Front Subframe: Service and Repair

Bushings for sub-frame, replacing

Special tools:
999 5457 PRESS TOOL 999 5457 Press Tool

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 it to one side.
Unhook the muffler from the rubber mountings.





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 the accompanying brackets and washers.
Carefully lower the engine/transmission unit approximately 90 mm.

Removing the bushings for the sub-frame





Use tool 999 5457 PRESS TOOL 999 5457 Press Tool.

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 the nut (6) from underneath.

Pull out the inner section of the bushing using 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 using the screwdriver where the section was tapped out. (The insert illustration shows a split sleeve.)





Pry out the bushing. Use the screwdriver.





Remove the inner section 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 releases from the bushing. Use a pipe wrench.

Installing the bushings in the sub-frame

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.





Position the counterhold on the top 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-hand front bushings are different. The left-hand front bushing has an oval hole.

Screw into place in the counterhold from underneath.

Note! Check that the marking on the bushing ends up opposite the marking on the sub-frame (see the 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 together with the washers and brackets.
Install the screws holding the brackets for the sub-frame in the bodywork.
Tighten the sub-frame screws. Tighten to 105 Nm . Angle-tighten 120° .
Tighten the bracket screws. Tighten to 50 Nm .





Install the wiring harness on the sub-frame.





Install the steering shaft using the markings made earlier. Use a new lock nut . Tighten to 20 Nm .
Install the locking shackle.





Hang the muffler.
Install the cross member. Tighten to 25 Nm .





Install a new screw and lock nut in the upper torque rod. Tighten to 35 Nm . Angle-tighten 90° .