Practical note  
Modifications to the suspension system may result in  
a deterioration of the driving characteristics and  
durability of the vehicle.  
During welding work, the springs must be covered to  
protect them from welding spatter.  
Do not touch the springs with welding electrodes or  
welding guns.  
Information  
For vehicles with Electronic Stability Control (ESC), do  
not change the wheelbase or extend the frame.  
Do not damage the surface or corrosion protection of  
the spring during removal and assembly.  
Do not add any additional axles.  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 50 of 166  
2.2 Brake system  
2.2.1 General information  
The brake system must be fully operational when the vehicle conversion is complete. Vehicle brake operating conditions must be checked,  
including the warning system and handbrakes.  
Warning note  
Air flow and cooling of the brake system must not be  
obstructed.  
Information  
The brake fluid level must remain visible.  
Free access to the brake fluid reservoir must be  
ensured for servicing work and adding brake fluid.  
2.2.2 Brake hoses  
Warning note  
Make sure that the mounting points for the brake hoses are  
removed or reattached with care. Damage to the brake  
hose mounting points or alignment may result in reduced  
clearance and cause wearing of major brake components.  
Renew any damaged parts before using the vehicle.  
Practical note  
Make sure the front and rear brake hoses are not twisted  
and are not near any body or chassis components.  
The front and rear brake hoses must not rub, chafe, or rest against the body or chassis or body parts. There must be a clearance between  
full retraction, full extension and full engagement under all operating conditions.  
Brake lines shall not be used to support or secure other components.  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 51 of 166  
2.2.3 Overrun brake connection  
Warning note  
A pre-installed overrun brake cable provides a pulsed brake  
signal with different frequencies. This pulsed signal is not a  
direct current (DC) signal. If a retrofitted brake controller is  
installed, the vehicle owner or installer must ensure that it  
is compatible with all pulsed signals from the pre-installed  
overun brake cable. Failure to ensure compatibility of your  
brake controller may result in loss of vehicle control, which  
could cause serious injury. If you have any questions about  
the specifications of the pulse signals, please contact your  
Volkswagen Commercial Vehicles partner or importer.  
A pre-installed cable is located behind the tread surface of the A-pillar and is marked TRAILER BRAKE CONTROLLER.  
Volkswagen Commercial Vehicles Body builder guidelines February 2023 edition  
The new Amarok Page 52 of 166  

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