Front Cross-Member Bushing: Service and Repair

Special Tools
999 5457

Preparation
Remove the ignition key and lock the steering wheel in the straight forward position.





Remove the front screw from the upper torque rod.





Mark up and remove the steering shaft joint from the steering gear.





Disconnect the wiring harness from the sub-frame.





Remove the exhaust pipe bracket and twist to one side.
Unhook the silencer from the rubber suspension.





Position a lifting table (minimum capacity 500 kg) under the sub-frame so that the engine/transmission unit cannot twist or slide.
Apply the lifting table so that the load is taken off the sub-frame screws.
Remove the sub-frame screws together with accompanying brackets and washers.
Carefully lower the engine/transmission unit approximately 90 mm (3.54")
Removing the sub-frame bushings
Use tool 999 5457.
Install





- the counterhold (1) on the upper side of the bushing.
- the cutting sleeve (3) and the screw with nut (6) from underneath.
Tighten the cutting sleeve until it stops against the counterhold. The cutting sleeve is now fixed in the bushing.
Remove the counterhold.





Position the threaded plate (2) above the bushing.
Install the spacer sleeve (5) and the screw with nut (6) from underneath.
Pull out the inner part of the bushing with the cutting sleeve.





Knock out a piece of the flange on the outer section of the bushing. Use a screwdriver and a hammer.

Note! Do not use a cold chisel.

Split the outer sleeve with the screwdriver at the missing piece. (The insert illustration displays a split sleeve.)





Bend out the bushing. Use a screwdriver.





Remove the inner part of the bushing from the cutting sleeve
Spray universal oil/rust oil between the bushing and the cutting tool. This makes it easier to remove the bushing from the cutting tool.
Install the bushing in a vise. Turn the cutting sleeve until it is free of the bushing. Use a pipe wrench.

Installing the bushings in the sub-frame





Position the counterhold on the upper side of the sub-frame.
Apply the drift (4) with the spikes upwards and the bushing with the rubber spikes downwards on the screw with the nut (6).

Note! The left and right front bushings are different. The left front bushing has oval holes.

Screw into place in the counterhold from underneath.

Note! Check that the bushing marking ends up opposite the marking on the sub-frame (see arrows).

Tighten the bushing to stop.
Remove the tools.
Finishing
Lift the engine/transmission unit up to the bodywork.





Install new screws in the sub-frame with the washers and brackets.
Install the retaining screws holding the sub-frame brackets in the bodywork.
Tighten the sub-frame screws to 105 Nm (77.4 ft. lbs.) and angle-tighten to 120°.
Tighten the bracket screws to 50 Nm (36.9 ft. lbs.)





Install the wiring harness on the sub-frame.





Install steering shaft as marked. Use a new locknut
Tighten to 20 Nm (14.8 ft. lbs.)
Install locking shackle.





Hang the silencer.
Install the cross member. Tighten to 25 Nm (18.4 ft. lbs.)





Install a new screw and locknut in the upper torque rod. Tighten to 35 Nm (25.8 ft. lbs.) and angle tighten 90°.