Removing and installing subframe - four-wheel drive: Audi A8 D3

🧭 Before you start

Secure the car against tipping, slacken the flange bolt on the wheels, then remove wheels and liners, vent the air springs at the connection piece, hang the calipers on wire and remove splash plates, level sender links, coupling rods and air spring struts from the transverse links. Remove the rear exhaust and air duct, mark and unbolt the propshaft, support the subframe on V.A.G 1383 A and V.A.G 1359/2 and lower it. Raise and centralise it, fit new bolts, refit everything with bush fixings hand-tight, tighten them at normal level, tighten the flange bolt, align the wheels, torque and angle the subframe bolts and re-adapt the reference position.

Fits: Audi A8 D3 (4E, 2002–2010)

• Special tools named: puller

Don't miss

• Load the luggage compartment with at least 100 kg before slackening subframe bolts.
• Never loosen or remove the residual pressure valve; vent only at the connection piece.
• Do not hang the brake calipers from their hoses; tie them to the body.
• Fit new subframe bolts and note the washer positions.
• Tighten bonded-bush fixings only with the car on its wheels at normal level.
• Check wheel alignment and re-adapt the reference position afterwards.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. ⚠ Before slackening off subframe bolts, secure vehicle to stop it tipping over (e.g. load of at least 100 kg in luggage compartment). — Position vehicle on lifting platform .
2. Slacken off flange bolt (arrow) first if:
3. ⚠ The vehicle must be standing on its wheels when loosening and tightening the flange bolt.-Accident risk- — Remove wheel trim; on light-alloy wheels, pull off trim cap (use puller in vehicle tool kit).
4. Remove wheel.
5. Secure brake disc with one wheel bolt.

6. Remove wheel housing liner 66.
7. Clean area around air connection.
8. Unscrew connection piece (1) on residual pressure valve (2). This will allow air to escape. [Note: The residual pressure valve (2) MUST NOT be loosened or removed.]
9. Seal both connections. Take care to prevent dirt entering the connections.
10. Pull connector (1) for brake caliper wiring harness out of bracket and unplug connector.
11. Unplug connector (2) from wheel speed sensor (2).
12. Detach brake caliper and attach to body 46. [Note: Tie up brake caliper to body with wire.Do not suspend the brake caliper from the brake hose.]
13. Unscrew bolts (1) to (3) from splash plate (4) and detach splash plate.
14. Unplug connector for vehicle level sender(1).
15. Detach brake pipe bracket (2).
16. Unscrew bolt (1) from coupling rod and disengage brake pipe bracket (2).
17. Swivel coupling rod to the rear.
18. Unscrew bolts (1) securing duct (2).
19. Detach air spring strut from transverse link and swivel to the rear (reference position) .
20. Detach pipes (4) on exhaust system.
21. Remove rear section of exhaust system. For this step, remove bolts (1) to (3) and take out the exhaust system (with the assistance of a second mechanic).
22. Unscrew bolts (arrows) securing air duct at rear final drive and detach air duct.
23. Before detaching propshaft (1) at rear final drive, position a wooden block on cross member (2) to support propshaft.
24. Make coloured mark to indicate position of propshaft at rear final drive.
25. Screw hexagon bolt M10 x 100 10.9(3) into rear final drive.
26. Use suitable lever (2) to counterhold when slackening off propshaft bolts (1).
27. Unscrew propshaft bolts (1).
28. Bring engine and gearbox jackV.A.G 1383 A with universal gearbox supportV.A.G 1359/2 into position under subframe with rear final drive.
29. Secure subframe with rear final drive on universal gearbox supportV.A.G 1359/2 to prevent it from dropping.
30. Remove subframe bolts (2) and bolts (3) and take off support (1).
31. Unscrew subframe bolts (1) to (4).
32. Carefully lower subframe. When doing this, guide brake calipers (arrows) through suspension components.
33. Initially only hand-tighten bolts/nuts for components with bonded rubber bush. Wheel bearing housing must first be raised (to reference position) before tightening bolts/nuts .
34. Position subframe with rear final drive on engine and gearbox jackV.A.G 1383 A with universal gearbox supportV.A.G 1359/2.
35. Secure subframe with rear final drive on universal gearbox supportV.A.G 1359/2 to prevent it from dropping.
36. Carefully raise subframe. When doing this, guide brake calipers (arrows) through suspension components.
37. Centralise subframe by aligning four holes inside bushes with tapped holes in body.
38. Install support (1) and screw in subframe bolts (2) and bolts (3) hand-tight.
39. Pay attention to installation position of washers (2) and (3).
40. Install new bolts with washers (1)…(4) to secure subframe.
41. Tighten bolts (1)…(4) to specified torque setting, but do NOT turn further .
42. Bolt propshaft onto rear final drive 39.
43. Fit air duct in position at rear final drive and tighten bolts (arrows)39.
44. Install and align exhaust system 26.
45. Tighten bolts (1) securing duct (2).
46. Plug in connector for vehicle level sender(1).
47. Attach brake pipe bracket (2).
48. Secure splash plate (4) with bolts (1) to (3). [Note: Bolts (2) and (3) are used to secure wiring harness bracket behind splash plate to wheel bearing housing.]
49. Bolt on brake caliper 46.
50. Attach brake pipe bracket (2) and tighten bolted joint (1) of coupling rod .
51. Plug connector (2) onto speed sensor.
52. Insert electrical connector (1) for brake caliper in bracket and plug in connector.
53. Screw on connection piece (1) at residual pressure valve (2).
54. Fit wheel housing liner 66.
55. Install bolt for vehicle level sender (1). Sender lever must face inwards.
56. Press down wheel bearing housing by hand and insert bolt (4) in air spring strut/transverse link.
57. Only hand-tighten nut (3).
58. Fit and secure wheel Wheels and tyres44.
59. Set down vehicle on its wheels .
60. With vehicle standing on ground at "„normal level“", tighten bolt (4). When doing this, counterhold nut (3).

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