Procedure 1
Sub-frame rear, replacing
Note: As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.
Removal
Removing the sub-frame
Raise the car.
Note: See Lifting points, body.
Remove:
- the rear wheels
- the screw for the drive shaft and wheel hub on both sides.
Remove:
- the wheels
- the ABS sensor and the ABS line from the bracket on the wheel spindle
- the brake caliper mounting screws.
Hang up the ABS line and the brake caliper. Use a piece of wire.
Remove:
- the screw for the bracket for the brake pipe on the sub-frame
- the locating pin for the brake disc
- the brake disc.
Remove:
- the return spring at the expander
- the expander.
Lift the brake shoe slightly. Grip the expander and pull it outwards to access the cable.
Unhook the expander from the metal bracket.
Remove the guide sleeve for the cable sleeve. Apply a screwdriver between the guide sleeve lug and wheel arch. Pry apart slightly to remove the sleeve.
Remove:
- the exhaust system.
- the propeller shaft from the viscous coupling.
Remove the plastic nut from the fender liner. Move the fender liner to one side.
Drill out the heat deflector plate rivet on the sub-frame left rear bushing.
Removing shock absorbers, lateral links and anti-roll bar links
Note: The shock absorbers are slightly compressed.
Remove:
- the shock absorbers (on both sides) from the control arms
- the screws for the mountings for the lateral link
- the lateral link on both sides
- the anti-roll bar link from the upper control arm (both sides).
Removing the position sensor (Four-C only)
Remove the position sensors.
Removing the screws from the track rods and control arms
Remove:
- the tie rod
- the control arm. First press the control arm outwards. Move it downwards at the inner mounting
- the control arm
- the link for the lower control arm against the sub-frame.
Removing the anti-roll bar
Remove:
- the anti-roll bar from its mountings on the sub-frame
- the anti-roll bar.
Remove the mechanical cables for the parking brake from the mountings in the heat deflector plate.
Carefully bend out the mechanical cables towards the wheel bearing housing. Ensure that the cables do not crack or break.
Detaching the final drive housing and rear axle member
Position mobile jack 998 5972 together with fixture 999 5972.
Adjust the plate against the lower cover and final drive.
Install a large hose clamp above the pipe and plate.
Remove the eight screws from the cover.
Lowering the final drive housing
Lower the final drive housing so that the drive shafts are angled inwards slightly.
Pry out the wheel bearing housing.
Remove the drive shaft from the hub.
Note: Be very careful with the drive shaft when removing it from the hub. The inner joint may be damaged if the shaft releases under its own weight.
Lower the final drive housing and shafts.
Slacken off the screw for the outer control arm mounting three turns.
Use hydraulic hole cylinder 951 2923, locating pin 999 7031 and mounting bracket 999 7030 together with connecting rod 999 7039.
Press off the wheel spindle.
Remove the wheel spindle from the upper control arm.
Removing the sub-frame
Position a lifting table under the sub-frame.
Remove:
- the four sub-frame mountings
- the sub-frame brackets screws
- the brake hose mounting stays from mountings on the brackets
- the brake pipes from the plastic clips on the brackets.
Note: Remove the fuel filter bracket on the right bracket.
Carefully lower the sub-frame.
Remove the three hoses on the EVAP canister.
Lower the sub-frame fully.
Removing components from the sub-frame
Remove the EVAP canister.
Remove:
- the mountings for the EVAP canister
- the collision protection.
Four-C only
Remove the cable harness for the shock absorber.
Installation
Note: For further information about tightening torques, see specification.
Installing components on the sub-frame
Install the upper control arm.
Note: The lateral link, tie rod, lower control arm and wheel spindle are installed on the new sub-frame, with the screws finger tightened, as one unit. This ensures that the wheel spindle is at the correct angle when it is tightened to the upper control arm at the indicated height.
Install:
- the wheel spindle to the upper control arm.
Note: Do not tighten so hard that the toothed segment goes into the bushing on the wheel spindle.
- the lateral links on the sub-frame. Finger tighten
- the link for the inner mounting for the control arm. Finger tighten
- the lower control arm on the sub-frame. Finger tighten.
Install an M12 x 70 mm screw together with a nut in the hole for the anti-roll bar on the control arm, to facilitate measuring.
Check the height measurement on the control arm. If necessary adjust the height measurement with a tie strap.
Tighten the wheel spindle to the upper control. Use an M10 screw.
Remove:
- the lateral link from the wheel spindle
- the lower control arm from the sub-frame.
Install:
- the collision protection. Tighten. See specifications
- the mounting for the EVAP canister. Use an M6 screw.
Four-C only
Install the cable harness for the shock absorber.
Install the EVAP canister. Use an M6 screw.
Installing the sub-frame
Make up two centering sleeves which are then placed on the rear mountings for the sub-frame. This will make it easier to center the rear suspension.
- Measurement on the centering sleeves: A=20 mm, B=13 mm, C=50 mm
- Place the sub-frame on a lifting table
- Raise the sub-frame so that it is approximately 15 cm from the bodywork.
Install the 3 connections on the EVAP canister.
Four-C only
Connect the connectors for the shock absorber on the sub-frame.
All AWD
Lift the sub-frame up completely to the bodywork.
Note: Ensure that the brake pipes are not crimped at the sub frame mountings.
Install:
- the mounting strut for the brake hose on the sub-frame bracket. Use an M8 screw
- the brake pipe in the clips on the sub-frame brackets.
Note: Do not tighten the screws yet. They will be tightened in the next two operations.
Install:
- the screws for the sub-frame, at the front edge through the brackets
- the screws for the brackets.
Note: Use new screws for the 4 mountings for the sub-frame.
Slide up the centering sleeves in the two rear mountings on the subframe.
Install the screw. Tighten lightly.
Tighten:
- the screws for the front mountings on the sub-frame (install the screws through the brackets). See specification.
- the M12 screws for the brackets.
Remove the screws for the rear mountings on the sub-frame.
Remove the centering sleeves.
Install:
- the screws for the rear mountings on the sub-frame. Tighten the screws. See specification
- the fuel filter with the holder on the right bracket. Use an M8 screw.
Remove the lifting table.
Preparations for the installation of the final drive
Lift the final drive together with the drive shafts so that the center of the drive shaft is slightly below the center of the wheel bearing housings.
Apply rust-proofing agent to the ends of the drive shafts.
Press out one of the wheel bearing housings. Align the drive shaft in the hub.
Then align the other side.
Installing the final drive on the sub-frame
Press the final drive up against the sub-frame. Align all screws.
Tighten the screws alternately. See specifications.
Remove the hose clamp from the pipe and plate.
Remove the jack.
Install the propeller shaft.
Note: Do not install the exhaust pipe yet.
Installing anti-roll bar
Install the anti-roll bar in the rear axle member. Use an M12 screw.
Use new lock nuts.
Note: Ensure that the cable for the parking brake passes below the ends of the anti-roll bar. Press the cables into place in the clamps on the heat deflector plate.
Installing the control arm and tie rod
Install:
- the control arms using new screws. Finger tighten
- the tie rod. Use new lock nuts. Finger tighten.
Installing the position sensor (Four-C only)
Install the position sensors.
Installing the torque arm and anti-roll bar links
Install the screws for the support arms. Do not tighten the screws yet.
Note: Do not install the screws in the wheel spindle.
Install the link for the anti-roll bar on the upper control arm on both sides. Use M10 screws. Use new nuts.
Finishing
Pop rivet the exhaust pipe heat deflector into the left rear sub-frame mounting.
Install the fender finer with the plastic nut.
Press the suspension up to its normal position.
Install:
- the mountings for the parking brake cable in the sub-frame. Use M8 screws
- the exhaust system.
Tighten:
- the 2 M12 screws for the lower control arm
- the link at the inner mounting on the control arm on the subframe. Use an M12
- the 2 M12 screws for the tie rod.
Install the lateral link against the wheel spindle. Hand-tighten the screw.
Tighten the 2 M12 screws for the lateral link.
Remove the mobile jack.
Install the spring struts on the control arms. Use a larger jimmy bar to bend the control arm down and to align the spring strut against the control arm. Tighten the M12 screw.
Press the cable sleeve guide sleeve into place in the mounting.
Install:
- the expander on the cable. Press the mounting together to lock the cable in the expander
- the expander between the brake shoes
- the return spring.
Check the function.
Install:
- the brake disc and the locating pin, M6
- the brake caliper. Use new screws. Tighten. See specifications
- the ABS sensor, M6
- the ABS line on the holder on the wheel spindle.
Tightening the drive shafts
Install the screws for the drive shafts on both sides. Use new screws. Tighten. See specifications.
Install the wheels.
Align the wheels.