Volkswagen Workshop Service and Repair Manuals

Repairing subframe

Special tools and workshop equipment required

t	Tensioning strap -T10038-

t	Locating pins -T10096-

t	Assembly tool -T10263-

t	Engine and gearbox jack -V.A.G 1383 A-

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

t	Foot pump -VAS 6179-

Pulling out front bonded rubber bush → Anchor Pulling in front bonded rubber bush → Anchor Pulling out rear bonded rubber bush → Anchor Pulling in rear bonded rubber bush → Anchor Pulling out front bonded rubber bush –  Remove rear wheels. –  Remove coil springs → Chapter. –  Remove rear silencer of exhaust system → Rep. gr.26. –  Disconnect electrical connections between rear axle and body. –  Remove anti-roll bar → Chapter. –  Remove track rods → Chapter.

–  Remove clip -1-.   Note Do not open brake line.

–  Now strap vehicle to lifting platform arms on both sides of vehicle using tensioning straps -T10038-.   WARNING If the vehicle is not strapped down, there is a great danger that the vehicle will slip off the lifting platform!

–  Position engine and gearbox jack -V.A.G 1383 A- with universal gearbox support -V.A.G 1359/2- beneath subframe and secure with strap.

–  Unscrew one hexagon bolt -1- or -2- on both sides.   Note Only the left side of vehicle is shown to improve clarity. To fix position of subframe, locating pins -T10096- must be screwed in successively at positions -1- and -2- on both sides of vehicle.

–  Fix position of subframe using 2 locating pins -T10096- and tighten to 20 Nm.   Note The locating pins -T10096- may be tightened only to a maximum of 20 Nm; otherwise the threads of the locating pins may be damaged. –  Replace subframe securing bolts on both sides one after the other with locating pins -T10096- and tighten to 20 Nm. The position of the subframe is now fixed. –  Lower subframe 10 cm using engine and gearbox jack -V.A.G 1383 A-. –  Mark installation position of bonded rubber bush relative to subframe using e.g. a felt tip pen.

–  Set up special tools as shown in figure. 1 -  Nut -T10263/5- 2 -  Washer, from -T10263- 3 -  Tube -T10263/6- 4 -  Hydraulic press -VAS 6178- and thrust piece -T10205/13- 5 -  Nut -T10263/5- 6 -  Spindle -T10263/4- –  Take up play in special tools. –  Pull out bonded rubber bush by actuating pump.   Note The outer ring of the bush shears off when the bonded rubber bush is pulled out. This occurs with a loud bang.

–  The bonded rubber bush must be removed from the tube -T10356/6- once the bush has been pulled out. –  Clamp tube -T10356/6- on the intended surfaces in a vice. –  Insert a screwdriver between tube -T10356/6- and bonded rubber bush and lever bush out of tube -arrow-. If necessary, apply a drift to bush and drive out with light hammer blows. Pulling in front bonded rubber bush Install in reverse order. In the process, note the following:

Distinguishing features of bonded rubber bushes I -  Front bonded rubber bush II -  Rear bonded rubber bush The front bonded rubber bushes have two notches on the upper side -arrows- and differ to the rear slightly in height → Electronic parts catalogue „ETKA“. The bonded rubber bush must be installed in a certain direction; note mark on subframe.

–  Insert bonded rubber bush -1- in subframe so that the nose and the plate -arrows- face perpendicular to direction of travel. –  Apply thrust piece -T10263/3--2- so that flattened sides also face perpendicular to direction of travel.

–  Set up special tools with bonded rubber bush on subframe as shown. 1 -  Nut -T10263/5- 2 -  Thrust piece -T10263/3- 3 -  Bonded rubber bush 4 -  Thrust piece -T10263/2- 5 -  Hydraulic press -VAS 6178- and thrust piece -T10205/13- 6 -  Nut -T10263/5- 7 -  Spindle -T10263/4- –  Take up play in special tools and bonded rubber bush. –  Operate pump to carefully pull bonded rubber bush in until collar lies »flush« on subframe. –  Install track rods → Chapter. –  Install anti-roll bar → Chapter. –  Join electrical connections between rear axle and body. –  Install rear silencer of exhaust system → Rep. gr.26. –  Install coil springs → Chapter. –  Fit rear wheels. Pulling out rear bonded rubber bush –  Remove rear wheels. –  Remove coil springs → Chapter. –  Remove rear silencer of exhaust system → Rep. gr.26.

–  Remove clip -1-.   Note Do not open brake line.

–  Now strap vehicle to lifting platform arms on both sides of vehicle using tensioning straps -T10038-.   WARNING If the vehicle is not strapped down, there is a great danger that the vehicle will slip off the lifting platform!

–  Position engine and gearbox jack -V.A.G 1383 A- with universal gearbox support -V.A.G 1359/2- beneath subframe and secure with strap.

–  Unscrew one hexagon bolt -1- or -2- on both sides.   Note Only the left side of vehicle is shown to improve clarity. To fix position of subframe, locating pins -T10096- must be screwed in successively at positions -1- and -2- on both sides of vehicle.

–  Fix position of subframe using locating pins -T10096-.   Note The locating pins -T10096- may be tightened only to a maximum of 20 Nm; otherwise the threads of the locating pins may be damaged. –  Replace subframe securing bolts on both sides one after the other with locating pins -T10096- and tighten to 20 Nm. The position of the subframe is now fixed. –  Lower subframe 10 cm using engine and gearbox jack -V.A.G 1383 A-. –  Mark installation position of bonded rubber bush relative to subframe using e.g. a felt tip pen.

–  Set up special tools as shown in figure. 1 -  Nut -T10263/5- 2 -  Washer, from -T10263- 3 -  Tube -T10263/6- 4 -  Hydraulic press -VAS 6178- and thrust piece -T10205/13- 5 -  Nut -T10263/5- 6 -  Spindle -T10263/4- –  Take up play in special tools. –  Pull out bonded rubber bush by actuating pump.   Note The outer ring of the bush shears off when the bonded rubber bush is pulled out. This occurs with a loud bang.

–  The bonded rubber bush must be removed from the tube -T10356/6- once the bush has been pulled out. –  Clamp tube -T10356/6- on the intended surfaces in a vice. –  Insert a screwdriver between tube -T10356/6- and bonded rubber bush and lever bush out of tube -arrow-. If necessary, apply a drift to bush and drive out with light hammer blows. Pulling in rear bonded rubber bush Install in reverse order. In the process, note the following:

Distinguishing features of bonded rubber bushes I -  Front bonded rubber bush II -  Rear bonded rubber bush The front bonded rubber bushes have two notches on the upper side -arrows- and differ to the rear slightly in height → Electronic parts catalogue „ETKA“. The bonded rubber bush must be installed in a certain direction; note mark on subframe.

–  Insert bonded rubber bush -1- in subframe so that the nose and the plate -arrows- face perpendicular to direction of travel. –  Apply thrust piece -T10263/3--2- so that flattened sides also face perpendicular to direction of travel.

–  Set up special tools with bonded rubber bush on subframe as shown. 1 -  Nut -T10263/5- 2 -  Thrust piece -T10263/3- 3 -  Bonded rubber bush 4 -  Thrust piece -T10263/2- 5 -  Hydraulic press -VAS 6178- and thrust piece -T10205/13- 6 -  Nut -T10263/5- 7 -  Spindle -T10263/4- –  Take up play in special tools and bonded rubber bush. –  Operate pump to carefully pull bonded rubber bush in until collar lies »flush« on subframe. –  Install rear silencer of exhaust system → Rep. gr.26. –  Install coil springs → Chapter. –  Fit rear wheels.

Specified torques

Component	Specified torque
Subframe to body t  Use new bolts	90 Nm + 90° further