Steel Subframe, Servicing

Steel Subframe, Servicing

Special tools, testers and auxiliary items required
^ Tensioning strap T10038
^ Locating pins T10096
^ Assembly tool T10263
^ Engine/transmission jack V.A.G. 1383 A
^ Hydraulic Press VAS 6178 with Pressure Head T10205/13
^ Hollow piston cylinder VAS 6179

Remove front bonded rubber bushing.

Pull in front bonded rubber bushing.

Pull out rear bonded rubber bushing.

Pull in rear bonded rubber mounting.

Front bonded rubber bushing, removing
- Remove rear wheels.
- Remove coil springs.
- Remove exhaust system rear muffler.
- Disconnect electrical connections between rear axle and body.
- Remove stabilizer bar.
- Remove tie rods.

- Remove the clip - 1 -.

Note: Do not disconnect the brake line.

- Now secure vehicle on both sides to lifting arms on hoist with straps T10038.

CAUTION! If vehicle is not secured, it could slide off of hoist.

- Place engine/transmission jack V.A.G. 1383 A with universal transmission support V.A.G. 1359/2 below subframe and secure with strap.

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

Note: For the sake of a better illustration, only the left side of the vehicle is shown.

To locate subframe, locating fixtures 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 fixtures T10096.

Note: Locating pins T10096 must only be tightened to maximum of 20 Nm, otherwise threads of locating pins may be damaged.

- Replace subframe bolts one after the other on both sides using locating fixtures T10096 and tighten them to 20 Nm.

Position of subframe is now secured.
- Lower subframe 10 cm using engine/transmission jack V.A.G. 1383 A.
- Mark installation position of bonded rubber bushing to subframe, e.g. with a felt-tip pen.

- Install special tools as depicted in the illustration.
1- Nut T10263/5
2- Washer, from T10263
3- Tube T10263/6
4- Hydraulic Press VAS 6178 with Pressure Head T10205/13
5- Nut T10263/5
6- Spindle T10263/4
- Pretension special tools.
- Pull out bonded rubber bushing by operating pump.

Note: The bearing outer race is sheared off when the bonded rubber bushing is removed. There is a loud crack when this happens.

- After removing the bonded rubber bushing, it must then be removed from tube T10356/6
- Mount tube T10356/6 on provided surfaces in a vise.
- Pry a screwdriver between tube T10356/6 and rubber bonded bushing - arrow - and, if necessary, remove bushing by tapping lightly with a hammer on the drift.

Pull in front bonded rubber bushing
Installation is performed in reverse order of removal. Observe the following when doing so:

Distinguishing characteristic, bonded rubber bushing
I - Bonded rubber bushing, front
II - Rear bonded rubber bushing, rear
The front rubber bonded bushing had two notches - arrows - on top and have slightly different installation heights.

Bonded rubber bushing must be installed in the correct direction, note marking on subframe.

- Install bonded rubber bushing - 1 - into subframe, so that the tab and plate - arrows - face perpendicular to direction of travel.
- Mount pressure piece T10263/3 - 2 - so that the flat side faces perpendicular to direction of travel.

- Insert special tools with bonded rubber bushing into subframe as illustrated.
1- Nut T10263/5
2- Press piece T10263/3
3- Bonded rubber bushing
4- Press piece T10263/2
5- Hydraulic Press VAS 6178 with Pressure Head T10205/13
6- Nut T10263/5
7- Spindle T10263/4
- Pretension special tool with bonded rubber bushing.
- Carefully insert bonded rubber bushing by operating pump until collar lies on subframe "without a gap".
- Install tie rods.
- Install stabilizer bar.
- Connect electrical connections between rear axle and the body.
- Install rear muffler.
- Install coil springs.
- Mount the rear wheels.

Pulling out rear bonded rubber bushing
- Remove rear wheels.
- Remove coil springs.
- Remove exhaust system rear muffler.

- Remove clip - 1 -.

Note: Do not disconnect brake line.

- Now secure vehicle on both sides to lifting arms on hoist with straps T10038.

CAUTION! If vehicle is not secured, it could slide off of hoist.

- Place engine/transmission jack V.A.G. 1383 A with universal transmission support V.A.G. 1359/2 below subframe and secure with strap.

- After removing bonded rubber bushing, it must then be removed from tube T10356/6
- Mount tube T10356/6 on the provided surfaces in a vise.
- Pry a screwdriver between the tube T10356/6 and rubber bonded bushing - arrow - and, if necessary, remove bushing by tapping lightly with a hammer on drift.

Pulling in rear bonded rubber bushing
Installation is in reverse order of removal. Observe the following when doing so:

Distinguishing characteristic, rubber bonded bushing
I - Bonded rubber bushing, front
II - Rear bonded rubber bushing, rear
The front rubber bonded bushing had two notches - arrows - on top and have slightly different installation heights.

Bonded rubber bushing must be installed in the correct direction, note marking on subframe.

- Install rubber bonded bushing - 1 - into subframe, so that tab and plate - arrows - face perpendicular to direction of travel.
- Mount pressure piece T10263/3 - 2 - so that the flat side faces perpendicular to direction of travel.

- Insert special tools with bonded rubber bushing into subframe as illustrated.
1- Nut T10263/5
2- Press piece T10263/3
3- Bonded rubber bushing
4- Press piece T10263/2
5- Hydraulic Press VAS 6178 with Pressure Head T10205/13
6- Nut T10263/5
7- Spindle T10263/4
- Pretension special tool with bonded rubber bushing.
- Carefully insert bonded rubber bushing by operating pump until collar lies on subframe "without a gap".
- Install the rear muffler.
- Install coil springs.
- Mount the rear wheels.

Tightening Specifications