Rear Cross-Member: Service and Repair

Subframe with Attachments

Special tools, testers and auxiliary items required

• Torque wrench (V.A.G 1331)

• Torque wrench (V.A.G 1332)

• Engine/transmission jack (V.A.G 1383 A) with universal transmission support (V.A.G 1359/2)

• Tensioning strap (T10038)

Removing

• For later assembling work where the drive axle to wheel hub threaded connection must be loosened, note that it must not be done while the vehicle is resting on its wheels. Loosen the connection between the drive axle and wheel hub. Refer to => [ Threaded Connection Between Drive Axle and Wheel Hub, Loosening and Tightening ] Procedures.

- Before starting work, determine dimension - a - from the center of the wheel to the lower edge of the wheel housing while the vehicle is resting on its wheels.






- Place the vehicle on a hoist.

- Remove wheels.

- Remove coil springs. Refer to => [ Coil Spring ] Removal and Replacement.

- Remove the rear muffler.

Applies to Vehicles with AWD






- Remove the driveshaft from the rear final drive.

- Secure the driveshaft - 3 - to the body. Refer to - 2 - using a wire - 1 -.

- Move rear driveshaft tube as far as possible in direction of transmission.

- If the vehicles as a sport differential, remove the bolts - arrows - and remove the bracket - 1 - from the rear final drive.






• Mark the connectors - 2 - for the oil pressure/temperature sensor and on the clutch valves.

- Mark the connectors - 2 - on the oil pressure/temperature sensors and on the clutch valves.

- Disconnect the connector - 4 - from the AWD pump (V415).

- Unclip the wiring harness - 3 - from the final drive and the subframe - 5 through 7 - and tie it up.

Continuation for All






- Remove the left and right bolt - 2 - and the bracket with wires - 1 -.

- Release the connector - 1 - from the left ABS wheel speed sensor (G46) and right ABS wheel speed sensor (G44) and remove it.






- Disconnect the right and left electro-mechanical parking brake connectors - 3 -.

- Remove the left and right bolt - 2 - and the bracket with wires - 6 -.

- Disconnect the connector - 5 - from the Left Rear Level Control System Sensor (G76) and, if equipped, from the Right Rear Level Control System Sensor (G77).

- Remove left wiring harness- 4 -, and if equipped, the right one as well and expose.

- If the vehicle has electronically controlled damping, disconnect the connector on the shock absorber and free up the wiring harness.

- Release the retaining tabs - A - and remove the stone deflector - 2 -.






- Remove the bolt - 2 - and washer - 1 -.






- Disconnect the connectors - 1 -.






- Remove the brake caliper.

- Guide the brake caliper past the wheel suspension and secure it on the body so the weight of the caliper does not stress or damage the brake hose or line.

- Attach the upper transverse link to the wheel bearing housing by hand - 1 -.

- Remove the cover - 1 - and - 2 -..






- Remove the wheel spoiler..

- Install the stone deflectors - 1 -, - 2 - and - 3 -, if applicable.







Before -LOOSENING- subframe bolts, secure vehicle against tipping over (e.g. load luggage compartment with approximately 50 kg).

- Place the (V.A.G 1383 A) with the (V.A.G 1359/2) under the subframe and secure it using the (T10038).






- Where installed, support the rear final drive - 1 - using a suitable wood block - 2 -.

- Support front of subframe with a suitable wood block - 4 - under crossmember - 3 -.

- Secure the (T10038) under the driveshaft and around the subframe and guide it behind the rear final drive.

- Route the (T10038) under the (V.A.G 1359/2) and tighten it.

- Remove the left and right bolt - 1 -.






- Remove bolts - Arrows -.






• Before lowering the subframe, make sure all the electrical wiring connections have been disconnected and removed.

- Carefully lower subframe with components. Be careful of the brake caliper and its lines.

Installing

Install in reverse order of removal. Pay attention to the following:

Tightening specifications, refer to => [ Subframe, Stabilizer Bar and Coupling Rod Assembly Overview ] Service and Repair.

Tightening specifications, refer to => [ Wheel Bearing Housing, Wheel Bearing Unit and Coil Spring Shock Absorber Assembly Overview ] Wheel Bearing Housing, Wheel Bearing Unit and Coil Spring Shock Absorber Assembly Overview.

• Bonded rubber bushings have a limited range of rotation. Therefore, do not pull the threaded connections on the wheel suspension tightly until the vehicle is positioned in the curb weight or control position.

• Raise the wheel bearing in curb weight position on vehicles with coil springs. Refer to => [ Wheel Bearing, with Coil Spring, Lifting to Curb Weight Position ] Rear Suspension.

- The center of the subframe mount holes must be aligned to the bolting points on the body.

- Align the subframe to the fuel tank so that dimension - a - on vehicles without a stone deflector is 19 mm and dimension - b - on vehicles with a stone deflector is 14 mm.






• Only install the coil springs when the subframe bolts have been tightened to the specification.

- Tighten the front wheels.

- Axle alignment required; see table. Refer to => [ Wheel Alignment ] Wheel Alignment.