Rear Subframe Mount: Service and Repair

Subframe Bonded Rubber Bushing, Replacing

Special tools, testers and auxiliary items required

• 50-200 Nm (V.A.G 1332)

• Engine-/Gearbox Jack (V.A.G 1383 A) with Universal Transmission Support (V.A.G 1359/2)

• Body Saw (V.A.G 1523 A)

• Hydraulic Press (VAS 6178)

• Pneumatic/Hydraulic Foot Pump (VAS 6179)

• Drip Tray for VAS 6100 (VAS 6208)

• Tensioning Strap (T10038)

• Assembly Tool (T10205) , only for rear bonded rubber bushing

• Assembly Tool (T10301)

• Locating Pins (T10300)

• Before replacing malfunctioning bushing, check other bushings as well.

• If tears, oil leaks or other damages are visible, these bushings must also be replaced.

Pressing Out the Bonded Rubber Mount

Before loosening subframe bolts, secure vehicle against tipping over (for example load luggage compartment with approximately 50 kg).

- Remove wheels.

- Mark position of crossmember on body using felt-tip pen.

- Remove left and right bolts - arrows - from crossmember.

- Remove rear exhaust system.

- Disconnect and disengage all electrical wires from body to axle.

- Secure subframe, refer to => [ Subframe, Securing ] Description and Operation.

• If the front bonded rubber bushing is replaced, an axle alignment must be performed.

• If the rear bonded rubber bushing is replaced, a road test must be performed. If steering wheel is crooked, vehicle must be aligned. Refer to => [ Wheel Alignment ] Wheel Alignment.

- Place (V.A.G 1383 A) with (V.A.G 1359/2) - 4 - under the subframe.

- Place a suitable block of wood - 1 - under the subframe - 5 - and another one - 6 - under the rear final drive - 3 -.

- Secure the subframe on the (V.A.G 1383 A) with the (T10038) - 2 -.

- Remove two remaining attachments bolts for subframe.

- Lower subframe with a 2nd technician. The following must be observed when doing so:

• Lower it only as far as necessary.

• Note electrical wires and brake hoses

• Lower subframe evenly from body

- Lower the subframe.

In order to press out the bonded rubber bushing, the cover on the mount's inner core must first be removed.

- Saw the bar - arrow - on the inner side of the cover - 1 - 6 times with the (V.A.G 1523 A). Saw the cuts - 2 - approximately 3 mm deep.

3 Underside of removed cover

- Pry off cover - 1 - with a screwdriver.

- If necessary, the support - arrow - with the small interior diameter must be removed from the (VAS 6178) and the support (T10205/13) for that installed.

- Place the tools on the front bonded rubber bushing as shown in the illustration.

1. Thrust piece (T10301/5)

2. Support Ring (T10301/4). The chamfer on the exterior diameter must face toward the subframe.

3. Tube (T10301/3)

4. Hydraulic cylinder (VAS 6178)

5. Washer (T10205/4)

6. Nut (T10301/2)

7. Spindle (T10301/1)

• Secure (VAS 6178) while pressing out.

• Bonded rubber bushing loosens abruptly. There is the risk of injuries by tools and bonded rubber bushing coming off!

- Place (VAS 6208) underneath.

- Press out bonded rubber bushing and collect escaping oil.

Pressing In the Bonded Rubber Mount

Installation location of front bonded rubber bushing

- Arrows - point in direction of travel.

Holes - A - are parallel to direction of travel

Seams - B - face perpendicular to direction of travel

Installation Location of Rear Bonded Rubber Bushing

- Arrows - point in direction of travel.

Holes - A - are parallel to direction of travel

Cutouts - B - face perpendicular to direction of travel.

- Place the tools on the front bonded rubber bushing as shown in the illustration.

1. Thrust piece (T10301/7)

2. Bonded rubber mount

3. Thrust plate (T10301/6)

4. Hydraulic cylinder (VAS 6178)

5. Washer (T10205/4)

6. Nut (T10301/2)

7. Spindle (T10301/1)

- Press in bonded rubber bushing until shoulder lies gap-free at subframe sleeve. Release the pressure several times over the cylinder and then install it again.

• After replacing the bearing, remove abrasions on subframe with a file.

• Correct paint damage on subframe with corrosion protection, primer and black top coat.

- Place the tools on the rear bonded rubber bushing as shown in the illustration.

1. Thrust piece (T10301/12)

2. Bonded rubber mount

3. Thrust plate (T10301/6)

4. Thrust plate (T10301/10)

5. Hydraulic cylinder (VAS 6178)

6. Washer (T10205/4)

7. Nut (T10301/2)

8. Spindle (T10301/1)

- Press in the bonded rubber bushing until shoulder lies gap-free at subframe sleeve. Release the pressure several times over the cylinder and then install it again.

• After replacing bearing, remove abrasions on subframe with a file.

• Correct paint damage on subframe with corrosion protection, primer and black top coat.

- Install the subframe with a 2nd technician and remove (T10300).

Install in reverse order of removal.