SUBFRAME, Servicing

Special tools and workshop equipment required 

• Safety Gloves
• Protective headgear with visor
• Press Plate:VW401 
• Press Piece - Multiple Use:VW412 
• Hydraulic Press:VAS6178 
• Pneumatic/Hydraulic Foot Pump:VAS6179 
• Pneumatic/Hydraulic Foot Pump - Pressure Gauge:VAS6179/1 
• Hydraulic Press - Bushing Tool Kit:VAS6779  with Support Ring - Assembly Device Kit:VAS6779/11  or Hydraulic Press - Bushing Tool Kit:VAS6779A 
• Rubber Bushing Assembly Device Kit:VAS6779A 
• Bearing Installer - Wheel Hub/Bearing Kit - Pressure Head:T10205/13  from the Bearing Installer - Wheel Hub/Bearing Kit:T10205A 

Replacing the Bonded Rubber Bushing for the Pendulum Support.

-- Remove the pendulum support. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .

-- Remove the left and right nuts -1- from the coupling rod -3- to do so counterhold with a four-point socket on the threaded pin.

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-- Remove the left and right coupling rod from the stabilizer bar -2-.

-- Remove the bolts -1- for the stabilizer bar.

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• Leave the stabilizer bar in the installation position on the vehicle.

Bonded Rubber Bushing, Pressing Out

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-- Position the special tool as shown:

1. Rubber Bushing Assembly Device Kit - Threaded Rod:VAS 6779/2 
2. Rubber Bushing Assembly Device Kit - Hexagon Nut:VAS6779/3 
3. Hydraulic Press:VAS6178  with Bearing Installer - Wheel Hub/Bearing Kit- Adapter 13:T10205/13 
4. Rubber Bushing Assembly Device Kit - Thrust Piece:VAS6779/5 
5. Rubber Bushing Assembly Device Kit - Tube:VAS6779/4 
6. Position the Hydraulic Press - Bushing Tool Kit -Thrust Piece:VAS6779/1  -1- with the flat side -arrow- in the direction of travel on the bonded rubber bushing.

-- Position the tool exactly flush in alignment of the bonded rubber bushing, to prevent tilting.

-- Pay attention that the :VAS6779/3  is seated correctly.

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-- The guide from the :VAS6779/3  -U- must be seated in the :T10205/13  -W-

-- The :VAS6779/3  -U- must be installed flush on the :T10205/13  -W-.

-- Connect the special tools as shown.

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1. Hydraulic Press:VAS6178 
2. Pneumatic/Hydraulic Foot Pump - Pressure Gauge:VAS6179/1 
3. Pneumatic/Hydraulic Foot Pump:VAS6179 

-- Pull the control knob on the pressure relief valve for the :VAS6179  to level -1-.

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• The control knob must be in the position -1-. The setting is a maximum pressure of 200 bar (2900.75 psi). In position -2- (700 bar (10152.64 psi)) the nominal load of the spindle is exceeded.

-- Carefully operate the :VAS6179  while monitoring the pressure indicator on the :VAS6179/1  -1-.

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-- Make sure that the indicator stays in the green display area. Do not exceed the maximum permitted pressure of 200 bar (2900.75 psi).

-- Press out both bonded rubber bushings until the upper bonded rubber bushing -2- is visible in the pendulum support opening -arrow- in the subframe.

-- Perform a visual inspection of the upper bonded rubber bushing outer race -2-.

• If the upper bonded rubber bushing outer race -2- is deformed, it must be destroyed through the opening for the pendulum support -arrow- in the subframe.

-- Using a chisel or similar tool -1-, make a break in the upper bonded rubber bushing outer race -2-.

• This work sequence is necessary to prevent tilting of the bonded rubber bushing outer race in the area of the pendulum support opening in the subframe.

-- Completely press out both bonded rubber bushings at the same time.

If the procedure does not work with the pressure specified, the repair setup must be checked. Submit feedback if necessary.

Preparing Bonded Rubber Bushings before Pressing in

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-- Place the bonded rubber bushings -1 and 2- on top of each other, so the openings -arrows- lay exactly over each other.

-- Tighten the bonded rubber bushings with the original bolts -3- hand tight.

-- Apply the red marking in phases as shown on the illustration. Dimension of the phase approximately 1 mm.

-- Place the bonded rubber bushing -1- with the bolt head facing up in the larger diameter of the :VAS6779/6  -2-.

-- Align the boded rubber bushing in the :VAS6779/6  .

• The bonded rubber bushing opening -arrows- must lay exactly in the recess on the :VAS6779/6  .

-- Position the special tool as shown:

1. Press Piece - Multiple Use:VW412 
2. Rubber Bushing Assembly Device Kit -Thrust Piece:VAS6779/5  , the side with the letter "A" points upward
3. Bonded Rubber Bushing
4. Rubber Bushing Assembly Device Kit - Funnel:VAS6779/6 
5. Rubber Bushing Assembly Device Kit - Tube:VAS6779/4 
6. Press Plate:VW401 

-- Press the bonded rubber bushing in the :VAS6779/6  -4- all the way on the :VAS6779/5  -2-.

-- Deburr the edge -1- at the top in the opening for the pendulum support in the subframe -2- as shown with a file to the dimension -a-.

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• Dimension -a- = 1 mm.

-- Turn the :VAS6779/11  -1- in the direction of -arrow- so that the tab -left arrow- points to the rear.

-- Position the :VAS6779/7  -1- from the left onto the :VAS6779/11  -2- in the direction of -arrow-.

-- Position the :VAS6779/7-1A  - 1- in the opening -lower arrow- for the pendulum support in the subframe at the same time push the insert -1- all the way upward and tighten using the bolt -upper arrow-.

-- Make sure that the :VAS6779/7-1A  is seated correctly in the pendulum support opening in the subframe.

Bonded Rubber Bushing, Pressing In

-- Remove the pendulum support from the boded rubber bushing.

-- Install the :VAS6779/2  -7- in the :VAS6779/7  -1-.

-- Position the special tool as shown:

1. Rubber Bushing Assembly Device Kit - Counterhold:VAS6779/7 
2. Hydraulic Press - Bushing Tool Kit - Funnel:VAS6779/6  , -arrow marking- on the funnel must be opposite of both bolts in the center -arrow A-.
3. Rubber Bushing Assembly Device Kit - Thrust Piece:VAS6779/9 
4. Incremental Ring:VAS6779/8  , the marking -III- on the incremental ring must point toward the cam -arrow B- on the Thrust Piece:VAS6779/9  .
5. Hydraulic Press:VAS6178  with Bearing Installer - Wheel Hub/Bearing Kit- Adapter 13:T10205/13 
6. Rubber Bushing Assembly Device Kit - Hexagon Nut:VAS6779/3 
7. Rubber Bushing Assembly Device Kit - Threaded Rod:VAS6779/2 

-- Connect the special tools as shown.

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1. Hydraulic Press:VAS6178 
2. Pneumatic/Hydraulic Foot Pump - Pressure Gauge:VAS6179/1 
3. Pneumatic/Hydraulic Foot Pump:VAS6179 

-- Pull the control knob on the pressure relief valve for the Pneumatic/Hydraulic Foot Pump:VAS6179  to level -1-.

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• The control knob must be in the position -1-. The setting is a maximum pressure of 200 bar (2900.75 psi). In position -2- (700 bar (10152.64)) the nominal load of the spindle is exceeded.

-- Carefully operate the :VAS6179  while monitoring the pressure indicator on the :VAS6179/1  -1-.

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-- Make sure that the indicator stays in the green display area. Do not exceed the maximum permitted pressure of 200 bar (2900.75 psi).

-- Press in both bonded rubber bushings at the same time.

• To prevent damage to the bonded rubber bushing outer race, while pushing in, pay attention that it is not tilted at the beginning.
• If necessary, release the tension and press in using the :VAS6179  .

• If the pressing in does not work with the pressure specified, the repair setup must be checked.

-- Remove special tool from the subframe and check seating of the pressed in bonded rubber bushing.

Further installation is the reverse order of removal.

Tightening Specifications 

• Refer to OVERVIEW - ASSEMBLY MOUNTS .