Repairing subframe, steel — VW

Repairing subframe, steel
Special tools and workshop equipment required
Assembly tool
T10205
Torque wrench
V.A.G 1332
Hydraulic press
VAS 6178
Foot pump
VAS 6179
Assembly tool
VAS 6779A
Thrust plate
VW 401
Press tool
VW 412
Renewing bonded rubber bushes for pendulum support
If fitted, remove front noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.
Remove hexagon nut
1
from coupling rod
3
(left and right sides).
Pull out coupling rod
3
from anti-roll bar
2
on left and right side.
Remove bolts
1
for anti-roll bar.
Leave the anti-roll bar in its installation position in the vehicle.
Remove pendulum support
Rep. gr.
10
Assembly mountings; Assembly overview - assembly mountings
.
Pressing out bonded rubber bush
Fit
assembly tool
VAS 6779
to subframe as shown in illustration.
Place
thrust piece for removal
VAS 6779-1
1
on bonded rubber bush so that flattened side
arrow
faces to direction of travel.
1 -
Thrust piece for removal
VAS 6779-1
2 -
Tube
VAS 6779-4
3 -
Thrust piece
VAS 6779-5
4 -
Hydraulic press
VAS 6178
and
thrust piece
T10205/13
5 -
Hexagon nut
VAS 6779-3
6 -
Threaded spindle
VAS 6779-2
Press out both bonded rubber bushes until the upper bonded rubber bush
2
is visible in the pendulum support opening
3
in subframe.
Carry out visual check of outer ring of upper bonded rubber bush
2
.
If outer ring of upper bonded rubber bush
2
is deformed, destroy it through opening of pendulum support
arrow
in pendulum support.
Using a chisel or similar
1
, create a break in the outer ring of the upper bonded rubber bush
2
.
Note
This process is necessary to prevent the canting of the outer ring of the upper bonded rubber bush in the area of the opening of the pendulum support in the subframe.
Press out both bonded rubber bushes together.
Preparing bonded rubber bush for pressing in
Place both bonded rubber bushes
1
and
2
together so that the cut-outs
arrows
line up precisely.
Bolt bonded rubber bushes
1
and
2
hand-tight together using original bolt
3
.
Insert bonded rubber bushes
1
into larger diameter of
tube
VAS 6779-6
2
with bolt head facing upwards.
Align bonded rubber bushes
1
in
tube
VAS 6779-6
2
. The cut-out in the bonded rubber bush must align exactly with the recess
arrow
in the
tube
VAS 6779-6
2
.
Press in bonded rubber bush
3
in
tube
VAS 6779-6
to stop, as illustrated.
Press tool
VW 412
Thrust piece
VAS 6779-5
, the side with the lettering
»A«
must face upwards.
Bonded rubber bush
Tube
VAS 6779-6
Tube
VAS 6779-4
Thrust plate
VW 401
Insert
counterhold
VAS 6779-6
1
into subframe.
Insert
insert
VAS 6779-9
with
plate
VAS 6779-10
2
into pendulum support opening in subframe.
Bolt
insert
VAS 6779-9
to
counterhold
VAS 6779-8
1
.
Ensure that the
insert
VAS 6779-8
2
is correctly seated in the pendulum support opening of the subframe
arrow
.
Pressing in bonded rubber bush
Screw
threaded spindle
VAS 6779-2
7
into
counterhold
VAS 6779-8
1
Fit
assembly tool
VAS 6779A
to subframe as shown in illustration.
1 -
Counterhold
VAS 6779/7
2 -
Funnel
VAS 6779/6
;
arrow mark
on
funnel
must align centrally between the two bolts
arrow
.
3 -
Thrust piece
VAS 6779/9
4 -
Stepped ring
VAS 6779/8
; mark
I
on
stepped ring
must align with mark
X
on
thrust piece
VAS 6779/9
.
5 -
Hydraulic press
VAS 6178
and
thrust piece
T10205/13
6 -
Hexagon nut
VAS 6779/3
7 -
Threaded spindle
VAS 6779/2
Press in both bonded rubber bushes together.
Remove
assembly tool
VAS 6779A
from subframe and check pressed-in bonded rubber bushes for proper seating.
Specified torques
Chapter
“
Assembly overview - subframe, steel
”
Pendulum support
Rep. gr.
10
Assembly mountings; Assembly overview - assembly mountings
Noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.