Audi Workshop Service and Repair Manuals

Renewing bonded rubber bushes

Special tools and workshop equipment required

t	Thrust piece -3416/2-

t	Assembly tool -T10205-

t	Assembly tool -T10254-

t	Assembly tool -T10263-

t	Torque wrench -V.A.G 1332-

t	Thrust piece -3348/1- from assembly tool -3348-

t	Two hose clips from charge air system tester -V.A.G 1687-

t	Engine and gearbox jack -V.A.G 1383 A- with universal gearbox support -V.A.G 1359/2-

t	Hydraulic press -VAS 6178-

t	Foot pump -VAS 6179-

t	Ring spanner insert -V.A.G 1332/10-

Removing –  Release handbrake.

–  Before commencing work, use measuring tape or similar to measure dimension -a- from wheel centre to lower edge of wheel housing. l  This measurement must be taken with the suspension in the unladen position (vehicle unladen). –  Make a note of the measured value. This will be needed when tightening the bolts and/or nuts on the suspension. –  Raise vehicle to working height. –  Remove wheels. –  Remove wheel spoiler on both sides → Rep. gr.66.

–  Unclip wire -2- for speed sensor from brackets -arrows- on both sides.

Vehicles with dynamic headlight range control –  Remove bolts -1 and 3-. Vehicle level sender -G76- with bracket -2- does not have to be removed.

All vehicles (continued): –  Remove clip -arrow B- for brake line (right-side). –  Pull brake hose (right-side) -1- out of bracket.

–  Unclip ABS wire (right-side) at bracket -1- and move clear.

–  Remove handbrake cables from retainers on both sides -arrows-. –  Bring engine and gearbox jack -V.A.G 1383 A- into position with a suitable support block or similar. –  Secure rear axle with a strap or similar when lowering. –  Unscrew bolts -1- for axle beam on both sides. –  Carefully lower rear axle with engine and gearbox jack -V.A.G 1383 A- until bonded rubber bush is accessible.   Note When lowering the rear axle take care not to damage or kink the brake lines on either side.

–  Mark installation position of bonded rubber bush -1- in relation to axle beam at bottom slit in outer sleeve -arrow- using a felt-tip pen or similar –  Extend marking to opposite side of sleeve.

–  Set up special tools as shown in illustration. 1 -  Spindle -T10254/5- 2 -  Nut -T10254/4- 3 -  Thrust piece -3416/2- 4 -  Bonded rubber bush 5 -  Tube -T10263/6- 6 -  Thrust plate -T10205/1- 7 -  Foot pump -VAS 6179- 8 -  Hydraulic press -VAS 6178- with press attachment -T10205/13- 9 -  Nut -T10254/4- –  Take up play in special tools.

–  Tube -T10263/6--1- must be positioned on bonded rubber bush so that outer diameter is able to rest evenly on axle beam -arrow-. –  Pull out bonded rubber bush by operating the pump.   Note The outer ring of the bonded rubber bush will shear off with a loud bang when the bush is removed.

–  The bonded rubber bush must be removed from the tube -T10356/6- once the bush has been pulled out. –  Clamp the tube -T10356/6- in a vice at the surfaces provided for this purpose. –  Use a screwdriver as a lever -arrow- between tube -T10356/6- and rubber bonded bush; if necessary, knock bonded rubber bush out by tapping a drift gently with a hammer.

Installing l  The outer sleeve of the bonded rubber bush consists of two half-sections which have to be pressed together before installation in order to press the bush into the axle beam without damage. –  Compress new bonded rubber bush -1- with two hose clips -arrows- as shown in illustration until the two half-sections come together.

–  Now bring bonded rubber bush with special tools into position at rear axle. 1 -  Spindle -T10254/5- 2 -  Nut -T10254/4- 3 -  Hydraulic press -VAS 6178- with press attachment -T10205/13- 4 -  Foot pump -VAS 6179- 5 -  Thrust plate -T10205/1- 6 -  Tube -T10263/6- 7 -  Bonded rubber bush 8 -  Thrust piece -3348/1- 9 -  Nut -T10254/4-

–  Before pressing in bonded rubber bush, make sure groove -1- in inner core of bush faces towards rear of vehicle and bottom slit -arrow- in outer sleeve is in line with marking on axle beam. –  Press in bonded rubber bush as far as first hose clip and then remove hose clip. –  Press in bonded rubber bush as far as second hose clip and then remove hose clip. –  Press in bonded rubber bush as far as stop. –  After installation, check that bonded rubber bush is in correct position. –  Tighten rear axle mountings in unladen position → Chapter. Remaining installation steps are carried out in reverse sequence. Tightening torque → Chapter „Exploded view - axle beam with attachments“