Removing Front-Axle Cross Member

Information 

When removing the front-axle cross member, the following parts remain on the front-axle cross member:

• Power-steering gear
• Anti-roll bar
• Lower trailing arm
• Diagonal arm

If the front-axle cross member is replaced, these parts must be changed over beforehand.

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Installation position of front-axle cross member (shown as an example/no longitudinal struts fitted on the 982)

Information 

Secure steering wheel with wheels in straight-ahead position (engage steering column lock or clamp steering wheel in center position with steering-wheel holder).

1. Disconnect universal joint from the steering gear.

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   Universal joint for steering column

   1. 1.1  Unscrew fastening screw -1- on universal joint.
2. Remove connecting links on both sides of the vehicle from the anti-roll bar.

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   Lower connecting link mounting

   1. 2.1  Unscrew fastening nut -1-  To unscrew the fastening nut, counter with a > 9546 - screwdriver  at the ball-joint pin.
   2. 2.2  Remove ball-joint pin from the bore in the anti-roll bar.
3. Remove tie rods on both sides of the vehicle from the wheel bearing housing.

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   Pressing off ball joint on tie rod

   1. 3.1  Unscrew lock nut and use a > 9546 - screwdriver  to counter at the ball-joint pin.
   2. 3.2  Coat the bellows and press-out tool with tire mounting paste to prevent damage to the bellows on the ball joint.
   3. 3.3  Press off tie-rod ball joint using > 9560 - press-out tool-1-  .
4. Unclip and remove control arm spoiler (air guide for brake Cooling) at the back of the diagonal arm.

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   Control arm spoiler

5. Remove lower trailing arm on both sides of the vehicle from the wheel bearing housing.

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   Removing lower trailing arm from wheel bearing housing

   1. 5.1  Secure the spring strut in the wheel bearing housing to the body using a cable strap -1-  to avoid putting extra strain on the spring strut mount.
      1. 5.1.1  Pull the cable strap through behind the clamping screw (shock-absorber pipe clamp) -3-  on the spring strut and secure it to the rear opening on the spring strut mount -2-  .
   2. 5.2  Coat the bellows and press-out tool with tire mounting paste to prevent damage to the bellows on the ball joint.
   3. 5.3  Unscrew fastening nut on the ball joint of the lower trailing arm -5-  and press off the ball joint using > 9560 - press-out tool-4- 
6. Loosen ball joint on the level sensor linkage -1-  from the lower trailing arm on both sides of the vehicle.

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   Ball joint on level sensor

7. Loosen level sensor mounting and Coolant pipe on both sides of the vehicle.

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   Level sensor mounting

   1. 7.1  Unscrew fastening screw -1-  .
8. Remove front-axle cross member.

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   Front-axle carrier

   1. 8.1  Support the front-axle cross member with a hydraulic lift (use a hard rubber base or wooden block).
   2. 8.2  Unscrew fastening screws -7-. 
   3. 8.3  Unscrew fastening screws -4-  and loosen clips on the bracket for the Coolant pipes.
   4. 8.4  Unscrew fastening nuts -2-  on the front-axle cross member and counter at the bolt using a Torx wrench.
   5. 8.5  Unscrew fastening screws -1 and 3-  .
   6. 8.6  Lower the front-axle cress member as far as required until you have enough room to disconnect the plug connections for the steering gear.
9. Release and unplug battery connector -2-  and vehicle signal connector -3-  from the steering gear motor. The torque sensor connector -1-  (connector at the very top) remains connected.

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   Connectors on steering gear control unit with front-axle cross member lowered

10. Remove front-axle cross member. To do this, lower the front-axle cross member using a hydraulic lift.

Installing front-axle cross member 

1. Check the bellows and clamping rings for damage and make sure they are seated securely. Replace them if necessary.
2. Lift front-axle cross member using a transmission jack.
3. Plug in battery connector -2-  and vehicle signal connector -3-  on the steering gear motor until they engage securely.

   The torque sensor connector -1-  (connector at the very top) was not disconnected when the front-axle cross member was removed.

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   Connectors on steering gear control unit

4. Fit front-axle cross member,

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   Front-axle carrier

   1. 4.1  Carefully move the front-axle cross member into installation position using the hydraulic lift.

      Make sure not to trap any lines and plug connections.

      Check that the lines are routed correctly.

   2. 4.2  Tighten fastening screws -1-  > Initial tightening 90 Nm (67 ftlb.) > Final tightening + 90° 
   3. 4.3  Tighten fastening screws -3-  > Initial tightening 90 Nm (67 ftlb.)  > Final tightening + 180° 
   4. 4.4  Tighten fastening nuts -2-  and counter at the bolt using a Torx wrench. > Initial tightening 90 (67 ftlb,) Nm  > Final tightening + 90° 
   5. 4.5  Clip in clips for coolant pipes and tighten fastening screws -4-. > Tightening torque 10 Nm (7.5 ftlb.) 
   6. 4.6  Tighten fastening screws -7-  > Initial tightening 90 Nm (67 ftlb.)  > Final tightening + 90° 
5. Fit universal joint on the steering gear.

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   Universal joint for steering column

   1. 5.1  Connect universal joint to the steering gear.
   2. 5.2  Insert fastening screw -1-  into universal joint and tighten it. > Initial tightening 20 Nm (15 ftlb.)  > Final tightening + 90° 
6. Fit connecting links on anti-roll bar.

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   Lower connecting link mounting

   1. 6.1  Guide ball-joint pin into the bore in the anti-roll bar.
   2. 6.2  Tighten fastening nut -1-  To tighten the fastening nut. counter with a > 9546 - screwdriver  at the ball-joint pin. > Initial tightening 40 Nm (30 ftlb.)  > Final tightening + 30° 

      Information 

      Following installation, seal the threaded joint securing lower trailing arm to wheel bearing housing and tie rod to wheel bearing housing with wax as shown in -Illustration-  . Use Pfinder AP14/4 for this (see PIWIS Parts Catalog - PET).

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      Applying wax on marked area

7. Fit lower trailing arm on the wheel bearing housing.

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   Fitting lower trailing arm on wheel bearing housing

   1. 7.1  Insert ball joint of the lower trailing arm into the wheel bearing housing.
   2. 7.2  Tighten fastening nut -1-  > Tightening torque 85 Nm (63 ftlb.) 
   3. 7.3  Remove cable straps.

      Information 

      Following installation, seal the threaded joint securing lower trailing arm to wheel bearing housing and tie rod to wheel bearing housing with wax as shown in -Illustration-  . Use Pfinder AP14/4 for this (see PIWIS Parts Catalog - PET).

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      Applying wax on marked area

8. Fit tie rod on wheel bearing housing,

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   Fitting tie rod on wheel bearing housing

   1. 8.1  Guide in control arm spoiler (air guide for brake cooling) and clip it in at the back of the longitudinal arm.
   2. 8.2  Tighten fastening nut -1-  Counter with a > 9546 - screwdriver  at the ball-joint pin while doing this. > Tightening torque 85 Nm (63 ftlb.) 
9. Clip in ball joint on the level sensor linkage -1-  on the lower trailing arm.

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   Ball joint on level sensor

10. 10  Secure bracket for level sensor and Coolant pipe.

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    Level sensor mounting

    1. 10.1  Move bracket for level sensor and Coolant pipe into installation position.
    2. 10.2  Tighten hexagon-head bolt -1-  > Tightening torque 10 Nm (7.5 ftlb.)