Volkswagen Golf Service & Repair Manual: Repairing subframe

Volkswagen Golf Service & Repair Manual / Running gear, axles, steering / Front suspension, drive shafts / Subframe / Repairing subframe

Repairing subframe

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 6779-

Thrust plate -VW 401-

Repairing subframe

Press tool -VW 412-

Renewing bonded rubber bushes for pendulum support

–	If fitted, remove front noise insulation → General body repairs, exterior; Rep. gr.66.

Repairing subframe

–	Unscrew nut -1- from coupling rod -3- on both sides.

–	Pull out coupling rod -3- from anti-roll bar -2- on left and right side.

Repairing subframe

–	Unscrew bolts -1- for anti-roll bar.

Leave the anti-roll bar in its installation position in the vehicle.

–	Remove pendulum support → Rep. gr.10.

Repairing subframe

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.

Repairing subframe

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 upper bonded rubber bush -2- is visible in pendulum support opening -arrow- 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.

Repairing subframe

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-.

Repairing subframe

–	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-.

Repairing subframe

–	Press in bonded rubber bush -3- in tube -VAS 6779/6- to stop, as illustrated.

1 -	Press tool -VW 412-

2 -	Thrust piece -VAS 6779/5-, the side with the lettering »A« must face upwards.

3 -	Bonded rubber bush

4 -	Tube -VAS 6779/6-

5 -	Tube -VAS 6779/4-

6 -	Thrust plate -VW 401-

Repairing subframe

–	Insert counterhold -VAS 6779/7--1- into subframe.

–	Insert counterhold attachment -VAS 6779/7-1A--2- into pendulum support opening in subframe.

–	Bolt insert -VAS 6779/7-1A- to counterhold -VAS 6779/7--1-.

–	Ensure that the insert -VAS 6779/7-1A--2 - is correctly seated in the pendulum support opening of the subframe -arrow-.

Repairing subframe

Pressing in bonded rubber bush

–	Screw threaded spindle -VAS 6779/2--7- into counterhold -VAS 6779/7--1-

–	Fit assembly tool -VAS 6779- to subframe as shown in illustration.

Repairing subframe

1 - Counterhold -VAS 6779/7-

2 - Tube -VAS 6779/6-, -arrow mark- on tube must align centrally between both 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 6779- from subframe and check pressed-in bonded rubber bushes for proper seating.

–	Bolt anti-roll bar to subframe and coupling rods.

–	Install pendulum support → Rep. gr.10.

–	Install front noise insulation → General body repairs, exterior; Rep. gr.66.

Specified torques

→ Chapter „Assembly overview - subframe“

Bolts for pendulum support, except for e-Golf → Rep. gr.10

Bolts for pendulum support, e-Golf → Electrical system; Rep. gr.93

Bolts for noise insulation → General body repairs, exterior; Rep. gr.66.

Removing and installing subframe with steering rack, RHD vehicles, except for e-Golf

Special tools and workshop equipment required Ball joint puller -T10187- ...

Removing and installing anti-roll bar

Special tools and workshop equipment required Torque wrench -V.A.G 1332- ...

Other materials:

Assembly overview - activated charcoal filter system
1 - Connecting hose From air filter to pressure control valve 2 - Hose clips 3 - Pressure regulating valve With tank pressure sensor -G400- 4 - Bolts ...

Handling refrigerants
WARNING Danger of freezing injuries. The refrigerant can emerge as liquid or as vapour. Do not open containers in which this refrigerant is present. ...

Assembly overview - suspension, multi-link suspension, front-wheel drive
1 - Wheel bearing housing Removing and installing → Chapter 2 - Bonded rubber bush Renewing → Chapter. 3 - Bolt Specified torque ͛ ...