SUBFRAME, Servicing

Special tools and workshop equipment required

Safety Gloves
Protective headgear with visor
Press Plate: VW401

Fig 1: Press Plate
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Press Piece - Multiple Use: VW412

Fig 2: Identifying Press Piece - Multiple Use VW412
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Hydraulic Press: VAS 6178

Fig 3: Identifying Hydraulic Press VAS6178
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Pneumatic/Hydraulic Foot Pump: VAS 6179

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Pneumatic/Hydraulic Foot Pump - Pressure Gauge: VAS 6179/1

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Rubber Bushing Assembly Device Kit: VAS 6779A

Fig 4: Rubber Bushing Assembly Device Kit
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Bearing Installer - Wheel Hub/Bearing Kit - Pressure Head: T10205/13 from the Bearing Installer - Wheel Hub/Bearing Kit: T10205A

Fig 5: Identifying Bearing Installer - Wheel Hub/Bearing Kit T10205A
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Replacing the bonded rubber bushing for the pendulum support.

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

-- Remove the left and right nuts -1- from the coupling rod -3-. Refer to COUPLING ROD, REMOVING AND INSTALLING .

-- Remove the left and right coupling rod -3- from the stabilizer bar -2-.

-- Remove the bolts -1- to remove the stabilizer bar from subframe.

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

Bonded Rubber Bushing, Pressing Out

Fig 6: Pressing Out Bonded Rubber Mount

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-- Position the Hydraulic Press - Bushing Tool Kit -Thrust Piece: VAS 6779/1 -item 1- with the flat side -arrow- in the direction of travel on the bonded rubber bushing.

Rubber Bushing Assembly Device Kit - Thrust Piece: VAS 6779/1
Rubber Bushing Assembly Device Kit - Tube: VAS 6779/4
Rubber Bushing Assembly Device Kit - Thrust Piece: VAS 6779/5
Hydraulic Press: VAS 6178 with Bearing Installer - Wheel Hub/Bearing Kit- Adapter 13: T10205/13
Rubber Bushing Assembly Device Kit - Hexagon Nut: VAS 6779/3
Rubber Bushing Assembly Device Kit - Threaded Rod: VAS 6779/2

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

-- Pay attention that the Rubber Bushing Assembly Device Kit - Hexagon Nut: VAS 6779/3 is seated correctly.

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-- The guide from the Hexagon Nut: VAS 6779/3 -U- must be seated in the Bearing Installer - Wheel Hub/Bearing Kit -Thrust Piece: T10205/13 -W-

-- The Hexagon Nut: VAS 6779/3 -U- must be installed flush on the Bearing Installer - Wheel Hub/Bearing Kit -Thrust Piece: T10205/13 -W-.

-- Connect the special tools as shown.

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Hydraulic Press: VAS 6178
Pneumatic/Hydraulic Foot Pump - Pressure Gauge: VAS 6179/1
Pneumatic/Hydraulic Foot Pump: VAS 6179

-- Pull the control knob on the pressure relief valve for the Pneumatic/Hydraulic Foot Pump: VAS 6179 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 (2, 900.76 psi). In position -2- (700 bar (10, 152.66 psi)) the nominal load of the spindle is exceeded.

CAUTION:

Risk of destroying components due to the pressure setting being too high.

- Never set the pressure greater that the specified (position 1 = 20 MPa).

CAUTION:

Risk of personal injury and property damage caused by the spindle breaking or the assembly tool deforming. Uncontrolled flying broken pieces possible.

- Wear safety gloves.

- Wear protective headgear with a visor.

- Pay attention when operating the foot pump, to not push the switch button in the lower position.

-- Carefully operate the Pneumatic/Hydraulic Foot Pump: VAS 6179 while monitoring the pressure indicator on the Pneumatic/Hydraulic Foot Pump - Pressure Gauge : VAS 6179/1 -item 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 (2, 900.76 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.

Fig 7: Identifying Thrust Piece

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-- 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.

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 directly over each other.

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

-- Apply the med 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 Hydraulic Press - Bushing Tool Kit - Funnel : VAS 6779/6 -2-.

Fig 8: Bonded Rubber Bushing & Funnel

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-- Align the boded rubber bushing in the Hydraulic Press - Bushing Tool Kit Funnel: VAS 6779/6 .

The bonded rubber bushing opening -arrows- must exactly lay in the recess on the Hydraulic Press - Bushing Tool Kit - Funnel: VAS 6779/6 .

-- Press the bonded rubber bushing -3- in the Hydraulic Press - Bushing Tool Kit - Funnel: VAS 6779/6 as shown in the illustration until stop.

Fig 9: Pressing In Bonded Rubber Bush

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Press Piece - Multiple Use: VW412
Rubber Bushing Assembly Device Kit -Thrust Piece: VAS 6779/5 , the side with the letter "A" points upward
Bonded Rubber Bushing
Rubber Bushing Assembly Device Kit - Funnel: VAS 6779/6
Rubber Bushing Assembly Device Kit - Tube: VAS 6779/4
Press Plate: VW401

-- Remove the bolt from the bonded rubber bushing.

-- Insert the Hydraulic Press - Bushing Tool Kit Counter Hold: VAS 6779/7 -item 1- in the subframe.

Fig 10: Identifying Counter Hold

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-- Insert the Hydraulic Press - Bushing Tool Kit Insert: VAS 6779/7-1A -item 2- in the pendulum support opening in the subframe. At the same time push the hydraulic press bushing tool all the way up and use the bolt to attach it to the Counter Hold: VAS 6779/7 .

-- Make sure that the Insert: VAS 6779/7-1A -item 2- is seated correctly in the subframe opening.

Bonded Rubber Bushing, Pressing In

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-- Install the Hydraulic Press - Bushing Tool Kit -Threaded Rod: VAS 6779/2 -item 7- in the Rubber Bushing Assembly Device Kit - Counterhold: VAS 6779/7 -item 1-.

-- Install the Hydraulic Press - Bushing Tool Kit: VAS 6779 as shown in the illustration on the subframe.

Rubber Bushing Assembly Device Kit - Counterhold: VAS 6779/7
Hydraulic Press - Bushing Tool Kit - Funnel: VAS 6779/6 , -arrow marking- on the Funnel must be opposite of both bolts -arrow-.
Rubber Bushing Assembly Device Kit - Thrust Piece: VAS 6779/9
Hydraulic Press - Bushing Tool Kit -Incremental Ring: VAS 6779/8 , the marking -I- on the Incremental Ring must align with the marking -X- on the Hydraulic Press - Bushing Tool Kit Thrust Piece: VAS 6779/9
Hydraulic Press: VAS 6178 with Bearing Installer - Wheel Hub/Bearing Kit- Adapter 13: T10205/13
Rubber Bushing Assembly Device Kit - Hexagon Nut: VAS 6779/3
Rubber Bushing Assembly Device Kit - Threaded Rod: VAS 6779/2

-- Connect the special tools as shown.

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Hydraulic Press: VAS 6178
Pneumatic/Hydraulic Foot Pump - Pressure Gauge: VAS 6179/1
Pneumatic/Hydraulic Foot Pump: VAS 6179

-- Pull the control knob on the pressure relief valve for the Pneumatic/Hydraulic Foot Pump: VAS 6179 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 (2, 900.76 psi). In position -2- (700 bar (10, 152.66 psi)) the nominal load of the spindle is exceeded.

CAUTION:

Risk of destroying components due to the pressure setting being too high.

- Never set the injection pressure greater that the specified (position 1 = 20 MPa).

CAUTION:

Risk of personal injury and property damage caused by the spindle breaking or the assembly tool deforming.

- Wear safety gloves.

- Wear protective headgear with a visor.

- Pay attention when operating the foot pump, to not push the switch button in the lower position.

-- Carefully operate the Pneumatic/Hydraulic Foot Pump: VAS 6179 while monitoring the pressure indicator on the Pneumatic/Hydraulic Foot Pump - Pressure Gauge : VAS 6179/1 -item 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 (2, 900.76 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 Pneumatic/Hydraulic Foot Pump: VAS 6179 .

CAUTION:

Risk of destroying components due to the pressure setting being too high.

- Never select the foot pump mode with the higher pressure.

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 performed in reverse order of the removal.

Tightening Specifications: