Suspension - Rear, Awd Audi A4 B5

DESCRIPTION

Rear suspension consists of a rear subframe, upper and lower control arms, lower track rods, wheel bearing housing, stabilizer bar and strut assembly. (Scheme 36)- (Scheme 37).

Scheme 36

Scheme 37

SUSPENSION WEIGHT CODES

For explanation of suspension weight codes (Scheme 38)

Scheme 38

HEADLIGHT RANGE CONTROL

Note. To avoid damage, use a 10 mm wrench with a thickness of .15" (4 mm) or less to hold stud when tightening sensor arm-to-linkage nut.

Remove linkage at lower control arm when necessary to service lower control arm or axle. When installing headlight range control, ensure sensor arm is pointing outward and downward. (Scheme 39) Linkage between sensor arm and lower control arm should be aligned vertically with vehicle weight resting on suspension.

Scheme 39

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

See SPECIFICATIONS & PROCEDURES SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

REMOVAL & INSTALLATION

AXLE SHAFT

Note. See AXLE SHAFTS - FRONT & REAR article in DRIVE AXLES section for axle shaft removal, installation and overhaul.

Note. To avoid damage, use a 10 mm wrench with a thickness of .15" (4 mm) or less to hold stud when tightening sensor arm-to-linkage nut.

Disconnect wire harness. Remove linkage from lower control arm. (Scheme 40) Remove headlight range control from subframe. To install, reverse removal procedure. Adjust linkage. See HEADLIGHT RANGE CONTROL under ADJUSTMENTS.

Scheme 40

LOWER CONTROL ARM

Note. Check wheel alignment after servicing.

Scheme 41

Scheme 42

Scheme 43

Scheme 44

1. Raise and support vehicle. Remove wheel.
2. Remove ABS sensor cable bracket. (Scheme 41)
3. Disconnect and plug brake lines at both connections on lower control arm. (Scheme 42)
4. On vehicles with headlight range control, disconnect linkage at control arm. (Scheme 39)
5. On all vehicles, remove self-locking nut and bolt mounting lower control arm to suspension strut (arrow 1). (Scheme 43)
6. Remove parking brake cable. See «PARKING BRAKE CABLES»(/audi/a4/b5-1994-1999/remont/mechanical-hydraulic/#disc-brakes) in BRAKES.
7. Remove eccentric bolt for wheel bearing housing to lower control arm (arrow 2). (Scheme 43)
8. Remove both mounting bolts for subframe to lower control arm (arrow). (Scheme 44)

Disassembly (Rear Inner Bushing)

Note. Replacement control arms have bushings installed.

Scheme 45

Scheme 46

1. Attach 3293 lower control arm assembly device to bushing with jaws of tool positioned between lip of bushing and lower control arm. Screw in threaded stem to force bushing slightly from lower control arm. (Scheme 45)
2. Attach commercially available puller (e.g. Kukko 15-0) to lower control arm. (Scheme 46) Insert 3118/8 adapter into hole in bonded rubber bushing. Screw Kukko 18-0 into Kukko 15-0 and centrally align. Screw in threaded stem A until bonded rubber bushing is pulled out. Tighten puller to pull out bushing half.
3. Attach 3349 puller to lower control arm. Screw in threaded stem of 3301/1 until second half of bushing is fully removed. (Scheme 47)

Reassembly (Rear Inner Bushing)

Insert two halves of bonded rubber bushing together with 3293/4 thrust pieces and threaded stem into lower control arm art right angles. Turn threaded stem until bonded rubber bushing is pulled fully in up to stop. (Scheme 48)

Scheme 47

Disassembly & Reassembly (Front Inner Bushing)

Using press and adapters, press out and in rear lower control arm bushing. (Scheme 49) When pressing out, make sure that the bonded rubber bushing does not rest on the end face of 3259 tube. Collar of 3259 tube faces VW401 thrust plate.

Scheme 48

Installation

1. Install in reverse order of removal. Always replace bolts and nuts.
2. When tightening suspension components with bonded rubber bushings, final tighten bolts with suspension at normal ride height. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/suspension-rear/#suspension-rear-awd__torque-specifications) .
3. Bleed brake system. See «BLEEDING BRAKE SYSTEM»(/audi/a4/b5-1994-1999/remont/mechanical-hydraulic/#disc-brakes) in BRAKES.
4. Check wheel alignment and adjust if necessary. See «SPECIFICATIONS & PROCEDURES»(/audi/a4/b5-1994-1999/remont/wheel-alignment/#specifications-procedures) article.

REAR SUBFRAME

Information not available from manufacturer. Subframe bolt tightening sequence (item 4) in (Scheme 50)

1. 1. Right-rear
2. 2. Left-rear
3. 3. Right-front
4. 4. Left-front

Note. Always replace subframe bolts and washers. Install washers with ribbed side upward.

Align rear axle after removal and installation. See SPECIFICATIONS & PROCEDURES SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

Scheme 49

Disassembly (Front Bushing)

Assemble 3291/4 tubular section (pay attention to recesses) together with 3291 assembly device at right angle to subframe. (Scheme 51) Attach two brass washers in such a way that annular grooves are next to one another (3291 assembly device). Install washer and screw on nut. Pull out bonded rubber bushing by turning nut. Insert hex head of 3291 assembly device into the recess in the 3291/4 tubular section. Apply grease to the annular grooves of the brass washers and to the threaded stem.

Scheme 50

Reassembly (Front Bushing)

1. Apply lubricant (e.g. G 294 421 A1) when pressing in bonded rubber bushings. (Scheme 52) Assemble 3291/1 thrust piece to bonded rubber bushing and insert at right angle into hole in subframe using 3291/5 tubular section (pay attention to recesses) and 3291 assembly device.
2. Ensure bushing is correctly aligned in subframe. The kidney-shaped recesses (arrows) must be parallel to the center line of the vehicle. Max. deviation of 10 to left or right is permissible. (Scheme 53)
3. Attach two brass washers with annular grooves facing one another and to 3291 assembly device. Install washer and screw on nut. Press in bonded rubber bushing fully by turning nut. While pulling in, hold 3291/1 thrust piece or bonded rubber bushing by hand to prevent turning.

A. Align bushing. (Scheme 53) Tighten nut to press bushing into subframe.

Scheme 51

Disassembly (Rear Bushing)

To remove front bushing, assemble tool on bushing. (Scheme 54) Ensure brass washer grooves are facing each other. Lube nut and washers. Tighten nut to remove bushing.

Scheme 52

Scheme 53

1. Apply lubricant (e.g. G 294 421 A1) when pressing in bonded rubber bushings. Attach 3291/1 thrust piece to bonded rubber bushing and insert at right angle into hole in subframe using 3291/3 tubular section and 3291 assembly device. Attach two brass washers with annular grooves next to one another and to 3291 assembly device. Install washer and screw on nut. (Scheme 55)
2. Ensure bushing is correctly aligned in subframe. The kidney-shaped recesses (arrows) must be parallel to the center line of the vehicle. Max. deviation of 10 to left or right is permissible. (Scheme 53)
3. Press in bonded rubber bushing fully by turning nut. While pulling in, hold 3291/1 thrust piece or bonded rubber bushing by hand to prevent turning. Insert hex nut of 3291 assembly device into recess in 3291/3 tubular section. Apply grease to the annular grooves of the brass washers and to the assembly device.

STRUT ASSEMBLY & UPPER CONTROL ARM

Note. Check wheel alignment after servicing.

Scheme 54

Scheme 55

1. Vehicle must be standing on its wheels above vehicle lift. Remove wheel trim. On light alloy wheels use puller in vehicle tool kit to remove trim cap. Loosen wheel bolts. Raise vehicle on lift. Remove wheel.
2. Loosen bolted connection of lower control arm to suspension strut (arrow 1). (Scheme 43)
3. Loosen bolts from wheel bearing housing to upper control arm (arrow 1). (Scheme 56)
4. Remove suspension strut mounting bracket bolts (arrows), push wheel bearing housing down and remove suspension strut along with control arm. (Scheme 57)
5. Remove bolts from shock absorber to upper control arm, and remove control arm. (Scheme 36)

Scheme 56

Scheme 57

Scheme 58

1. Put strut assembly in tool. Using spring compressor, compress strut spring until upper spring mount is free. (Scheme 58) Make sure the coil spring is seated correctly in the VAG1752/3 adapter.
2. Compress coil spring using VAG1752/1 spring compressor until upper shock absorber mount is free.
3. Remove nut (arrow) and bolt. (Scheme 59) Remove suspension strut mounting bracket and damper ring. Remove compressed spring together with VAG1752/1 spring compressor. Remove faulty shock absorber from VAG1752 suspension strut tensioner and dispose of properly.

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

1. Clamp strut in tool. Ensure lower spring stop is positioned properly. (Scheme 61) Pay attention to the position of the step on the lower spring retainer (arrow).
2. Compress new coil spring using VAG1752/1 spring compressor. (Scheme 62) Fit compressed coil spring onto shock absorber. Colored marking on coil spring must be facing down toward spring retainer. End of spring coil should be resting against stop of spring retainer (arrow).
3. Install damper ring so that end of spring coil is resting against stop of damper ring (arrow). (Scheme 63)
4. Install suspension strut mounting bracket. Install securing bolt into suspension strut mounting bracket and screw on nut (arrow) loosely. (Scheme 64) Install locating bolt A into suspension strut mounting bracket and secure loosely with nut. Nut faces in direction of travel!
5. Turn suspension strut mounting bracket until pointer on degree scale (on VAG1752 suspension strut tensioner) is pointing to 21 +/- 2 degrees (with locking bolt D loose). L is for left-hand suspension strut; R is for right-hand suspension strut. (Scheme 65) Illustration shows the position of the degree scale when assembling the right-hand suspension strut.
6. move lever arm C with locating bolt A perpendicular to height adjuster B. (Scheme 66) Tighten locking bolt D. Relieve tension from compressed coil spring and remove VAG1752/1 spring compressor. Remove locating bolt A from suspension strut mounting bracket.
7. Tighten nut (arrow) to 52 ft. lbs. (70 N.m). Tighten an additional 1/4-turn (90 degrees). (Scheme 67) Remove suspension strut from VAG1752 suspension strut tensioner. Illustration shows right-hand suspension strut.
8. Tighten upper mount bolt and nut. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/suspension-rear/#suspension-rear-awd__torque-specifications).

To install, reverse removal procedure. Always use NEW upper and lower strut assembly and upper inner control arm bolts and nuts. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

UPPER CONTROL ARM (FORGED)

Note. Left and right upper control arms are identical. Check wheel alignment after servicing.

Raise and support vehicle. Remove strut assembly and upper control arm. For procedures, see STRUT ASSEMBLY & UPPER CONTROL ARM .

Disassembly

Note. Replacement upper control arms include bushings. Left and right-sides are identical.

Scheme 66

Scheme 67

Scheme 68

1. Attach 3292 assembly device with both sides of tool jaws between bearing and control arm. (Scheme 68) Screw in spindle up to stop so that tool compresses rubber metal bushing against eye in control arm eye. Be careful not to damage the surface of the control arm.
2. Secure 3292/2 to 3292 using bolts a (M10 x 80). (Scheme 69) Attach 3292/4. Screw spindle into 3292 until bonded rubber bushing is pressed out.
3. Using press and adapters, press out upper control arm outer bushing. (Scheme 70) Make sure to install 41-501 lower pipe piece exactly correct.

Scheme 69

Scheme 70

1. Install bonded rubber bushing at right angle to control arm. (Scheme 71) Install 3288/2 and 3350/2 pressure pieces as shown together with bolts and press in bushing up to stop in control arm eye.
2. Using press, install outer bushing into upper control arm. (Scheme 72) Bushing can be installed with slit in outer cover in any installed position. Press in bushing up to stop.

UPPER CONTROL ARM (STAMPED STEEL)

Note. Left and right upper control arms are identical. Check wheel alignment after servicing.

1. Raise and support vehicle. Remove strut assembly and upper. See «STRUT ASSEMBLY & UPPER CONTROL ARM»(/audi/a4/b5-1994-1999/remont/suspension-rear/#suspension-rear-awd__strut-assembly-upper-control-arm) for procedures.
2. To install, reverse removal procedure. Always use NEW nuts and bolts. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/suspension-rear/#suspension-rear-awd__torque-specifications) .

Note. Replacement upper control arms include bushings.

Using press and adapters, press out inner and outer bushings. (Scheme 73) Be careful not to damage the surface of the upper control arm.

Scheme 71

Reassembly

Using press and adapters, press out inner and outer bushings. (Scheme 74) Press bushings fully in up to stop.

Scheme 72

WHEEL BEARING HOUSING

Scheme 73

Scheme 74

1. Vehicle must be standing on its wheels above vehicle lift. Remove wheel trim. On light alloy wheels use puller in vehicle tool kit to remove trim cap. Loosen axle shaft collar bolt in wheel hub.
2. Loosen wheel bolts. Raise vehicle on lift. Remove wheel. Pull ABS wheel speed sensor from wheel bearing housing. Remove axle shaft collar bolt.
3. Remove bolt for connecting link to wheel bearing housing (arrow 2). (Scheme 56)
4. Remove track rod from wheel bearing housing. (Scheme 37)
5. Using 3287 ejection device for steering rod, press track rod off wheel bearing housing. (Scheme 76)
6. Remove bolts mounting brake caliper to wheel bearing housing. Remove brake caliper without disconnecting brake hose and hang from body. Do not allow caliper to hang by brake hose. The unsupported weight can stretch and damage the hose. Remove brake disc.
7. Mark installation position of eccentric washer for bolt (arrow 2) for wheel bearing housing to lower control arm and remove. (Scheme 43)
8. Remove wheel bearing housing to upper control arm bolt (arrow 1). Remove wheel bearing housing from drive axle and remove. (Scheme 56)

Scheme 75

Scheme 76

Scheme 77

1. Position 3292/1 support onto bonded rubber bushing. (Scheme 77) Push 3292 assembly device over 3292/1 support and move into position. Tighten threaded spindle up to stop so that both jaws of 3292 assembly device are located in annular groove between bonded rubber bushing and wheel bearing housing.
2. Center 3292/2 cross bar and move fully up against 3292/1 support by tightening both bolts. Screw in spindle of 3292/2 cross bar until bushing is drawn out. (Scheme 78)
3. Install bonded rubber bushing on both sides and perpendicular to hole in wheel bearing housing. Position one 3293/3 thrust piece each onto two bushings and use threaded spindle to draw in bushing up to stop. (Scheme 79)

Wheel Bearing Replacement

Note. Using VAG 1459B allows technician to service wheel bearing and wheel hub on vehicle. Follow manufacturer's instructions.

1. Using press, remove wheel bearing. (Scheme 80)
2. If necessary, remove any corrosion/dirt from hole in wheel bearing housing. Press in bearing A until fully seated. (Scheme 80) Larger inner diameter of wheel bearing faces wheel hub.

Scheme 78

Wheel Hub Replacement

Using press, remove and install wheel hub. see scheme 46 When installing, VW519 sleeve must only contact the bearing inner race when pressing in the wheel hub. Press fully home.

Scheme 79

Scheme 80

1. With wheel hub removed, install separating device into annular groove of bearing inner race and preload with spindle. see scheme 47 Press bearing inner race off wheel hub.

1. To install, reverse removal procedure. Always use NEW self-locking nuts and upper outer control arm-to-wheel bearing housing bolt. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b5-1994-1999/remont/suspension-rear/#suspension-rear-awd__torque-specifications) .
2. Check wheel alignment after servicing. See «SPECIFICATIONS & PROCEDURES»(/audi/a4/b5-1994-1999/remont/wheel-alignment/#specifications-procedures) SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• SPECIFICATIONS & PROCEDURES
• AXLE SHAFTS - FRONT & REAR
• PARKING BRAKE CABLES
• HEADLIGHT RANGE CONTROL
• TORQUE SPECIFICATIONS
• STRUT ASSEMBLY & UPPER CONTROL ARM