Volkswagen Golf Service & Repair Manual: Repairing subframe

Special tools and workshop equipment required

Assembly tool -T10205-

Torque wrench -V.A.G 1332-

Hydraulic press -VAS 6178-

Foot pump -VAS 6179-

Assembly tool -VAS 6779-

Thrust plate -VW 401-

Press tool -VW 412-

Renewing bonded rubber bushes for pendulum support

If fitted, remove front noise insulation → General body repairs, exterior; Rep. gr.66.

Unscrew nut -1- from coupling rod -3- on both sides.
Pull out coupling rod -3- from anti-roll bar -2- on left and right side.

Unscrew bolts -1- for anti-roll bar.

Leave the anti-roll bar in its installation position in the vehicle.

Remove pendulum support → Rep. gr.10.

Pressing out bonded rubber bush

Fit assembly tool -VAS 6779- to subframe as shown in illustration.
Place thrust piece for removal -VAS 6779-1--1- on bonded rubber bush so that flattened side -arrow- faces to direction of travel.

1 - Thrust piece for removal -VAS 6779/1-

2 - Tube -VAS 6779/4-

3 - Thrust piece -VAS 6779/5-

4 - Hydraulic press -VAS 6178- and thrust piece -T10205/13-

5 - Hexagon nut -VAS 6779/3-

6 - Threaded spindle -VAS 6779/2-

Press out both bonded rubber bushes until upper bonded rubber bush -2- is visible in pendulum support opening -arrow- in subframe.
Carry out visual check of outer ring of upper bonded rubber bush -2-.

If outer ring of upper bonded rubber bush -2- is deformed, destroy it through opening of pendulum support -arrow- in pendulum support.

Using a chisel or similar -1-, create a break in the outer ring of the upper bonded rubber bush -2-.

Note This process is necessary to prevent the canting of the outer ring of the upper bonded rubber bush in the area of the opening of the pendulum support in the subframe.

Press out both bonded rubber bushes together.

Preparing bonded rubber bush for pressing in

Place both bonded rubber bushes -1- and -2- together so that the cut-outs -arrows- line up precisely.
Bolt bonded rubber bushes -1- and -2- hand-tight together using original bolt -3-.

Insert bonded rubber bushes -1- into larger diameter of tube -VAS 6779/6--2- with bolt head facing upwards.
Align bonded rubber bushes -1- in tube -VAS 6779/6--2-. The cut-out in the bonded rubber bush must align exactly with the recess -arrow- in the tube -VAS 6779/6--2-.

Press in bonded rubber bush -3- in tube -VAS 6779/6- to stop, as illustrated.

1 -	Press tool -VW 412-

2 -	Thrust piece -VAS 6779/5-, the side with the lettering »A« must face upwards.

3 -	Bonded rubber bush

4 -	Tube -VAS 6779/6-

5 -	Tube -VAS 6779/4-

6 -	Thrust plate -VW 401-

Insert counterhold -VAS 6779/7--1- into subframe.
Insert counterhold attachment -VAS 6779/7-1A--2- into pendulum support opening in subframe.
Bolt insert -VAS 6779/7-1A- to counterhold -VAS 6779/7--1-.
Ensure that the insert -VAS 6779/7-1A--2 - is correctly seated in the pendulum support opening of the subframe -arrow-.

Pressing in bonded rubber bush

Screw threaded spindle -VAS 6779/2--7- into counterhold -VAS 6779/7--1-
Fit assembly tool -VAS 6779- to subframe as shown in illustration.

1 - Counterhold -VAS 6779/7-

2 - Tube -VAS 6779/6-, -arrow mark- on tube must align centrally between both bolts -arrow-.

3 - Thrust piece -VAS 6779/9-

4 - Stepped ring -VAS 6779/8-, mark -I- on stepped ring must align with mark -X- on thrust piece -VAS 6779/9-.

5 - Hydraulic press -VAS 6178- and thrust piece -T10205/13-

6 - Hexagon nut -VAS 6779/3-

7 - Threaded spindle -VAS 6779/2-

Press in both bonded rubber bushes together.
Remove assembly tool -VAS 6779- from subframe and check pressed-in bonded rubber bushes for proper seating.

Repairing subframe