Subframe, Servicing, from 05/28/2012

Front Bonded Rubber Bushing, Replacing

Special tools and workshop equipment required

• Tensioning Strap -T10038-
• Hydraulic Press - Rear Subframe Bushing Tool Kit -T10263-
• Subframe Bushing Assembly Tool Kit -T10356-
• Engine and Gearbox Jack -VAS6931-
• Hydraulic Press -VAS6178- with Bearing Installer - Wheel Hub/Bearing Kit- Pressure Head -T10205/13-
• Pneumatic/Hydraulic Foot Pump -VAS6179-
• Bearing Installer - Wheel Hub/Bearing Kit -T10205-

Note

• If a bonded rubber bushing is faulty, then the bonded rubber bushing on the opposite side must also be replaced. Refer to the Parts Catalog for the allocation.
• Check the other bearing before switching out a defected bonded rubber bushing.
• If there are any tears or other visible damages, replace the bonded rubber bushing.
• In order to replace the rubber bonded bushing, the subframe must be lowered either at the front or at the rear. It is not necessary to remove the subframe.
• Identify mounting location to subframe before removing the bonded rubber bushing.

Pressing Out Bonded Rubber Bushing, Front

• Loosen the wheel bolts.
• Raise the vehicle.
• Remove the wheels.
• Remove the spring.
• Remove the rear muffler.
• Disconnect the electric connections between the rear axle and the body.
• Remove the stabilizer bar.
• Remove the tie rods.
• Remove the clamps -1- on both sides of the vehicle.

Note

Do not disconnect the brake line.

• Secure both sides of the vehicle on the hoist arms using Tensioning Straps -T10038-.

WARNING

The vehicle could slide off the hoist if it is not secured.

• Place the Engine and Gearbox Jack -VAS6931- with Universal Support Plate -VAG1359/2- below subframe and secure with strap.

• Remove hex head bolt -1 or 2- on both sides.

Note

Only the left side of the vehicle is shown in the illustration.

To secure the subframe, Locating Pins -T10096- must be screwed in one after the other on both sides of the vehicle at positions -1 and 2-.

• Secure the position of the subframes using two Locating Pins -T10096- to 20 N·m.

Note

Locating Pins -T10096- may only be tightened to a maximum of 20 N·m, since otherwise the threads of the locating bolts will be damaged.

• Replace the bolts of the subframe one after the other on both sides using Locating Pins -T10096- and tighten them to 20 N·m.

The subframe position is now secured.

• Mark the installation location of the bonded rubber bushing on the subframe with a felt-tip pen -1-.

Note

Apply the mark -1- on the subframe in the middle of the recess on the bonded rubber mounting -2-.

• Use a screwdriver -2- to pry off the anti-twist mechanism -1- near the bonded rubber bushing mounting retaining lugs.
• Lower the subframe approximately 100 mm using the Engine and Gearbox Jack -VAS6931-.

• Unclip the brake line -1- from the clip -arrow- on the left side.

Note

This will destroy the clip, so it will have to be replaced.

• Use the special tools as shown.

1. 1
   Hydraulic Press - Rear Subframe Bushing Tool Kit - Nut -T10263/5-
2. 2
   Subframe Bushing Assembly Tool Kit-Press Piece -T10356/1-
3. 3
   Subframe
4. 4
   Subframe Bushing Assembly Tool Kit-Pipe -T10356/2-, side with shoulder points to subframe
5. 5
   Bearing Installer - Wheel Hub/Bearing Kit - Gripping Device -T10205/1-
6. 6
   Hydraulic Press -VAS6178- with Bearing Installer - Wheel Hub/Bearing Kit- Pressure Head -T10205/13-
7. 7
   Hydraulic Press - Rear Subframe Bushing Tool Kit - Nut -T10263/5-
8. 8
   Hydraulic Press - Rear Subframe Bushing Tool Kit-Threaded Rod -T10263/4-

• Pretension special tools.
• Press out the bonded rubber bushing.

Note

• When removing the bonded rubber mounting, the bearing outer race is sheared off. There is a loud crack when this happens.
• After removing the bonded rubber bushing, it must be removed from the Tube -T10356/2- by tapping lightly with a hammer.

Press In on the Front Bonded Rubber Bushing

• Apply a line -1- on the vertical rib of the bonded rubber bushing to help mount.

• Apply mounting paste to the outer edge of the bonded rubber bushing.
• Insert special tools with bonded rubber bushing into subframe as illustrated.

1. 1
   Hydraulic Press - Rear Subframe Bushing Tool Kit - Nut -T10263/5-
2. 2
   Subframe Bushing Assembly Tool Kit-Thrust piece -T10356/7- - the mark -A- points to the subframe
3. 3
   Subframe
4. 4
   Adjust the bonded rubber bushing to the marks (the marks need to align)
5. 5
   Assembly Tool - Bushing -T10356/8- - the flattened sides need to fit into the cover of the bonded rubber bushing -arrows-.
6. 6
   Bearing Installer - Wheel Hub/Bearing Kit - Gripping Device -T10205/1-
7. 7
   Hydraulic Press -VAS6178- with Bearing Installer - Wheel Hub/Bearing Kit Pressure Head -T10205/13-
8. 8
   Hydraulic Press - Rear Subframe Bushing Tool Kit - Nut -T10263/5-
9. 9
   Hydraulic Press - Rear Subframe Bushing Tool Kit - Threaded Rod -T10263/4-

• Check the position of the bonded rubber bushing and, if necessary, align and pre-tighten special tools with bonded rubber bushing.

Note

• Make sure that the hose from the Hydraulic Press -VAS6178- to the Pneumatic/Hydraulic Foot Pump -VAS6179- runs between the trailing arm and the fuel tank when installed.
• Make sure that the bonded rubber bushing is not bent when installing. Otherwise the outer ring could become damaged.

• Operate the pump to press in the bonded rubber bushing until the shoulder is positioned on the subframe "without gap".

Install in reverse order of removal. Note the following:

Tightening Specifications

Rear Bonded Rubber Bushing, Replacing

Special tools and workshop equipment required

• Tensioning Strap -T10038-
• Hydraulic Press - Rear Subframe Bushing Tool Kit -T10263-
• Subframe Bushing Assembly Tool Kit -T10356-
• Engine and Gearbox Jack -VAS6931-
• Hydraulic Press -VAS6178- with Bearing Installer - Wheel Hub/Bearing Kit- Pressure Head -T10205/13-
• Pneumatic/Hydraulic Foot Pump -VAS6179-
• Bearing Installer - Wheel Hub/Bearing Kit -T10205-

Note

• If a bonded rubber bushing is faulty, then the bonded rubber bushing on the opposite side must also be replaced. Refer to the Parts Catalog for the allocation.
• Check the other bearing before switching out a defected bonded rubber bushing.
• If there are any tears or other visible damages, replace the bonded rubber bushing.
• In order to replace the rubber bonded bushing, the subframe must be lowered either at the front or at the rear. It is not necessary to remove the subframe.
• Identify mounting location to subframe before removing the bonded rubber bushing.

Pressing Out Rear Bonded Rubber Bushing

• Loosen the wheel bolts.
• Raise the vehicle.
• Remove the wheels.
• Remove the spring.
• Remove the rear muffler.
• Remove the clamps -1- on both sides of the vehicle.

Note

Do not disconnect the brake line.

• Secure both sides of the vehicle on the hoist arms using Tensioning Straps -T10038-.

WARNING

The vehicle could slide off the hoist if it is not secured.

• Place the Engine and Gearbox Jack -VAS6931- with Universal Support Plate -VAG1359/2- below subframe and secure with strap.

• Remove hex head bolt -1 or 2- on both sides.

Note

Only the left side of the vehicle is shown in the illustration.

To secure the subframe, Locating Pins -T10096- must be screwed in one after the other on both sides of the vehicle at positions -1 and 2-.

• Location position of subframe with Locating Pins -T10096-.

Note

Locating Pins -T10096- may only be tightened to a maximum of 20 N·m, since otherwise the threads of the locating bolts will be damaged.

• Replace the bolts of the subframe one after the other on both sides using Locating Pins -T10096- and tighten them to 20 N·m.

The subframe position is now secured.

• Mark the installation location of the bonded rubber bushing on the subframe with a felt-tip pen -1-.

Note

Apply the mark -1- on the subframe in the middle of the recess on the bonded rubber mounting -2-.

• Use a screwdriver -2- to pry off the anti-twist mechanism -1- near the bonded rubber bushing mounting retaining lugs.
• Lower the subframe approximately 100 mm using the Engine and Gearbox Jack -VAS6931-.

• Unclip the brake line -1- from the clip -arrow- on the left side.

Note

This will destroy the clip, so it will have to be replaced.

• Use the special tools as shown.

1. 1
   Hydraulic Press - Rear Subframe Bushing Tool Kit - Nut -T10263/5-
2. 2
   Subframe Bushing Assembly Tool Kit - Thrust Piece -T10356/5-
3. 3
   Subframe
4. 4
   Subframe Bushing Assembly Tool Kit - Tube -T10356/6-, side with offset points to subframe
5. 5
   Bearing Installer - Wheel Hub/Bearing Kit - Gripping Device -T10205/1-
6. 6
   Hydraulic Press -VAS6178- with Bearing Installer - Wheel Hub/Bearing Kit Pressure Head -T10205/13-
7. 7
   Hydraulic Press - Rear Subframe Bushing Tool Kit - Nut -T10263/5-
8. 8
   Hydraulic Press - Rear Subframe Bushing Tool Kit-Threaded Rod -T10263/4-

• Pretension special tools.
• Press out the bonded rubber bushing.

Note

• When removing the bonded rubber mounting, the bearing outer race is sheared off. There is a loud crack when this happens.
• After removing the bonded rubber bushing, it must be removed from the Subframe Bushing Assembly Tool Kit - Tube -T10356/6- by tapping lightly with a hammer.

Press In the Rear Bonded Rubber Bushing

• Apply a line -1- on the vertical rib of the bonded rubber bushing to help mount.

• Apply mounting paste to the outer edge of the bonded rubber bushing.
• Insert special tools with bonded rubber bushing into subframe as illustrated.

1. 1
   Hydraulic Press - Rear Subframe Bushing Tool Kit - Nut -T10263/5-
2. 2
   Subframe Bushing Assembly Tool Kit - Bushing -T10356/7- - the marking -B- points to the subframe
3. 3
   Subframe
4. 4
   Adjust the bonded rubber bushing to the marks (the marks need to align)
5. 5
   Subframe Bushing Assembly Tool Kit - Bushing -T10356/8- - the flattened sides need to fit into the cover of the bonded rubber bushing -arrows-.
6. 6
   Bearing Installer - Wheel Hub/Bearing Kit - 1 -T10205/1-
7. 7
   Hydraulic Press -VAS6178- with Bearing Installer - Wheel Hub/Bearing Kit Pressure Head -T10205/13-
8. 8
   Hydraulic Press - Rear Subframe Bushing Tool Kit - Nut -T10263/5-
9. 9
   Hydraulic Press - Rear Subframe Bushing Tool Kit - Threaded Rod -T10263/4-

• Check the position of the bonded rubber bushing and, if necessary, align and pre-tighten special tools with bonded rubber bushing.

Note

Make sure that the bonded rubber bushing is not bent when installing. Otherwise the outer ring could become damaged.

• Operate the pump to press in the bonded rubber bushing until the shoulder is positioned on the subframe "without gap".

Install in reverse order of removal. Note the following:

Tightening Specifications