Subframe, AWD, Removing and Installing

Special tools, testers and auxiliary items required

Fig 1: Identifying Special Tools - Subframe, AWD, Removing And Installing

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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
Hex bolt M10 x 100 10.9

Removing

NOTE:

The steps show how to remove the subframe as a complete unit (i.e. with the rear final drive, stub axle carrier/wheel bearing housing, trapezoidal control arm, etc.).
Measure vehicle after repair → Wheel Alignment .

CAUTION: Before loosening the subframe bolts make sure the vehicle does not sit at an angle (e.g. load the luggage compartment with at least 100 kg).

Place vehicle on a hoist → Positioning Vehicle on Hoist and Wheels .

Perform the following steps on the left and right sides.

NOTE:

Fig 2: Wheel Hex Bolt

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Loosen collar bolt - arrow - first if:
- The driveshaft will be replaced
- or other component will be replaced that require the collar to be removed.

CAUTION: When loosening and tightening collar bolt, vehicle must stand on wheels.

-risk of accident-

Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
Remove wheel.
Secure brake disc with a wheel bolt.
Remove wheel housing liner → 66 - EXTERIOR EQUIPMENT .

Clean air connection area.

Fig 3: Residual Pressure Valve & Connecting Piece

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Remove connecting piece - 1 - at residual pressure valve - 2 -. Air escapes then.

NOTE:

Generally, residual pressure valve - 2 - must not be loosened or removed.

Seal both connections. Ensure no dust particles enter connections.

Fig 4: Brake Caliper Wiring Harness Connector & Connector

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Remove brake caliper wiring harness connector - 1 - from retainer and disconnect it.
Disconnect connector - 2 - from speed sensor.
Remove brake caliper and secure it on the body → 46 - BRAKES - MECHANICAL COMPONENTS .

NOTE:

Secure brake caliper to body with wire.
Do not allow brake caliper to hang from brake line.

Fig 5: Cover & Bolts

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Remove bolts - 1 - through - 3 - from cover - 4 - and remove cover.

Fig 6: Level Control System Sensor Connector & Brake Line Bracket

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Remove level control system sensor connector - 1 -.
Remove brake line bracket - 2 -.

Fig 7: Coupling Bolt & Brake Line Bracket

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Remove coupling bolt - 1 - and disengage brake line bracket - 2 -.
Tilt coupling back.

Fig 8: Bolts & Wiring Bushing

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Remove bolts - 1 - from wiring bushing - 2 -.
Remove air spring damper on transverse link and tilt it back (control position) → Wheel Bearing Housing, Raising to Control Position to Tighten Bolts .

Fig 9: Exhaust System Bolts & Exhaust System Lines

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Remove exhaust system lines - 4 -.
Remove rear portion of the exhaust system. Remove bolts - 1 - through - 3 - and exhaust system (a second technician is needed).

Fig 10: Bottom Cover Bolts

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Remove air duct bolts - arrows - on rear final drive and remove air duct.

Fig 11: Support Rear Final Drive With Wood Block On Crossmember

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Before removing driveshaft - 1 - on the rear final drive, support it with a wood block on the crossmember - 2 -.

Fig 12: Identifying Drive Shaft Flange To Rear Final Drive Mating Marks (Make Marks If Missing)

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Mark position of driveshaft on rear final drive with paint.

Fig 13: Locating Front And Rear Driveshaft Bolts

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Install hex bolt M10 x 100 10.9 - 3 - in rear final drive.
To loosen bolts - 1 - , counterhold driveshaft using an assembly lever - 2 -.
Remove driveshaft bolts - 1 -.
Place engine/transmission jack V.A.G 1383 A with universal transmission mount V.A.G 1359/2 under subframe with rear final drive.

Secure subframe with rear final drive to universal transmission holder V.A.G 1359/2 so it does not fall off.

If applicable

Fig 14: Subframe Bolts & Support

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Remove subframe bolts - 2 - , bolts - 3 - and support - 1 -.

Affects all vehicles

Fig 15: Subframe Bolts & Brake Caliper

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Remove subframe bolts - 1 - through - 4 -.
Lower subframe carefully. Guide brake caliper - arrows - through the suspension.

Installing

Installation is in reverse order of removal. Observe the following when doing so:

First tighten bolts/nuts on components with bonded rubber bushings by hand. Raise the wheel bearing housing to tighten bolts/nuts → Wheel Bearing Housing, Raising to Control Position to Tighten Bolts .

Fig 16: Subframe Bolts & Brake Caliper

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Place subframe with rear final drive on engine/transmission jack V.A.G 1383 A with universal transmission mount V.A.G 1359/2.
Secure subframe with rear final drive to the universal transmission holder V.A.G 1359/2 so it does not fall off.
Raise subframe carefully. Guide brake caliper - arrows - through suspension.
Center subframe over four bearing holes to body.

If applicable

Fig 17: Subframe Bolts & Support

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Insert support - 1 - and tighten subframe bolts - 2 - and bolts - 3 - by hand.

Affects all vehicles

Fig 18: Subframe Bolts & Brake Caliper

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Note location of the washers - 2 - and - 3 -.
Install subframe bolts - 1 - through - 4 - with new washers.
Tighten bolts - 1 - through - 4 - to specification with no additional turn.

Only tighten bolts - 1 - through - 4 - to specification with an additional turn after the vehicle alignment → Wheel Alignment .

Install driveshaft on the rear final drive → 39 FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE or 39 - FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE 0AR .

Fig 19: Bottom Cover Bolts

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Position air duct on the rear final drive and tighten the bolts - arrows - → 39 - FINAL DRIVE, DIFFERENTIAL for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE or 39 - FINAL DRIVE, DIFFERENTIAL for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE .
Install and align the exhaust system →
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.

Fig 20: Bolts & Wiring Bushing

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Tighten bolts - 1 - on wiring bushing - 2 -.

Fig 21: Level Control System Sensor Connector & Brake Line Bracket

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Connect level control system sensor connector - 1 -.
Install brake line bracket - 2 -.

Fig 22: Cover & Bolts

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Tighten cover - 4 - with bolts - 1 - through - 3 -.

NOTE:

The bolts - 2 - and - 3 - secure the wiring harness bracket located behind the cover plate on the wheel bearing housing.

Install brake caliper → 46 - BRAKES - MECHANICAL COMPONENTS .

Fig 23: Coupling Bolt & Brake Line Bracket

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Install brake line bracket - 2 - and tighten coupling rod threaded connection - 1 -.

The wheel bearing housing must be lifted into control position to install and tighten the bolts → Wheel Bearing Housing, Raising to Control Position to Tighten Bolts .

Fig 24: Brake Caliper Wiring Harness Connector & Connector

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Connect connector - 2 - on speed sensor.
Insert brake caliper connector - 1 - into retainer and connect it.

Fig 25: Residual Pressure Valve & Connecting Piece

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Tighten connecting piece - 1 - on residual pressure retaining valve - 2 -.
Install wheel housing liner → 66 - EXTERIOR EQUIPMENT .

Fig 26: Level Control System Sensor Bolt, Nut & Brake Line Bracket & Air Spring Damper/Transverse Link Bolt

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Install level control system sensor bolt - 1 -. The sensor lever must face inward.
Press wheel bearing housing down by hand and insert bolt - 4 - in air spring damper/transverse link.
Only tighten nut - 3 - by hand.
Mount wheel and tighten → 44 - WHEELS, TIRES, VEHICLE ALIGNMENT .

Place vehicle on wheels → Positioning Vehicle on Hoist and Wheels .

Fig 27: Level Control System Sensor Bolt, Nut & Brake Line Bracket & Air Spring Damper/Transverse Link Bolt

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Tighten bolt - 4 - with the vehicle at the "standard level" and resting on the floor. Counterhold nut - 3 - when doing this.

Only when you have loosed collar screw:

Always use a new collar screw!

Tighten driveshaft collar bolt → Installing .
Perform vehicle alignment → Wheel Alignment .

Fig 28: Subframe Bolts & Brake Caliper

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Tighten subframe bolts - 1 - through - 4 - to specification with additional turn and.
Re-adapt control position → Control Position, Programming .