Rear Cross-Member: Service and Repair
Sub-frame rear, replacingSpecial tools: 999 5659
Removing the sub-frame
Preparations
Raise the car.
Note: Lift the sill edges so that the rear axle is free.
Remove
- the wheels
- the mounting screws for the brake caliper
- the ABS sensor
- The mountings for the ABS line. Hang up the line and the brake caliper. Use a piece of wire
- the screw for the bracket for the brake pipe on the sub-frame
- the locating pin for the brake disc
- the brake disc.
- the return spring at the expander
- the expander. Lift the brake shoe slightly.
Unhook the expander (1) from the mounting for the mechanical cable.
- 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.
- the parking brake cable from the tie rod and sub-frame
- the exhaust system.
- the springs and shock absorbers.
- EVAP canister screw.
Note: The EVAP canister hangs in the bodywork when the sub-frame is lowered.
Remove
- the plastic nut for the fender liner. Bend the fender liner out of the way.
Drill out the heat deflector plate rivet on the sub frame left rear bushing.
Remove 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 components from the sub-frame
Note: The lateral link, tie rod, lower control arm and wheel spindle are removed from the sub-frame as one unit.
Remove
- the lateral links from the sub-frame
- the tie rods
- the wheel spindle from the upper control arm
- the anti-roll bar control arms from the upper control arm
- the anti-roll bar from the sub-frame.
Installing the sub-frame
Install components on the sub-frame
Note: To ensure that there is no exhaust leakage, see: Flanged joint, assembling.
Install
- the upper control arm.
- the anti-roll bar on the new sub-frame. Tighten to 80 Nm.
Note: Lateral link, tie rod, lower control arm and wheel spindle are installed on the new sub-frame as one unit.
Install
- the wheel spindle to the upper control arm. Do not tighten so hard that the toothed segment goes into the bushing on the wheel unit
- the lateral links on the sub-frame. Finger tighten
- tie rods on the sub-frame. Finger tighten
- the lower control arm on the sub-frame. Finger tighten.
- Install a M12x70 mm screw and nut in the hole for the anti-roll bar on the control arm, to assist when measuring
- Check the height measurement on the control arm. If necessary adjust the height measurement using a tie strap
- Tighten the wheel spindle to the upper control arm. Tighten to 50 Nm
- Install anti-roll bar control arms to the upper control arm. Tighten to 80 Nm.
Note: Counterhold the ball joint so as not to damage the boot.
Reinstall the sub-frame
- Hint: 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. Measured at the centering sleeves A=20 mm, B=13 mm, C=50 mm.
Place the sub-frame on a lifting table.
- Lift up the sub-frame enough to be able to install the EVAP canister. Tighten to 25 Nm
- Lift the sub-frame up completely to the bodywork.
Release the lower control arms from the sub frame.
Note: Ensure that the brake pipes are not crimped at the sub-frame mountings.
Install
- the brake line mounting stays on the sub-frame bracket. Tighten to 25 Nm
- the brake pipe in the clips on the sub-frame brackets.
- Note: Use new screws for the sub-frame mountings.
- Slide up the centering sleeves in the two rear mountings on the sub-frame
- Install the screw. Tighten lightly
- Install the screws for the front mountings on the sub-frame.
- Install the screws through the brackets
- Install the screw for the brackets
- Tighten all the front mountings. Tighten to 80 Nm
- Remove the screw for the rear mountings on the sub-frame. Remove the centering sleeves
- Install the screws for the rear mountings on the sub-frame. Tighten to 80 Nm
- Install the fuel filter and holder on the right bracket. Tighten to 25 Nm.
Remove the lifting table.
Finishing
- Pop rivet the heat deflector for the exhaust pipe into the left rear mounting on the sub-frame
- Install the fender liner. Tighten the fender liner with the plastic nut.
Install
- the parking brake cable mounting in the subframe. Tighten to 25 Nm
- the mounting for parking brake cable on the tie rod
- the exhaust system.
- the springs and shock absorbers.
Note: At the same time, tighten the tie rods and lateral links to the sub-frame. Tighten to 80 Nm.
Use tensioner 999 5659.
Press the cable sleeve guide sleeve into place in the mounting.
Install
- the expander on the mounting for the mechanical cable
- the expander between the brake shoes
- the return spring.
Check the function.
Install
- the brake disc and the locating pin. Tighten to 10 Nm
- the brake caliper. Use new screws. Tighten to 60 Nm
- the ABS sensor. Tighten to 10 Nm
- the ABS line on the holder on the wheel spindle
- the wheels.
Align the wheels.