Suspension, Wheels, Steering Audi A4 B7

Vehicles up to VIN 400 000

* 1 These specified values correspond to a wheel offset of ET 39 mm and a load condition "empty without driver".

* 2 These specified values correspond to a wheel offset of ET 42 mm and a load condition "empty without driver".

Vehicles from VIN 400 001

* 1 These specified values correspond to a wheel offset of ET 42 mm and a load condition "empty without driver".

Note. The specified values apply to all engine versions. Tracks change with use of wheels with different offset.

Front gas-filled strut, venting and emptying

A - Venting through drill holes

Scheme 1

1. Clamp gas-filled strut vertically in vise, with piston ends facing downward.

1. Drill a 3 mm diameter hole - arrow A - through outer strut tube.

Note. Gas escapes when drilling.

1. Continue drilling until tube inside is drilled through (approx. 25 mm deep).
2. Drill a second hole, 6 mm diameter - arrow B - , through outer and inner strut tubes.
3. Hold strut over oil collecting pan and move piston rod back and forth several times over entire range until no more oil escapes.

B - Open with pipe cutter

Special tools, testers and auxiliary items required

1. Pipe cutter, e.g. Stahlwille Express 150/3

Scheme 2

1. Drill a 3 mm diameter hole - arrow - through outer strut tube or saw through tube wall.

Note. Gas escapes when drilling or sawing.

1. Position a pipe cutter (e.g. Stahlwille Express 150/3) as shown in illustration and cut through outer tube.
2. Pull piston rod upward, hold inner tube in place with pliers and push it downward so that it remains in outer tube when piston rod is slowly raised.
3. Remove piston rod from inner tube.
4. Empty strut tube.

Rear gas-filled strut, venting

A - venting through drill holes

Scheme 3

1. Clamp gas-filled strut vertically in vise, with piston ends facing downward.

1. Drill a 3 mm diameter hole - arrow A - through outer strut tube.

Note. Gas escapes when drilling.

1. Continue drilling until tube inside is drilled through (approx. 25 mm deep).
2. Drill a second hole, 6 mm in diameter - arrow B - , through outer and inner strut tubes.
3. Hold strut over oil collecting pan and move piston rod back and forth several times over entire range until no more oil escapes.

B - Open with pipe cutter

Special tools, testers and auxiliary items required

1. Pipe cutter, e.g. Stahlwille Express 150/3

Scheme 4

1. Drill a 3 mm diameter hole - arrow - through outer strut tube or saw through tube wall.

Note. Gas escapes when drilling or sawing.

1. Position a pipe cutter (e.g. Stahlwille Express 150/3) as shown in illustration and cut through outer tube.
2. Pull piston rod upward, hold inner tube in place with pliers and push it downward so that it remains in outer tube when piston rod is slowly raised.
3. Remove piston rod from inner tube.
4. Empty strut tube.

Power steering gear, emptying

Note. Room temperature should be at least 20°C to empty steering gear.

Scheme 5

1. Turn steering pinion in direction of - arrow - to stop.

Scheme 6

1. Clamp steering gear horizontally in vise.
2. Place collecting reservoir under steering gear.
3. Saw steering gear at place indicated by - arrow A -.
4. Hold cut steering gear over oil collecting pan and allow hydraulic oil to drain. If necessary, turn steering pinion to opposite stop.

Strut leak

Struts are frequently rejected and exchanged because of leaks. Examinations on test stand and on the vehicle have shown that the replacement of a large number of rejected strut was not justified.

Slight leaking of oil ("sweating") at piston rod seal is no reason to replace a strut. A strut with oil is OK under the following circumstances

Scheme 7

1. Oil leak (shown screened in illustration) is visible, but dull, matte and possibly dry from dust
2. Oil leak reaches at most, from upper shock absorber seal (piston rod seal) to lower spring plate - arrow -.

Note. A slight oil leak is advantageous because it lubricates the piston rod seal and extends its service life. This applies to struts on front and rear axles

Strut, noises

Struts are frequently rejected and exchanged because of rumbling noises. Examinations on the test stand and vehicle have shown that there was not a complaint with approx. 70% of the rejected shock absorbers and the replacement was not justified.

With complaints that are interpreted as rumbling or knocking sounds, proceed as follows.

1. Determine on a road test with the customer - if possible on a dry stretch of road with irregularities - where, when and how these sounds change.

Note. In the rarest cases, the strut is the cause of the noises.

Strut, checking while removed

Faulty struts are noticeable when driving due to loud rumbling noises - a result of wheel hopping - especially on poor stretches of road. Moreover, they can be recognized by a large loss of oil.

Note. Struts are maintenance-free, shock absorber oil cannot be topped off.

A removed strut can be checked by hand as follows

1. Press strut together by hand.

1. Piston rods must move smoothly and with uniform difficulty over the entire range

1. Release piston rods.

1. On struts with sufficient gas pressure, piston rods return to initial position by themselves.

Note. If this is not the case, strut must be replaced. As long as there is no large loss of oil, the mode of operation corresponds to that of a conventional strut. The damping function is also completely available without gas pressure, as long as there is no large loss of oil. However, noise may increase.

Struts, testing on shock tester

Struts can be checked while installed using the shock tester (strut testing device). The damping effect can be evaluated based on the dial reading or print-out.

Special tools, testers and auxiliary items required

1. Boge shock tester or
2. Sachs shock tester V.A.G 1975 or
3. Maha shock absorber tester VAS 1990

Note. Temperature +10 to +40°C. Driver in vehicle. Tire pressure OK. Drive vehicle straight onto center of wheel contact plates. Front wheels in straight position. Parking not engaged, foot brake not activated.

Threshold

Strut condition can only be judged as follows

1. Sufficient damping effect

or

1. Insufficient damping effect

Note. Intermediate values for reduced damping performance cannot be read out. A prognosis on service life is not permitted. Measured values that come about from involvement of suspension travel end stops are incorrect.

The following values apply only to the test stands named above. If the specified values are exceeded, the strut action has weakened enough that a replacement is recommended.

Scheme 8

Example

Threshold = 70

1. a = greater than 70: Insufficient damping effect
2. a = less than 70: Sufficient damping effect

Strut combination installed in vehicle is indicated by corresponding PR number on vehicle data plate.

Clarification of weight Production Relevant numbers (PR no.) Clarification of Production Control numbers (PR No.)

Threshold "a" in mm

Note. If the readout value is greater than the limit value "a" (table value): Damping effect insufficient --> replace strut. If the readout value is less than the limit value "a" (table value): Damping effect sufficient --> strut does not need to be replaced.

Vehicles up to VIN 400 000

Vehicles from VIN 400 001

Damaged threads, repairing

Damaged threads can be repaired with wire inserts (Heli-Coil).

See component overviews to learn which threads can be repaired.

Shavings that remain in the body must be imbedded in wax.

Longmember thread, servicing

It is possible to service the threads of weld nuts in longitudinal member depending on certain conditions.

1. Servicing work may only be performed once per thread.
2. If servicing is necessary after this, the nuts must be replaced.

1. Have thread repair checked by the responsible foreman or next person in charge.
2. Thread insert must be same length as thread in body.
3. Correct any damage to the underbody sealant layer.

General Information

When installing waxed components, contact surfaces must be cleaned. Contact surfaces must be free of wax and grease.

Torque specifications for unoiled bolts and nuts are given.

Welding or straightening operations are not permitted on load-bearing or wheel-controlling components.

Always avoid the following actions with coil springs: Hammer stroke, welding beads, applying color identification later.

Do not perform any welding or grinding (separating work) in coil spring or suspension strut area! Cover coil spring or suspension struts if necessary.

Vehicles without drive axle must not be moved, otherwise wheel bearing will be damaged. If vehicle must be moved, observe the following

1. Install an outer joint in place of the drive axle.
2. Tighten outer joint to 115 Nm (screw M14) or 200 Nm (screw M16).

Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms if vehicle is in curb weight position --> Wheel bearing, lifting to curb weight position

If the vehicle must still be aligned, every bolt and nut that must be loosened for adjustment is only tightened to torque specification. After measurement/adjustment is complete, tighten bolts and nuts to prescribed additional torque angle.

Scheme 9

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A
2. Tensioning Strap T10038
3. Wheel hub support T10149

Note. All bolts at suspension parts with bonded rubber bushings must always be tightened in curb weight position (unloaded condition).

Bonded rubber bushings have a limited torsional range.

Parts with bonded rubber bushings must be brought into a position that corresponds to the position in driving mode before being tightened (curb weight position)

Otherwise, bonded rubber bushing will be stressed resulting in a shortened service life.

By raising appropriate suspension using engine/transmission jack V.A.G 1383 A and Wheel Hub Support T10149 , this position can be simulated on the hoist.

Scheme 10

1. Before starting work, take measurement - a - , e.g. with tape measure, from center of wheel to lower edge of wheelhouse.

The measurement must be taken in curb weight position (unloaded).

1. Make a note of the measurement. It will be needed for tightening the bolts/nuts.

Before appropriate suspension is raised, vehicle must be strapped to lift arms of hoist using tensioning straps T10038.

If a vehicle is not secured, there is danger that the vehicle could slip off the lift!

1. Turn wheel hub until one of the holes for the wheel bolts is at the 12 o'clock position.
2. Install wheel hub support T10149 with wheel bolt on wheel hub.

Scheme 11

1. Using engine/transmission jack V.A.G 1383 A , lift wheel bearing housing until dimension - a - is reached.

Tightening of the respective bolts/nuts must then only occur after dimension - a - , which was measured before installation between the wheel hub center and the lower edge of wheelhousing, has been attained

1. Tighten respective bolts/nuts.
2. Lower steering knuckle.
3. Move engine/transmission jack away from under vehicle.
4. Remove wheel hub support T10149.

Scheme 12

1 - Hex bolt, 75 Nm

2 - Washer

3 - Hex bolt

1. Always replace if removed

4 - Upper rear link

1. Removing and installing --> «Upper links, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__upper-links-removing-and-installing)
2. Replace bearing --> «Top front and rear link bearings, replacing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__top-front-and-rear-link-bearings)

5 - Hex bolt, 7 Nm

1. For adjusting track constants "S"

6 - Bolt

7 - Hex nut, self-locking, 45 Nm

1. Always replace if removed

8 - Hex bolt, 40 Nm

9 - Nut, self-locking

1. Always replace if removed

10 - Upper front link

1. Mounting bracket, removing and installing --> «Mounting bracket and upper links»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Replace bearing --> «Top front and rear link bearings, replacing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__top-front-and-rear-link-bearings)

11 - Suspension strut

1. Note different vehicle versions, see vehicle data plate. «Clarification of Production Control numbers (PR No.)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__clarification-of-production-control-numbers-pr)
2. On vehicles with Dynamic Ride Control (DRC II), empty and fill system --> «Dynamic Ride Control (DRC II), emptying and filling»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__dynamic-ride-control-drc-ii-emptying)
3. Removing and installing --> «Suspension strut»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Servicing --> «Suspension strut, servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-servicing)

1. Mounting bracket, removing and installing --> «Mounting bracket and upper links»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

12 - Hex head screw, 70 Nm plus an additional 180° turn.

1. Always replace if removed

13 - Lower guide link

1. Guide link, removing and installing --> «Guide link, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__guide-link-removing-and-installing)

If hydro-mount leaks, it must be replaced --> Guide link mountings, replacing

14 - Hex nut, self-locking, 110 Nm

1. Always replace if removed

15 - Wheel bearing housing

1. On vehicles with headlight range control module, note sensor removal and installation --> «Vehicles with automatic headlight vertical aim control, vehicle level sensor»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Removing and installing --> «Wheel bearing housing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Servicing --> «Wheel bearing housing with bolted wheel bearing, servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

16 - Collar bolt

1. Always replace if removed
2. Note work sequence when loosening «Remove drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__remove-drive-axle) , when tightening «Install drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle) .
3. Torque specification «Install drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle)

17 - Flange bolt, 10 Nm

18 - Shield plate

19 - Nut, self-locking

1. Always replace if removed

20 - Hex bolt 90 Nm

21 - Subframe support

1. A tunnel crossmember can also be installed instead of subframe supports.
2. Tunnel crossmember, removing and installing --> «Tunnel crossmember»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

22 - Hex bolt, 55 Nm

23 - Hex bolt

1. 110 Nm plus an additional 90° ( 1 / 4 turn)
2. Always replace if removed
3. Threads in body can be repaired according to DIN 8140 using wire thread inserts (Heli-Coil). The thread insert must be same length as the threads in the body.

24 - Hex bolt

1. 40 Nm plus an additional 90° ( 1 / 4 turn)
2. Always replace if removed

25 - Connecting link

26 - Hex bolt

1. 40 Nm plus an additional 90°( 1 / 4 turn)
2. Always replace if removed

27 - Lower link

1. On vehicles with headlight range control module, note sensor removal and installation --> «Vehicles with automatic headlight vertical aim control, vehicle level sensor»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Control arm, removing and installing on vehicles with 3.0L TDI and 3.2L FSI --> «Control arm, removing and installing (vehicles with 3.0L TDI and 3.2L FSI)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__control-arm-removing-and-installing-vehicles)

28 - Hex bolt 70 Nm plus an additional 180° turn.

1. Always replace if removed

29 - Hex bolt, 75 Nm

1. Always replace if removed
2. Threads in body can be repaired according to DIN 8140 using wire thread inserts (Heli-Coil). Thread insert must be same length as thread in body.

30 - Subframe

1. Various versions --> «Subframe bushings, replacing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__subframe-bushings-replacing)
2. On vehicles with headlight range control module, note sensor removal and installation --> «Vehicles with automatic headlight vertical aim control, vehicle level sensor»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
3. Removing and installing --> «Subframe»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

1. Bonded rubber bushings for subframe, replacing --> «Subframe bushings, replacing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__subframe-bushings-replacing)
2. Tunnel crossmember, removing and installing --> «Tunnel crossmember»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

31 - Nut, self-locking

1. Always replace if removed

32 - Nut, self-locking

1. Always replace if removed

33 - Multi-point socket head bolt

1. First pre-tighten all screws to 15 Nm, then tighten all screws to specified torque.
2. Torque specifications

Bolt M 8: 40 Nm

Bolt M10: 70 Nm

34 - Backing plate

35 - Drive axle

1. Removing and installing --> «Front drive axle, servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

36 - Hex bolt

1. Always replace if removed

37 - Nut, self-locking

1. 50 Nm plus an additional 90°( 1 / 4 turn)
2. Always replace if removed

38 - Collar nut

1. 50 Nm
2. Always replace if removed

Suspension strut, removing and installing

Special tools, testers and auxiliary items required

Scheme 13

1. Engine/transmission jack V.A.G 1383 A
2. Torque wrench V.A.G 1331
3. Torque wrench V.A.G 1332

Removing

On vehicles with Dynamic Ride Control (DRC II), empty and fill system --> Dynamic Ride Control (DRC II), emptying and filling

1. Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
2. Remove wheel.
3. Secure brake disc with a wheel bolt.
4. Before removing left suspension strut, level control system sensor link must be loosened from link on vehicles with headlight range control module by opening retaining clip --> «Vehicles with automatic headlight vertical aim control, vehicle level sensor»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Unclip ABS line from bracket at brake caliper.

Vehicles with brake caliper HP-2

Scheme 14

1. Remove hex bolt - 2 - and remove brake line bracket.
2. Remove bolts - 1 - from brake caliper and remove brake caliper.
3. Reinstall brake line bracket. Install hex bolt - 2 - and tighten.
4. Secure brake caliper to body so that caliper weight does not bend or damage brake line.

Continued for all vehicles

1. Remove brake caliper and secure to body so that weight of caliper does not stress or damage brake hose or brake line.

Scheme 15

1. Remove clip - 1 - with a pair of pliers.

This clip does not need to be inserted again.

1. Remove - 2 - , remove hex bolt and remove both control arms upward.

The slits in the wheel bearing housing must not be widened using a chisel or similar tool!

1. Protect steering gear boot from damage with a protective sleeve.

For clarity the illustration shows a steering gear that has been removed.

Protective sleeve - 1 - can be ordered under part number 893 512 137.

Scheme 16

1. A 20 to 25 mm strip, dimension - A - , must be cut out of protective sleeve - 1 -.
2. Carefully deburr cut surfaces.
3. Slide protective sleeve over steering gear boot. The open side of sleeve must point downward.

In order not to damage lower link joints, it is necessary to brace against too strong rebound, e.g. using engine/transmission jack V.A.G 1383 A.

Scheme 17

1. Remove hex bolt - arrow - from suspension strut/control link.
2. Swing wheel bearing housing to side.
3. Loosen coolant reservoir connection.
4. Remove plenum chamber cover.

Scheme 18

1. Remove screw cover - arrow -.

Scheme 19

1. Remove hex bolts - 1 - in plenum chamber.
2. Take out suspension strut with mounting bracket.

Do not damage protective joint boot when doing this!

Installing

1. Insert suspension strut with mounting bracket into suspension turret. Tighten hex bolts - 1 -.

Note. Make sure that washers are seated correctly.

1. Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms if vehicle is in curb weight position --> «Wheel bearing, lifting to curb weight position»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__wheel-bearing-lifting-to-curb-weight)

Scheme 20

1. Insert suspension strut forked head into control arm and tighten threaded connection - 1

Note. Bolt must be inserted opposite direction of travel.

Scheme 21

1. Insert both upper link joint pins in wheel bearing housing and bend downward as much as possible using pliers T40067.

Scheme 22

1. Insert new bolt - 2 - and self-locking nut and tighten
2. Insert ABS wiring into retainer on brake caliper.
3. Install brake disc, install and tighten brake caliper. --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)
4. On vehicles with headlight range control, install vehicle level sensor link at control arm --> «Vehicles with automatic headlight vertical aim control, vehicle level sensor»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

Suspension strut, servicing

Special tools, testers and auxiliary items required

Scheme 23

1. Spring compressor V.A.G 1752/1
2. Spring mounting tool V.A.G 1752/2
3. Spring holder V.A.G 1752/4
4. Spring holder V.A.G 1752/6

Scheme 24

1. Shock absorber set T10001/3
2. Shock absorber set T10001/4
3. Shock absorber set T10001/7
4. Shock absorber set T10001/11

Assembly overview

Scheme 25

1 - Collar nut, 50 Nm

1. Always replace

2 - Strut mounting

3 - Washer

4 - Mounting bracket

1. Installed location «Mounting bracket location»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

5 - Coil spring

1. Removing «Coil spring, removing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing) and «Coil spring, removing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Installing «Coil spring, installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__coil-spring-installing)
3. Note different vehicle versions, see vehicle data plate. «Clarification of Production Control numbers (PR No.)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__clarification-of-production-control-numbers-pr)

6 - Additional spring

7 - Protective sleeve

8 - Protective cap

9 - Lower spring support

10 - Lower spring seat

1. Installed location «Lower suspension strut installation location»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

11 - Strut

1. Replacing «Strut, replacing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Note different vehicle versions, see vehicle data plate. «Clarification of Production Control numbers (PR No.)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__clarification-of-production-control-numbers-pr)
3. Faulty strut must be vented and emptied before disposal --> «Disposal of fluid-filled components to meet environmental requirements»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

Clarification of Production Control numbers (PR No.)

Strut combination installed in vehicle is indicated by corresponding PR number on vehicle data plate.

Scheme 26

Example of a vehicle data sticker

1. Front axle PR no. is item - A -.
2. Rear axle PR no. is item - B -.

The vehicle data sticker is located in spare wheel well and in Maintenance booklet.

You can find the suspension version PR no. in illustration see - arrow -.

1BA = Standard suspension

1BE = Sport suspension (20 mm lower than 1BA)

1BD = Sport suspension S4

1BR = Comfort - heavy duty suspension (13 mm higher than 1BA)

1BV = Sport suspension (quattro GmbH)

2MC = Basic suspension (quattro GmbH RS4)

2ME = Sport suspension (quattro GmbH RS4)

Scheme 27

1. Suspension strut, clamping in vise
2. Pretension coil spring using spring compressor V.A.G 1752/1 and spring holder V.A.G 1752/4 until upper suspension strut is free.

Scheme 28

Coil spring, removing

1. When doing so, ensure correct seating of coil spring in spring holder V.A.G 1752/4 - arrow -.

Coil spring, removing

1. Remove collar nut from piston rod with special tools T10001/3 , T10001/11 and T10001/7.
2. Remove individual components of suspension strut and pretension coil spring using spring compressor V.A.G 1752/1.

Scheme 29

1. Remove protective cap - 1 - and lower spring support - 2 -.
2. Mark installation position of lower suspension strut to strut.
3. Loosen suspension strut - 3 - using plastic hammer and remove upward.

Scheme 30

A - strut/control arm bolt axis

I = left, B = 65° ± 2°

II = right, C = 87° ± 2°

1. Drive suspension strut downward using plastic hammer according to self-provided marking.

With a new damper, transfer marking from old damper.

Note different installation locations on left and right sides.

Suspension strut trimming - arrow - must result in clearance to body.

Coil spring, installing

1. Install suspension strut, lower spring support and protective cap.
2. Position pre-tensioned coil spring on lower spring support using spring holder V.A.G 1752/4. End of spring coil must rest against stop - arrow -.

Permissible deviation: ± 2°.

Scheme 31

Position mounting bracket with spring support on pre-tension spring so that spring supports rests against end of coil spring - arrow -.

Permissible deviation: ± 2°.

1. Position individual suspension strut components. Ensure end of spring rests against upper spring support stop.
2. Tighten collar nut with special tools
3. Do not release spring tension yet

Scheme 32

1. Tension suspension strut with spring compressor vertically in spring mounting tool V.A.G 1752/2.

Scheme 33

1. Loosen lower locking lever and turn upper suspension strut until spring mounting tool V.A.G 1752/2 scale is at 7°.
2. Ensure ends of spring rest against spring seat and spring support stops.
3. Lock locking lever.

Scheme 34

Seen in direction of travel

I = left

II = right

A - strut/control arm bolt axis

1. Adjust angle B.

B = 7°

1. Spring mounting tool V.A.G 1752/2 arm - arrow - must be aligned with center of mounting bracket.
2. Release tension on spring tensioner 1752/1 and remove.
3. Check adjustment, repeat procedure if necessary.

Permissible deviation: ± 2°.

Wheel bearing housing, removing and installing

Special tools, testers and auxiliary items required

Scheme 35

1. Ball joint puller T40010
2. Torque wrench V.A.G 1331
3. Torque wrench V.A.G 1332

Removing

1. Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
2. Remove drive axle bolt (only loosen on vehicle resting on wheels -risk of accident-) «Remove drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__remove-drive-axle)
3. Remove ABS speed sensor wiring from wheel bearing housing bracket.

Vehicles with brake caliper HP-2

1. Remove hex bolt - 2 - and remove brake line bracket.
2. Remove bolts - 1 - from brake caliper and remove brake caliper.
3. Reinstall brake line bracket. Install hex bolt - 2 - and tighten.
4. Secure brake caliper to body so that caliper weight does not bend or damage brake line.

Continued for all vehicles

1. Remove brake caliper and secure to body so that weight of caliper does not stress or damage brake hose or brake line.

1. Remove ABS speed sensor bolt - 5 -.
2. Disengage ABS cable at wheel bearing housing
3. Remove disc brake.

Scheme 36

1. Remove bolts - arrows - and remove shield.

Scheme 37

1. Remove combi-bolt - 3 - and bolt - 4 -.

Note. Align vehicle after repair --> Wheel alignment . Do not use a chisel or similar tool between steering arm - 1 - and tie rod ball joint sealing washer - 2 - when removing tie rod, otherwise sealing washer could be damaged. Tie rod may only be pressed off steering arm over tie rod ball joint pin ends or driven with a wooden or rubber hammer.

1. Press or pull tie rod downward to remove.
2. Remove nut from guide link joint pins enough so that it is flush with joint pin threads. Use 4 mm socket wrench to hold joint pin, if necessary.

Scheme 38

1. Separate guide link joint pin from tapered seat using ball joint puller T40010.

Note. Do not damage protective joint boot when doing this! Ensure both puller lever arms are parallel to each other when using greatest force.

1. On vehicles with headlight range control, remove vehicle level sensor link from link --> «Vehicles with automatic headlight vertical aim control, vehicle level sensor»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Remove nut from control arm guide link joint pins enough so that it is flush with joint pin threads. Use 4 mm socket wrench to hold joint pin, if necessary.

Scheme 39

1. Separate lower link joint pin from tapered seat using ball joint puller T40010.

Note. Ensure both puller lever arms are parallel to each other when using the greatest force.

1. Remove nut - 1 - , remove hex bolt and lift out both links - 2 - upward.

The slits in the wheel bearing housing must not be widened using a chisel or similar tool!

1. Swing wheel bearing housing in direction of arrow away to side, when doing this remove drive axle pin from wheel hub.
2. Secure drive axle to body, e.g. with wire.
3. Remove nut from joint pin of track control link.
4. Remove wheel bearing housing.

Installing

1. Install wheel bearing housing.
2. Install outer drive axle joint into hub and hand tighten with a new hex bolt.
3. Insert control arm and guide link joint pins in wheel bearing housing.
4. Install new self-locking nuts and tighten counterhold joint pins, e.g. with hex socket wrench 4 mm.

1. Insert both upper link joint pins in wheel bearing housing and bend downward as much as possible using assembly tool Pliers T40067.

1. Insert new bolt - 1 - and self-locking nut and tighten

Scheme 40

Note. Tie rod (tie rod ball joint) must only be inserted in steering arm - 1 - by hand. Sealing washer - 2 - must not be stressed under any circumstances.

1. Install tie rod.

1. Install new self-locking nuts - 4 - and tighten
2. Tighten hex bolt - 3
3. Install ABS speed sensor. --> «45 - ANTI-LOCK BRAKE SYSTEM»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)
4. On vehicles with headlight range control, install vehicle level sensor link at control arm --> «Vehicles with automatic headlight vertical aim control, vehicle level sensor»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Install cover plate and tighten
2. Fit brake disc, screw on brake caliper. --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)
3. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide
4. Tighten drive axle hex bolt (only with vehicle resting on wheels -risk of accident-) «Install drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle)

1. Perform vehicle alignment --> «Wheel alignment»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Check front axle, alignment must take place on a VW/Audi recommended alignment stand.

Scheme 41

Special tools, testers and auxiliary items required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Punch VW 407
4. Punch VW 412

1. Thrust pad VW 511
2. Press tube 30 - 100

Scheme 42

1. Sleeve VW 416 B

Scheme 43

1. Sleeve VW 519
2. Torque wrench V.A.G 1331
3. Torque wrench V.A.G 1332
4. Separating tool Kukko 15-17

Assembly overview

Scheme 44

1 - Wheel bearing housing

2 - Cap bolts

1. 80 Nm plus an additional 90°( 1 / 4 turn)

3 - Sockets

4 - Ball bearing

1. Pressing out 82 mm dia. «Pressing wheel hub out of 82 mm diameter wheel bearing housing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Pressing in 82 mm dia.--> «Pressing wheel hub into 82 mm diameter wheel bearing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Bearing inner ring, pressing off --> «Press bearing inner race from hub»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Removing and installing «Removing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__removing)

1. Installed location
2. The larger diameter of the wheel bearing faces the hub

5 - Wheel hub

1. Pressing out «Pressing wheel hub out of 82 mm diameter wheel bearing housing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Pulling off bearing inner race --> «Press bearing inner race from hub»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Tie rod version
4. Wheel hub/brake disc contact surfaces and threaded holes are to be free of paint and dirt

1. Light weight wheel hub --> «Light weight wheel hub»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

Removing

1. Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).

Remove drive axle

1. Remove drive axle hex bolts (only loosen if vehicle is standing on wheels -risk of accident-).
2. Remove wheel.
3. Secure brake disc with a wheel bolt.
4. Remove ABS speed sensor wiring from wheel bearing housing bracket.

Vehicles with brake caliper HP-2

1. Remove hex bolt - 2 - and remove brake line bracket.
2. Remove bolts - 1 - from brake caliper and remove brake caliper.
3. Reinstall brake line bracket. Install hex bolt - 2 - and tighten.
4. Secure brake caliper to body so that caliper weight does not bend or damage brake line.

Continued for all vehicles

1. Remove brake caliper and secure to body so that weight of caliper does not stress or damage brake hose or brake line.

1. Remove ABS speed sensor screw - 5 -.
2. Remove disc brake.

1. Remove bolts - arrows
2. Remove cover plate

1. Loosen nut - 1 - , remove hex bolt and lift out both control arms - 2 - upward.

The slits in wheel bearing housing must not be widened using a chisel or similar tool!

1. Swing wheel bearing housing in direction of arrow away to side, when doing this remove drive axle pin from wheel hub.
2. Secure drive axle to body, e.g. with wire.

Scheme 45

1. Remove cap bolts - 1
2. Remove wheel bearing unit.

Scheme 46

Scheme 47

1. Insert separating device, e.g. Kukko 15-17, in bearing inner race ring groove - arrow - and pretension with spindle.

Scheme 48

1. Press bearing inner race off from wheel hub.

Light weight wheel hub --> Light weight wheel hub

Scheme 49

1. When pressing on, thrust piece VW 511 must bear only against inner race.

Installing

1. Insert wheel bearing unit in wheel bearing housing.

1. Install cap bolts - 1 - and tighten
2. Install outer drive axle joint into hub and hand tighten with a new hex bolt.

1. Remove any adhesive residue on joint pin threads.

1. Insert both upper link joint pins in wheel bearing housing and bend downward as much as possible using assembly tool T40067.

1. Insert new bolt - 1 - and self-locking nut and tighten
2. Install ABS speed sensor.
3. Install brake disc, fasten brake caliper. --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)
4. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

1. Tighten drive shaft hex screw (only with vehicle resting on wheels -risk of accident-) «Install drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle) .

Alignment must take place on a VW/Audi recommended alignment stand.

Scheme 50

The light weight wheel hub is different from conventional wheel hub - 1 - due to the slide washer - 2 - and sleeve.

The light weight wheel hub must only be used in conjunction with the corresponding wheel bearing.

Slide washer - 1 - should be replaced if deformed or damage during wheel bearing removal.

Slide washer, removal and installation

Special tools, testers and auxiliary items required

1. Assembly tool T40089/1

Scheme 51

1. Press piece VW 473

Scheme 52

1. Thrust plate VW 401

Slide washer, replacing

1. Carefully pry off slide washer - 1 - , e.g. with a screwdriver.
2. Position slide washer on wheel hub.

Scheme 53

1. Install special tools as shown in illustration.

1. Press piece VW 473
2. Assembly tool T40089/1
3. Slide washer
4. Wheel hub
5. Thrust plate VW 401

1. Press slide washer off using assembly tool T40089/1 as shown in illustration up to wheel bearing hub radius.

Note. Slide washer must be pressed on up to wheel bearing hub radius.

Mounting bracket, removing and installing

Removing

1. Remove suspension strut --> «Suspension strut, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-removing-and-installing)
2. Remove mounting bracket from suspension strut --> «Suspension strut, servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-servicing)

Installing

1. Fasten mounting bracket to suspension strut --> «Suspension strut, servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-servicing)
2. Install suspension strut --> «Suspension strut, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-removing-and-installing) .

Upper links, removing and installing

Removing

1. Remove suspension strut --> «Suspension strut, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-removing-and-installing)

Scheme 54

1. Remove nuts - 1 - and remove bolts - 2
2. Remove links - 3 - and - 4

Installing

1. Secure upper links - 3 - and - 4 - using new bolts - 2 - and new nuts - 1 - just enough so that links cannot move in their positions.

Upper front link

Scheme 55

1. Adjust height - A -.

A = 81 mm ± 2 mm

Upper rear link

Scheme 56

1. Adjust height - A -.

A = 70 mm ± 2 mm

Procedure for upper front and rear links

1. Tighten nuts - 1
2. Check upper control arm positions
3. Repeat adjustment, if necessary
4. Reinstall mounting bracket --> «Suspension strut, servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-servicing) .

Top front and rear link bearings, replacing

Special tools, testers and auxiliary items required

Scheme 57

1. Assembly tool 3301
2. Assembly tool 3301/1
3. Assembly tool 3301/3

Scheme 58

1. Assembly tool 3348/2
2. Assembly tool 3348/3

Note. Use protective covers when clamping aluminum links.

Scheme 59

Pulling out bushing

Scheme 60

Installed location of bushing

A = 90° ± 5°

Scheme 61

Pulling in bushing

A - Bushing

Scheme 62

Special tools, testers and auxiliary items required

1. Engine support bridge 10 - 222 A
2. Support 10 - 222 A/1
3. Testing mandrel 3393
4. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332
2. Engine/transmission jack V.A.G 1383 A

Removing

1. Support engine entirely with engine support bridge.
2. Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
3. Remove wheels.
4. Secure brake disc with a wheel bolt.

1. Remove sound insulation. --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

Convertible only

1. Remove front diagonal brace --> «Diagonal braces»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Continued for all vehicles

Scheme 63

1. Before removing subframe, check whether holes - 1 - and - 2 - are aligned using special tool 3393.

If this is not the case, a vehicle alignment must be performed after carrier is installed.

Scheme 64

1. Remove nuts - arrows - at transmission mounts if necessary.

Scheme 65

1. Remove nuts - 1
2. On vehicles with headlight range control, remove vehicle level sensor link from link --> «Vehicles with automatic headlight vertical aim control, vehicle level sensor»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Remove ABS speed sensor screw - 5 -.
2. Remove ABS speed sensor wiring from wheel bearing housing bracket.

Vehicles with brake caliper HP-2

1. Remove hex bolt - 2 - and remove brake line bracket.
2. Remove bolts - 1 - from brake caliper and remove brake caliper.
3. Reinstall brake line bracket. Reinstall hex bolt - 2 - and tighten.
4. Secure brake caliper to body so that caliper weight does not bend or damage brake line.

Continued for all vehicles

1. Remove brake caliper and secure to body so that weight of caliper does not stress or damage brake hose or brake line.

To avoid damaging upper link joints, wheel bearing housing must be braced against a rebound that is too strong, e.g. using engine/transmission jack V.A.G 1383 A

1. Remove bolt - 1
2. Remove bolt - 4
3. Remove bolt - 3
4. Loosen guide link/subframe connection.

1. Remove tunnel crossmember if necessary --> «Tunnel crossmember, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__tunnel-crossmember-removing-and-installing) .
2. Place engine/transmission jack V.A.G 1383 A with wooden block under subframe and press lightly against.

Scheme 66

1. Remove hex bolts - 1 -.
2. Remove hex bolts - 2 - and lower rear subframe.
3. Remove guide link hex bolts.
4. Remove guide links from subframe.

Note. To prevent link and guide link pins from being over flexed, they should be secured with a wire or something similar during removal.

Scheme 67

1. Remove power steering line - arrow - from console.

1. Remove bolt - 3 -.
2. Loosen hex bolts - 2 - until subframe can be removed.

Installing

Scheme 68

1. Insert subframe and install hex bolts - 5 - and - 6 -.
2. Insert suspension strut hex bolts at link.
3. Guide control arms and guide links into subframe.

Before tightening subframe, it must be fixed to body using Testing Mandrel 3393.

Scheme 69

1. Holes - 1 - and - 2 - of subframe and hole - 3 - of aluminum bracket must line up on both sides.

Note. This attachment only replaces subsequent vehicle alignment measurements when: The subframe is removed completely and installed. Holes - 1 - and - 2 - lined up before the repair.

1. Position hex bolts - 1 - and - 2 -.
2. Protect holes in body for mounting Testing Mandrel 3393 against corrosion.

1. Install nut - 1 -.

1. Install transmission mount nuts - arrows - if necessary.

1. Clip cable - arrow - into console.

Tightening sequence

Note. Threads in body can be repaired according to DIN 8140 using wire thread inserts (Heli-Coil). Thread insert must be same length as thread in body. Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms if vehicle is in curb weight position --> Wheel bearing, lifting to curb weight position

1. Tighten hex bolts - 2 - and - 5
2. Tighten hex bolts - 1 -.

1. Tighten transmission mount nuts - arrows - --> 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE «34 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-01x-front-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE «34 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-manual-transmission-02x-four-wheel-drive) for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE «34 CONTROLS, HOUSING»(ref-278904-S35642730482008020700000) for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE or --> 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V «37 CONTROLS, HOUSING»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#6-speed-automatic-transmission-09l-all-wheel-drive) for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE

1. Tighten bolt - 2
2. Tighten engine mount nuts - 1 -. --> 10 - ENGINE - ASSEMBLY for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «10 - ENGINE - ASSEMBLY»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 10 ENGINE - ASSEMBLY for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «10 - ENGINE - ASSEMBLY»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «10 - ENGINE - ASSEMBLY»(ref-278885-S28123014792008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «10 - ENGINE - ASSEMBLY»(ref-278884-S30565723472008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

1. Tighten control arm hex head screws - 3
2. Tighten guide link hex bolts
3. Tighten connecting link to stabilizer bar - 4
4. Suspension strut to link

1. Install tunnel crossmember if necessary --> «Tunnel crossmember, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__tunnel-crossmember-removing-and-installing) .

1. Tighten ABS speed sensor screw - 5 -. --> «45 - ANTI-LOCK BRAKE SYSTEM»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)
2. Tighten brake caliper to wheel bearing housing --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)
3. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

Convertible only

1. Install front diagonal brace --> «Diagonal braces»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Continued for all vehicles

Note. If the subframe has been located to the body with Testing Mandrel 3393 before subframe removal and installation (before tightening bolts), vehicle alignment does not have to be done. If the subframe was not located, vehicle alignment must be done.

1. Perform vehicle alignment --> «Wheel alignment»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Alignment must take place on a VW/Audi recommended alignment stand.

Subframe bushings, replacing

Note. Various subframe versions are installed. Subframe with bonded rubber bushings in subframe/body mounting points (all vehicles except convertible). Bonded rubber bushings cannot be replaced. Subframe without bonded rubber bushings in subframe/body mounting points, rather with welded steel bushings (convertible only). Steel bushings cannot be replaced, replace subframe if damaged.

Special tools, testers and auxiliary items required

1. Assembly tool 3291
2. Puller 3351/1
3. Puller 3351/4
4. Installation device 3372

1. Installation device 3372/1
2. Installation device 3372/2
3. Thrust pad 30 - 205

To replace subframe bushing, subframe must be removed --> Subframe, removing and installing

Scheme 70

Pulling out bonded rubber bushing

1. Saw or cut rubber shoulder off subframe bushing up to outer bushing.

Note. If the paint on the surface of the subframe should be damaged, the surface should be protected against corrosion.

Scheme 71

Pulling out rear bonded rubber bushing

Ensure installation device - 3372 - is seated correctly and cannot tilt.

Scheme 72

Pulling out bonded rubber bushing

All bonded rubber bushings on subframe are pulled out using same special tool.

Scheme 73

Preparing to pull-in subframe bushing

1. Position installation device Installation Device 3372 and insert segments 3372/2.

Scheme 74

Bonded rubber bushing, aligning

The bonded rubber bushings must be aligned with a long rectangular tube or straightedge.

A = 90° ± 5°

Only tension subframe in a vise using protective clamps!

Scheme 75

Pulling in rear bonded rubber bushing

To press on bonded rubber bushing, use installation lubricant G 294 421 A1.

1. Pull in bushing - A - until thrust piece -3372/1- is flush with upper edge of installation device Installation Device 3372.
2. Remove Installation Device 3372 and segments 3372/2 upward.

Scheme 76

Pulling in rear bonded rubber bushing

1. Insert segments -3372/2- between bridge -3351/4- and subframe.
2. Pull mounting in onto stop.

If paint on the surface of subframe should be damaged, the surface should be protected against corrosion.

Scheme 77

Pulling in front bonded rubber bushing

To press on bonded rubber bushing, use installation lubricant G 294 421 A1.

1. Insert segments -3372/2- in tube - 3372 -.
2. Pull in mount - A - until thrust piece -3372/1- is flush with upper edge of Installation Device 3372.

Scheme 78

Pulling in front bonded rubber bushing

1. Raise Installation Device 3372 and remove segments -3372/2-.
2. Replace bridge -3351/41 with thrust piece -3351/1 and then push mounting in onto stop.

If paint on the surface of subframe should be damaged, the surface should be protected against corrosion.

Bonded rubber bushing stop wedges, removing and installing

Removing

1. Remove subframe supports.
2. Pull stop wedges downward out of bonded rubber bushings.

Installing

Scheme 79

1. Push stop wedges - 1 - positioned in bonded rubber bushing as shown in illustration in to stop.

Illustration shows subframe from below.

1. Install subframe supports.

Tunnel crossmember, removing and installing

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A
2. Torque wrench V.A.G 1331
3. Torque wrench V.A.G 1332

Removing

1. Remove sound insulation. --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

Scheme 80

1. Remove combi-bolts - arrows
2. Support transmission with engine and transmission jack V.A.G 1383 A and a wooden block.

Scheme 81

1. Remove bolts - 1 - and - 2 -.
2. Remove tunnel crossmember

Installing

1. Tighten combi-bolt - 1 - to 110 Nm + 90 °.

Use new washer and bolt.

1. Tighten combi-bolt - 2 - to 65 Nm.

1. Tighten combi-bolts - arrows - to 23 Nm.
2. Install sound insulation. --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

Vehicles with automatic headlight vertical aim control, vehicle level sensor

Vehicles with gas discharge headlights come standard with automatic headlight range control. -->

1. «94 LIGHTS, SWITCHES - EXTERIOR»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)
2. 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET

To function properly, the automatic vertical aim control system needs information about compression travel or rebound travel at the front and rear axles.

For this, the position of the lower left link relative to the body is transferred to Left Front Level Control System Sensor G78 via a coupling rod. This transmits electrical signals to the Headlamp Range Control Module J431.

Headlamp Range Control Module J431 -->

1. «94 LIGHTS, SWITCHES - EXTERIOR»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)
2. 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET

On the rear axle, the signals are transmitted to Headlamp Range Control Module J431 from G76 Left Rear Level Control System Sensor G76.

These signals are required for determining vehicle level.

The automatic headlight range control reacts independently to changes in vehicle level.

The vehicle level can change in the following situations

1. Towing a trailer
2. Different load conditions; vehicle empty, vehicle partially or fully loaded
3. Slow or fast driving habit

Checking the headlight basic setting is necessary when

1. The track control link has been removed and reinstalled or replaced
2. Assembly work was performed on level control system sensor
3. The level control system sensor was replaced
4. The retaining clip for the coupling rod on track control link has been loosened.

Headlight basic setting -->

1. «94 LIGHTS, SWITCHES - EXTERIOR»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment)
2. 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET

Scheme 82

1 - Hex bolt, 9 Nm

2 - Bracket

3 - Left Front Level Control System Sensor G78

1. Is checked electrically through On Board Diagnostics (OBD)
2. In the event of complaints, perform --> "Guided Fault Finding" using Vehicle Diagnosis, Testing and Information System VAS 5051A
3. Removing and installing «Removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__removing-and-installing)

4 - Hex nut, self-locking, 10 Nm

1. Always replace if removed

5 - Connecting link from Left Front Level Control System Sensor G78

1. Do not remove connecting link from Left Front Level Control System Sensor G78 ball head!

6 - Retaining clip

1. Retaining clip closure must face upward at control arm and backward in direction of travel.

7 - Hex socket head bolt, 4 Nm

8 - Pop rivet

Removing and installing

Special tools, testers and auxiliary items required

Scheme 83

1. Torque wrench V.A.G 1332

Scheme 84

1. Torque wrench V.A.G 1410

When removing and installing control arm, it is necessary to loosen Left Front Level Control System Sensor G78 retaining clip.

Note. To install connecting link to Left Front Level Control System Sensor G78 crank, use an open-end wrench (wrench width 10) with dimension - A - = 4 mm to avoid damaging the seal.

Scheme 85

1. Dimension - A - = 4 mm
2. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide
3. Left Front Level Control System Sensor G78 connecting link retaining clip is secured at control arm between stops with a clamp.

When installing headlight range control, ensure correct position of crank and connecting link to each other.

Note. Connecting link must face forward diagonally. Crank must face rearward.

Control link, removing and installing, (all engine versions except 3.0L TDI and 3.2L FSI)

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A

1. Ball joint puller T40010
2. Torque wrench V.A.G 1331
3. Torque wrench V.A.G 1332

Removing

1. Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
2. Remove wheel.
3. Remove sound insulation. --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET
4. On vehicles with headlight range control, remove Left Front Level Control System Sensor G78 from control link --> «Vehicles with automatic headlight vertical aim control, vehicle level sensor»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Secure brake disc with a wheel bolt.
2. Remove nut from guide link joint pins enough so that it is flush with joint pin threads. Use 4 mm socket wrench to hold joint pin, if necessary.

1. Separate control link joint pin from tapered seat using ball joint puller T40010.

Note. Ensure both puller lever arms are parallel to each other when using greatest force, adjust if necessary. To avoid damaging upper link joints, wheel bearing housing must be braced against a rebound that is too strong, e.g. using engine/transmission jack V.A.G 1383 A

1. Remove hex bolt - 1 -.
2. Remove bolts - 2 - and - 4 - , remove connecting link.
3. Remove hex bolt - 3 -.
4. Remove lower control link.

Installing

Note. Bolts and nuts must be replaced. Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control links if vehicle is in curb weight position --> Wheel bearing, lifting to curb weight position

1. Install new hex head bolt - 3 - and new hex nut and tighten
2. Remove adhesive residue at joint pins from control link
3. Tight nut at joint pins (control link)
4. Tighten threaded connection - 1

1. Tighten bolt - 2
2. Tighten bolt - 4
3. On vehicles with headlight range control, install vehicle level sensor link at control link --> «Vehicles with automatic headlight vertical aim control, vehicle level sensor»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
4. Install sound insulation. --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

1. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

Control arm, removing and installing (vehicles with 3.0L TDI and 3.2L FSI)

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A

1. Ball joint puller T40010
2. Torque wrench V.A.G 1331
3. Torque wrench V.A.G 1332
4. Engine support bridge 10 - 222 A

Removing

Removal of right control link with 3.0L TDI engine is performed as already described for all engine versions --> Control link, removing and installing, (all engine versions except 3.0L TDI and 3.2L FSI)

1. Support engine entirely with engine support bridge.
2. Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
3. Remove wheel.
4. Remove sound insulation. --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

1. Install sound insulation. --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET
2. On vehicles with headlight range control, remove Left Front Level Control System Sensor G78 from control arm --> «Vehicles with automatic headlight vertical aim control, vehicle level sensor»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
3. Secure brake disc with a wheel bolt.
4. Remove nut from guide link joint pins enough so that it is flush with joint pin threads. Use 4 mm socket wrench to hold joint pin, if necessary.

1. Separate control link joint pin from tapered seat using ball joint puller T40010.

Note. Ensure both puller lever arms are parallel to each other when using greatest force, adjust if necessary. To avoid damaging upper control link joints, wheel bearing housing must be braced against a rebound that is too strong, e.g. using engine/transmission jack V.A.G 1383 A

1. Remove hex bolt - 1 -.
2. Remove bolts - 2 - and - 4 - , remove connecting link.
3. Remove nut from threaded connection - 3 -.

1. Remove nut - 1 -.
2. Remove bolts - 2 - and - 3 -.

Scheme 86

1. Pull engine mount and stabilizer bar console - 3 - downward and remove bolts - 2 -.
2. Remove control link - 1 -.

Installing

Installation is in reverse order of removal. Note the following

Note. Bolts and nuts must be replaced. Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms if vehicle is in curb weight position --> Wheel bearing, lifting to curb weight position

1. Remove adhesive residue at joint pins from control link
2. On vehicles with headlight range control, install vehicle level sensor link at control arm --> «Vehicles with automatic headlight vertical aim control, vehicle level sensor»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Torque specifications --> Component, assembly overview

1. Install sound insulation. --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET
2. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

Scheme 87

Special tools, testers and auxiliary items required

1. Assembly tool 3301
2. Assembly tool 3301/3
3. Assembly tool 3301/4
4. Support Arm Bearing Inst. Tool 3346

1. Assembly tool 3346/1
2. Assembly tool 3346/2
3. Assembly tool 3346/3
4. Assembly tool 3350/1

Note. Use protective covers when clamping aluminum control links.

Scheme 88

Inner bushing, removing

1. Mark location of old bushing.

Scheme 89

Bushing installation location

1. Transfer installation mark for old bushing to new bushing

Scheme 90

Inner bushing, pulling in

1. Insert bearing - A - in thrust piece (3346/1) to a depth of 3.2 mm.
2. Pull bushing in onto stop.

Scheme 91

Pull out outer bushing

Pull in outer bushing

To press in, use installation lubricant G 294 421 A1 thinned with water at a ratio of 1:100.

1. Pull in bushing in center.

Chamfers on bushing and control link must align.

Guide link, removing and installing

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A

1. Ball joint puller T40010
2. Torque wrench V.A.G 1332

Removing

1. Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
2. Remove wheel.
3. Secure brake disc with a wheel bolt.
4. Remove brake caliper and secure to body if ball joint puller T40010 cannot be installed.

Note. Install brake line bracket on brake caliper HP-2 before securing to body to avoid damaging brake lines. Secure brake caliper to body so that caliper weight does not stress or damage brake hose or brake line.

1. Remove nut from guide link joint pins enough so that it is flush with joint pin threads. Use 4 mm socket wrench to hold joint pin, if necessary.

1. Separate guide link joint pin from tapered seat using ball joint puller T40010.

Note. Do not damage protective joint boot when doing this! Ensure both puller lever arms are parallel to each other when using greatest force.

1. Place engine/transmission jack V.A.G 1383 A with wooden block under subframe and press lightly against.
2. Remove hex head bolts - 2 - and - 3 - on both sides.
3. Lower subframe slightly using engine/transmission jack V.A.G 1383 A.

Ensure brake line surface and underbody protection is not damaged!

Scheme 92

1. Remove hex bolt - 1 -.
2. Remove guide link.

Installing

Note. Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control links if vehicle is in curb weight position --> Wheel bearing, lifting to curb weight position

Scheme 93

1. Tighten nut on joint pin
2. Tighten hex head bolt - 2
3. Tighten hex head bolt - 3
4. Install brake caliper, if necessary. Refer to --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)

1. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

Scheme 94

Special tools, testers and auxiliary items required

1. Assembly tool 3301
2. Assembly tool 3346/2
3. Assembly tool 3346/3
4. Assembly tool 3347

1. Assembly tool 3347/2
2. Assembly tool 3348

Scheme 95

Remove hydraulic mount at control link

Note. Use protective covers when clamping aluminum control links.

Scheme 96

Installation position of hydro-bushing

Arrow applied to hydraulic bushing - 1 - points in joint pin direction.

The permissible deviation is ± 5°.

A = View - arrow A

Scheme 97

Pull in hydro-bushing

1. Insert hydro-bushing - A - into special tool (3347/2).
2. Tighten together with sleeve - 3348 - , spindle -3346/2- and hex nut.
3. Pull in hydro-bushing - A - until it stops.

Stabilizer bar, removing and installing

Special tools, testers and auxiliary items required

Scheme 98

1. Torque wrench V.A.G 1331

Removing

1. Remove sound insulation.

1. Remove bolt -2

Scheme 99

1. Remove hex nut - 2 -.
2. Remove stabilizer

Installing

Note. If you replace stabilizer, note chassis version. Stabilizer and bushing must be free of grease.

1. Install new nuts - 2 - but do not tighten.

1. Tighten new bolts - 2

1. Tighten nuts - 2 - to 25 Nm.
2. Install sound insulation. --> «50 BODY, FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «50 - BODY - FRONT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

Cross brace, removing and installing

Note. Cross brace is only installed on certain vehicle versions. It is located on front plenum chamber cross panel.

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

Removing

Scheme 100

1. Remove plenum chamber cover rubber seal in direction of - arrow -.
2. Remove plenum chamber cover - 1 - forward.

Scheme 101

1. Remove combi-bolts - 2 - and - 4 -.

1. Remove cross brace - 1 - upward out of plenum chamber - 5 -.

3 - Left mounting bracket welded to body

6 - Right mounting bracket welded to body

Arrow - points in direction of travel

Installing

Installation is in reverse order of removal.

Combi-bolt torque specification: 25 Nm

Front diagonal braces, removing and installing

Front diagonal braces, removing and installing --> Front or rear diagonal braces, removing and installing

Drive axle, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332

Remove drive axle

1. Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
2. Loosen outer drive axle joint bolt a maximum of 90° (only loosen with vehicle resting on wheels -risk of accident-).
3. Remove wheel.
4. Install all five wheel bolts hand-tight.

1. Remove drive axle outer joint screw.
2. Remove drive axle from flange shaft/transmission.

If there is not enough room available to remove drive axle, perform following steps

1. Remove nut - 1 - , remove hex bolt and lift out both control links - 2 - upward.

The slits in the wheel bearing housing must not be widened using a chisel or similar tool!

Note. Do not loosen bolts - 3 - and - 4 - , otherwise the adjustment of the front axle will change!

1. Swing wheel bearing housing to side.
2. Remove drive axle.

Install drive axle

1. Insert drive axle in wheel bearing housing.
2. Insert both upper control links, insert new bolt and tighten new nut ; while tightening, press control link as far as possible toward wheel bearing housing.
3. Fasten drive axle to flange shaft/transmission.
4. Fasten drive axle outer joint

Note. When tightening drive axle outer joint to pre-tightening torque specification, vehicle must not come in contact with floor; otherwise wheel bearing can be damaged.

A second technician is needed for next step

1. 1st Technician: Sit in vehicle and operate foot brake
2. 2nd Technician: Tighten drive axle hex bolt to pre-tightening torque

Hex bolt M14: 115 Nm

Hex bolt M16: 200 Nm

1. Install wheel and place vehicle on floor.
2. Turn drive axle bolt an additional 180°. (Only turn additional turn on vehicle resting on wheels -risk of accident-).

Scheme 102

Special tools, testers and auxiliary items required

1. Sleeve VW 426
2. Thrust plate VW 401
3. Thrust plate VW 402
4. Assembly tool T10065

1. Punch VW 408 A

Scheme 103

Special tools, testers and auxiliary items required

1. Pressure spindle 3207
2. Hose clamp pliers V.A.G 1275
3. Torque wrench V.A.G 1331
4. CV joint boot clamp tool V.A.G 1682

Component, overview

Filling outer joint with grease G 000 603.

Filling triple roller joint with grease G 000 605.

Grease quantity and type

Grease joint again when replacing protective joint boot.

Scheme 104

1 - Bolt

1. Always replace if removed
2. Loosen «Remove drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__remove-drive-axle)
3. Fastening «Install drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle)
4. Torque specification «Install drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle) .

2 - Clamp

1. Replace

3 - Constant velocity (CV) joint boot

1. Check for tears and chafing
2. Before clamping hose clamp, raise protective joint boot briefly to balance pressure.

4 - Clamp

1. Replace

5 - Multi-point socket head bolt

6 - Triple roller joint housing

7 - Triple rotor star with rollers

1. Chamfer - arrow - faces splines drive axle splines
2. When installing triple roller star on profile shaft, profile shaft splines must be lightly coated with grease used in joint.

8 - Circlip

1. Replace

9 - O-ring

1. Replace

10 - Cover

1. Replace

11 - Clamp

1. For triple roller joint
2. Replace

12 - CV boot for triple roller joint

1. Check for tears and chafing
2. Before clamping hose clamp, raise protective joint boot briefly to balance pressure. Joint must be in center position.

13 - Axle shaft

14 - Circlip

1. Replace
2. Insert in shaft groove

15 - Outer constant velocity joint

1. Replace only as a unit
2. Installing: Drive onto shaft using plastic hammer until compressed circlip seats.
3. Greasing «Grease quantity and type»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Checking --> «Outer constant velocity (CV) joint, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__outer-constant-velocity-cv-joint-checking)

1. When installing joint on profile shaft, profile shaft splines must be lightly coated with grease used in joint.

Triple roller joint, disassembling

1. Axle shaft, clamping in vise

Use protective vise covers!

1. Open clamp on joint and slide back protective boot.

Scheme 105

1. Bend open metal tabs with flat-head screwdriver and pry off housing.

Scheme 106

1. Mark installation position of parts - 1 - to - 3 - with lines.

If the parts are not marked when assembling, the components are not brought back to their previous installation position, then it is possible that it will be noisy when driving.

A waterproof felt tipped pen is suitable for marking.

1 - Triple roller joint housing

2 - Triple roller star

3 - Axle shaft

1. Take O-ring - arrow - out of groove.
2. Hold joint and take drive axle out of vise.

Scheme 107

1. Remove circlip from triple roller joint/drive axle.

1 - Circlip pliers (commercially-available)

1. If protective boot is damaged, remove, e.g. with shears. Otherwise, carefully turn back.
2. Insert drive axle in press.

Scheme 108

1. Hold drive axle, then press triple roller star off drive axle.

Ensure roller bodies are free when pressing off.

1. Remove triple roller star with rollers and set aside on a clean surface.
2. Remove joint from drive axle.
3. Pull joint protective boot off from drive axle.
4. Clean drive axle, joint piece and groove for oil seal.

Triple roller joint, assembling

1. Slide joint protective boot onto drive axle.
2. Slide joint piece onto drive axle.

Mount triple roller star

The chamfer on star faces toward shaft, this is used as an assembly aid.

Scheme 109

1. Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.

Scheme 110

1. Install triple roller star onto shaft as per markings and drive in to stop.

A second technician is needed to slide protective boot back.

Use Tube Trans. Drive Shaft VW 426 shown in illustration.

1. Insert circlip, make sure seated correctly.
2. Press 80 grams of joint grease from repair kit, into triple roller joint.
3. Slide joint piece over rollers and secure.
4. Press 30 grams of joint grease, from repair kit, into reverse side of triple roller joint.

1. Install joint protective boot. The bead in CV boot must engage in joint piece groove.
2. Remove drive axle from vise and tighten joint in vise.

1. Insert new sealing ring - arrow - from repair kit into groove.

Scheme 111

1. Install new cover on joint. The holes of the cover and joint must align.
2. Install clamp.

Observe note Install clamp. under Triple roller joint AAR 2600 i or 3300 i, assembling .

Outer constant velocity joint, servicing

Outer CV joint, removing

1. Secure drive shaft with protective covers in vise clamp.
2. Remove clamp and slide boot back.

Scheme 112

1. Screw Pressure Spindle 3207 with M 16/M14 thread version into joint pins until constant velocity joint is press off of drive axle.
2. Remove circlip

Outer CV joint, installing

1. Slide joint protective boot onto drive axle.

Protective boot and boot seat on drive axle must be free of grease.

1. Install new circlip

Circlip (snap ring) must be replaced.

1. Apply 50 g joint grease in inside of joint.

1. Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.

Scheme 113

1. Screw old drive axle bolt into joint as shown in illustration.
2. Drive joint onto drive axle with plastic hammer until circlip engages.
3. Apply 40 g joint grease in boot side of joint.

Grease quantities, see table Grease quantity and type

1. Bleed protective joint boot.
2. Close clamp.

Outer constant velocity (CV) joint, checking

In order to replace grease in case of strong soiling, joint must be disassembled or if journal surface of balls must be checked for wear and damage.

Removing

Scheme 114

1. Before disassembling mark ball hub position in relation to ball cage and housing using an electric scriber or oil stone.
2. Swivel ball hub and ball cage.
3. Remove balls one after another.

Scheme 115

1. Turn cage, until two rectangular windows - arrow - contact joint body.
2. Lift out cage together with hub.

Scheme 116

1. Swing segment of hub into rectangular window of cage.
2. Tilt hub out of cage.

6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small indentations (pitting) and signs of seizure. Excessive backlash in the joint will cause knocking or jolts under load change. In such cases joint should be replaced. Flattening and running marks of balls are no reason to replace joint.

Installing

1. Install cage with hub in joint housing.
2. Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body must be re-established.

Scheme 117

Special tools, testers and auxiliary items required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Punch VW 408 A
4. Punch VW 411

1. Sleeve VW 416 B
2. Thrust pad VW 447 H

Scheme 118

Special tools, testers and auxiliary items required

1. Hose clamp pliers V.A.G 1275
2. Torque wrench V.A.G 1331
3. Torque wrench V.A.G 1332
4. CV joint boot clamp tool V.A.G 1682

1. Assembly tool T10065

Scheme 119

1. Slide hammer - complete set VW 771

Scheme 120

1. Assembly device T40018 for triple roller joint AAR 3300 i
2. or Assembly device T40084 for triple roller joint AAR 2600 i

Filling triple roller joint shaft with grease

Grease joint again when replacing protective joint boot.

Scheme 121

1 - Clamp

1. Always replace
2. Different clamps possible depending on model
3. Can also be installed with pliers 3340

2 - CV boot for triple roller joint

1. Protective joint boot must fit in groove and on joint contour.

3 - Clamp

1. Always replace

4 - Circlip

1. Only present on certain versions

5 - Spring washer

1. Only present on certain versions
2. Installed location «Location of spacer and spring washer (wheel side)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

6 - Spacer ring (plastic)

1. Only present on certain versions
2. Installed location «Location of spacer and spring washer (wheel side)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

7 - Circlip

1. Always replace
2. Insert before mounting in ring groove (not visible with joint installed)

8 - Outer constant velocity joint

1. Replace only as a unit
2. Pressing off «Driving outer constant velocity joint down»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Installing
4. Drive joint onto shaft with a plastic hammer until circlip engages.

1. Greasing --> «Component overview»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. When installing joint on profile shaft, profile shaft splines must be lightly coated with grease used in joint.

9 - Bolt

1. Always replace if removed
2. Loosen «Remove drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__remove-drive-axle)
3. Fastening «Install drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle)
4. Torque specification «Install drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle)

10 - Clamp

1. Different versions for protective joint boot in rubber or Hytrel
2. Replace

11 - Outer constant velocity protective joint boot

1. Check for tears and chafing
2. Before clamping hose clamps, raise protective joint boot briefly to balance pressure «Protective joint boot, ventilating»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Different version in rubber or Hytrel

12 - Clamp

1. Replace

13 - Axle shaft

1. Different versions

14 - Circlip

15 - Triple roller star

1. Chamfer - arrow - faces splines drive axle splines
2. When installing triple roller star on profile shaft, profile shaft splines must be lightly coated with grease used in joint.

16 - Circlip

1. Replace
2. Insert in shaft groove

17 - Multi-point socket head bolt

18 - Triple roller joint housing

Joint protective boots made from rubber are tightened with hose clamp pliers V.A.G 1275.

Scheme 122

Scheme 123

1. Secure drive axle with protective covers in vise clamp.
2. Remove large clamping sleeve and turn back protective joint boot.
3. Strike a copper or brass drift on CV joint inner race with a hammer

Scheme 124

Only for joint protective boot of rubber

A vacuum can form in joint when installing protective joint boot.

This pressure pulls a fold in while driving, see - arrow -.

Note the following

1. Before clamping, clamping sleeves, balance pressure by raising protective joint boot.

Scheme 125

Items 1 to 3 only present on certain versions.

1 - Circlip

2 - Spring washer

3 - Spacer ring (plastic)

Instructions only apply to stainless steel clamps.

Scheme 126

Tightening hose clamp on outer joint

1. Position CV Joint Boot Clamp Tool VAG 1682 as shown in illustration. Make sure that the jaws of tension clamp seat in corners - arrows B - of hose clip.
2. Tighten hose tie by turning spindle using a torque wrench (do not bend tensioning clamp).

1. Torque specification: 20 Nm
2. Use torque wrench with a range of 5 to 50 Nm (e.g. torque wrench V.A.G 1331).
3. Ensure the spindle thread is not tight. If necessary lubricate with MOS 2 grease.
4. If the thread is tight e.g. dirty, the required tensioning force for the hose clamp will not be achieved in spite of correct torque specification settings.

Triple roller joint AAR 2600 i or 3300 i, disassembling

Removal

1. Clamp drive axle horizontally in vise.

Note. Use protective vise covers. Ensure drive axle is not damaged.

1. Mark location of joint to drive axle

If parts are not marked when assembling, the components are not brought back to their previous installation position then it is possible that it will be noisy when driving.

A waterproof felt tipped pen is suitable for marking.

Scheme 127

1. Open clamps - arrows -.
2. Slide back protective boot.

Distinguishing characteristic of drive axle AAR 2600 i to AAR 3300 i

Scheme 128

1. Determine dimension - A - as shown in illustration.

1. Dimension - A - 74 mm = driveshaft AAR 2600 i
2. Dimension - A - 77 mm = driveshaft AAR 3300 i

1. Guide triple roller joint AAR 3300 i assembly device T40018 or triple roller joint AAR 2600 i assembly device T40084 behind joint.

Scheme 129

Guide pins - 1 - must contact joint.

1. Bring installation device into contact with joint by turning knurled thumb screws - 2 -.

Note. Joint must be secured without play in assembly device T40018 or T40084. Only install screws - 2 - hand-tight.

Scheme 130

1. Screw multi-purpose tool VW 771 into assembly device T40018 or T40084.

Drive axle AAR 3300 i assembly device T40018 is shown in illustration.

Use assembly device T40084 with drive axle AAR 2600 i.

1. Pull joint out horizontally with impact tool.

Leave joint in assembly device T40018 or T40084.

Scheme 131

1. Mark installation position of parts 1 and 2 with lines.

If parts are not marked when assembling, the components are not brought back to their previous installation position then it is possible that it will be noisy when driving.

A waterproof felt tipped pen is suitable for marking.

1 - Drive axle

2 - Triple roller star

1. Remove grease with lint-free cloth.

Scheme 132

1. Remove circlip.

1 - Pliers (commercially available)

1. Press triple roller star off of drive axle

Assembly tool T10065/4 must not be applied to roller body.

1. Remove protective boot
2. Remove grease on shaft splines
3. Check roller body and ball cage for wear
4. Clean drive axle and housing.

Triple roller joint AAR 2600 i or 3300 i, assembling

Assembly

1. Slide new protective boot onto drive axle.

Scheme 133

1. Press on circlip - 1 - to center of splines

Scheme 134

1. Use special tool shown in illustration.

Depending on drive axle version, T10065/3 must be used instead of assembly device T10065/2.

Triple roller star, pressing onto drive axle

The chamfer on star faces toward drive axle, this is used as an assembly aid.

1. Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.
2. Install triple roller star onto shaft as per markings and drive in to stop.

Scheme 135

This illustration only applies to conical drive axle - arrow - !

1. Use special tool shown in illustration.

Special tool T10065/2 must not come in contact with roller body

Scheme 136

This illustration only applies to cylindrical drive axle - arrow - !

1. Use special tool shown in illustration.

Special tool T10065/3 must not come in contact with roller body

1. Press triple roller joint onto drive axle
2. Circlip must engage audibly, triple roller star must lie against circlip with no gap.

1. Install circlip.

1 - Pliers (commercially available)

1. Press 70 grams of joint grease, from repair kit, into reverse side of triple roller joint.
2. Lightly lubricate roller body

Make sure roller body does not tilt!

Scheme 137

1. Press joint over triple roller start with plastic hammer

Drive axle AAR 3300 i assembly device T40018 is shown in illustration.

1. Press remaining quantity of grease in protective boot.
2. Ensure correct seating of boot on joint.
3. Boot must fit in groove and on joint contour

Scheme 138

1. Position joint in center position. See min - max position

Note. While positioning joint in center position, it is necessary to bleed protective boot, e.g. with a screwdriver. - Arrow

Scheme 139

1. Install clamp.

Note. For a better alignment of multi-point socket head bolts when installing drive axle, clamping sleeve connecting tube - 2 - must be between joint connecting flanges - 1 -.

Scheme 140

1. Tension small clamp using hose clamp pliers V.A.G 1275.

Scheme 141

Special tools, testers and auxiliary items required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Punch VW 412
4. Clamp 40 - 204 A

1. Support sleeve VW 522
2. Punch VW 411

Scheme 142

1. Press piece VW 434

Scheme 143

1. Pressing appliance VW 459

Individual component overview

Constant velocity joints are packed with grease G 000 603

Grease quantity and type

Grease joint again when replacing protective joint boot.

Scheme 144

1 - Bolt

1. Always replace if removed
2. Loosen «Remove drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__remove-drive-axle)
3. Fastening «Install drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle)
4. Torque specification «Install drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle) .

2 - Outer constant velocity joint

1. Replace only as a unit
2. Removing «Outer CV joint, removing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__outer-cv-joint-removing)
3. Installing «Outer CV joint, installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__outer-cv-joint-installing)
4. Greasing «Grease quantity and type»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

1. Checking --> «Outer constant velocity (CV) joint, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. When installing joint on profile shaft, profile shaft splines must be lightly coated with grease used in joint.

3 - Circlip

1. Always replace
2. Insert before mounting in ring groove (not visible with joint installed)

4 - Clamp

1. Replace

5 - Outer constant velocity protective joint boot

1. Check for tears and chafing, replace if necessary
2. In case of damage, check outer constant velocity joint --> «Outer constant velocity (CV) joint, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Before clamping hose clamps, raise protective joint boot briefly to balance pressure.
4. Sealing surfaces must be free of grease when installing.

6 - Axle shaft

7 - Cover

1. Always replace

8 - Gasket

1. Always replace

9 - Circlip

1. Replace
2. Insert in shaft groove

10 - Inner constant velocity joint

1. Exterior diameter: 100 mm
2. Replace only as a unit
3. Removing «Inner CV joint, removing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__inner-cv-joint-removing)
4. Installing «Inner CV joint, installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__inner-cv-joint-installing)

1. Greasing «Grease quantity and type»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Adhesive surface must be free of oil and grease
3. Checking --> «Inner constant velocity (CV) joint, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__inner-constant-velocity-cv-joint-checking)
4. When installing joint on profile shaft, profile shaft splines must be lightly coated with grease used in joint.

11 - Backing plate

12 - Multi-point socket head bolt

13 - Protective boot with cap

1. In case of damage, check inner constant velocity joint --> «Inner constant velocity (CV) joint, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__inner-constant-velocity-cv-joint-checking)
2. Check for tears and chafing
3. Replace only as a unit
4. Removing «Inner CV joint, removing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__inner-cv-joint-removing)

1. Installing «Inner CV joint, installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__inner-cv-joint-installing)
2. Protective boot-drive axle sealing surfaces and cap must be free of grease when installing

Inner CV joint, removing

1. Drive axle, clamping in vise

Use protective vise covers for this.

Scheme 145

1. Pry off cap, e.g. with a screwdriver.

Scheme 146

1. Remove seal - arrow

Scheme 147

1. Drive protective joint boot cap under with a brass or copper drift

Clamping sleeves must not be loosened.

Scheme 148

1. Remove circlip

Scheme 149

1. Press inner CV joint off of drive axle with special tool shown in illustration.
2. Remove inner CV joint protective boot from drive axle.

Scheme 150

1. Apply sealant - hatched surface - to clean surface on inner side of protective joint boot cap: Sealant bead: unbroken, 2 to 3 mm dia. Skirt area around inner holes - arrow -.
2. Use sealant D 454 300 A2 for this
3. Slide joint protective boot onto drive axle.

1. Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.

Protective boot and cap contact surfaces must be free of grease!

Scheme 151

1. Press on joint until stop.

Chamfer on inner diameter of ball hub (splines) must face contact shoulder of drive axle.

Use special tool shown in illustration.

Press block 40-204 A and clamping surfaces on drive axle must be free of grease.

1. Install circlip
2. Check circlip for correct seating.

Circlip must be replaced

1. Apply 50 g joint grease in boot.

Make sure you do not damage sealant bead.

Scheme 152

1. Using bolts - arrows - , align protective boot and cap with screw holes.

It must be aligned exactly because it cannot be aligned after driving on.

1. Drive off protective boot with cap using plastic hammer.
2. Clear away leaking sealing immediately.
3. Apply 30 g joint grease in CV joint through ball paths.

1. Grease seal contact surface - arrow -.
2. Remove adhesive foil from seal and adhere to CV joint.
3. Align new cover with screw holes.

It must be aligned exactly because it cannot be aligned after pressing on.

Scheme 153

1. Press cover on with special tool shown in illustration.

Scheme 154

1. Position protective joint boot between - arrows -.

Outer CV joint, removing

1. Drive axle, clamping in vise

Use protective vise covers for this.

1. Open clamps.
2. Slide back protective boot

1. Strike a copper or brass drift on CV joint inner race with a hammer
2. Remove joint

Outer CV joint, installing

1. Slide joint protective boot onto drive axle.
2. Insert new circlip

Circlip (snap ring) must be replaced

1. Apply 50 g joint grease in inside of joint.

1. Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.

1. Screw old drive axle bolt into joint as shown in illustration.
2. Drive joint onto drive axle with plastic hammer until circlip engages.
3. Apply 40 g joint grease in boot side of joint.
4. Bleed protective joint boot.

1. Close clamp.

In order to replace grease in case of strong soiling, joint must be disassembled or if journal surface of balls must be checked for wear and damage.

Disassembling

1. Before disassembling mark ball hub position in relation to the ball cage and housing using an electric scriber or oil stone.
2. Swivel ball hub and ball cage.
3. Remove balls one after another.

1. Turn cage, until two rectangular windows - arrow - contact joint body.
2. Lift out cage together with hub.

1. Swing segment of hub into rectangular window of cage.
2. Tilt hub out of cage.

Checking

6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small indentations (pitting) and signs of seizure. Excessive backlash in the joint will cause knocking or jolts under load change. In such cases joint should be replaced. Flattening and running marks of balls are no reason to replace joint.

Assembling

1. Install cage with hub in the joint housing.

Note. Cage must be installed laterally correct.

1. Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body must be re-established.
2. Pack grease into joint body, grease quantity and type «Grease quantity and type»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Inner constant velocity (CV) joint, checking

In order to replace grease in case of strong soiling, joint must be disassembled and if journal surfaces and balls must be checked for wear and damage.

Disassembling

Note. Ball hub and joint are paired and should be identified before removal. Do not interchange cage allocation.

Scheme 155

1. Swivel ball hub and ball cage.
2. Press out ball joint housing in direction of - arrow -.
3. Press balls out of cage.

Scheme 156

1. Flip out ball hub from ball cage via running path of ball - arrows -.
2. Check joint housing, ball hub, ball cage and balls for indentations (pitting) and signs of seizure.

Note. Excessive backlash in the joint will cause knocking or jolts under load change. In such cases the joint must be replaced. Flattening and running marks of balls are no reason to replace joint.

Assembling

Scheme 157

1. Insert ball hub into ball cage via two chamfers. The hub can be installed in any position. Press balls into cage.
2. Insert hub with cage and balls at right angle to joint.

Scheme 158

1. When inserting make sure that the wide space - a - on joint housing is aligned with the narrow space - b - on hub after swiveling in.
2. Chamfer on inner diameter of wheel hub (splines) must face toward drive axle.

Scheme 159

1. Install ball hub, whereby hub must be swiveled out of cage - arrows - far enough to allow balls to fit into ball tracks.

Scheme 160

1. Press cage firmly - arrow - until hub swings fully in position.

Constant velocity joint, checking for function

Constant velocity joint is properly assembled, if ball hub can be slid back and forth by hand over whole compensation length.

Scheme 161

Special tools, testers and auxiliary items required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Punch VW 412
4. Clamp 40 - 204 A

1. Support sleeve VW 516
2. Punch VW 409

Constant velocity joints are packed with grease G 000 603

Grease quantity and type

Grease joint again when replacing protective joint boot.

Scheme 162

1 - Cover

1. Always replace

2 - Circlip

1. Remove and install with commercially-available circlip pliers

3 - Inner constant velocity joint

1. Exterior diameter: 108 mm
2. Replace only as a unit
3. Removing «Inner CV joint, removing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Installing «Inner CV joint, installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

1. Greasing «Grease quantity and type»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Adhesive surface must be free of oil and grease
3. Checking --> «Inner constant velocity (CV) joint, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. When installing joint on profile shaft, profile shaft splines must be lightly coated with grease used in joint.

4 - Protective boot with cap

1. In case of damage, check inner constant velocity joint --> «Inner constant velocity (CV) joint, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Check for tears and chafing
3. Replace only as a unit
4. Protective boot-drive axle sealing surfaces and cap must be free of grease when installing

5 - Backing plate

6 - Multi-point socket head bolt

7 - Axle shaft

8 - Clamp

1. Always replace

9 - Outer constant velocity protective joint boot

1. Without ventilation bore
2. Check for tears and chafing; replace if necessary.
3. In case of damage, check outer constant velocity joint --> «Outer constant velocity (CV) joint, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Sealing surfaces must be free of grease when installing.

10 - Clamp

1. Always replace

11 - Circlip

1. Replace
2. Installed location «Location of spacer and spring washer (wheel side)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

12 - Spring washer

1. Installed location «Location of spacer and spring washer (wheel side)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

13 - Spacer ring (plastic)

1. Installed location «Location of spacer and spring washer (wheel side)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

14 - Circlip

1. Always replace
2. Insert in shaft groove

15 - Outer constant velocity joint

1. Replace only as a unit
2. Servicing --> «Outer constant velocity joint, servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Installing: Drive onto shaft using plastic hammer until compressed circlip seats.
4. Circlip must lie in joint chamfer when guiding in, guide with pliers if necessary.

1. Greasing «Grease quantity and type»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Checking --> «Outer constant velocity (CV) joint, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. When installing joint on profile shaft, profile shaft splines must be lightly coated with grease used in joint.

16 - Bolt

1. Always replace if removed
2. Loosen «Remove drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__remove-drive-axle)
3. Fastening «Install drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle)
4. Torque specification «Install drive axle»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__install-drive-axle) .

1. Drive axle, clamping in vise

Use protective vise covers for this.

Scheme 163

1. Drive cover down with copper or brass drift

1. Remove circlip
2. Remove joint grease and mark location of CV joint to drive axle.

Scheme 164

1. Clamp drive axle in vise at CV joint, as shown in illustration.
2. A 2nd technician must hold drive axle horizontally so that CV joint is not damaged.
3. Bend edge - arrow - of cap up slightly with small flat chisel.
4. Drive cap down with copper or brass drift

Scheme 165

1. Press CV joint off of drive axle.
2. Remove protective boot with cap.

Inner CV joint, installing

1. Apply sealant D 454 300 A2 - hatched surface - to clean surface on inner side of protective boot cover or cap, and. Sealant bead: unbroken, 2 to 3 mm dia., skirt area around inner holes - arrow -.

Protective boot and cap contact surfaces must be free of grease!

1. Slide new protective boot with cap onto drive axle.
2. Pack 85 g joint grease into boot.

1. Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.

Scheme 166

1. Secure CV joint from coming apart, e.g. with adhesive tape - arrow -.
2. Press off CV joint.

Note. Position ball hub with chamfer on inner diameter (splines) on drive axle.

Use special tool shown in illustration.

Press block 40-204 A and clamping surfaces on drive axle must be free of grease.

1. Install circlip
2. Press 35 g joint grease into joint through ball races.

1. Using bolts - arrows - , align protective boot and cap with screw holes.

It must be aligned exactly because it cannot be aligned after driving on.

1. Drive off protective boot with cap using plastic hammer.
2. Clear away leaking sealant immediately.

Scheme 167

1. Align new cover with bolts - arrows - to screw holes.

It must be aligned exactly because it cannot be aligned after driving on.

1. Drive cover on with a plastic hammer.
2. Clear away leaking sealing immediately.

Outer CV joint, removing

1. Drive axle, clamping in vise

Use protective vise covers for this.

1. Open clamps.
2. Slide back protective boot

1. Strike a copper or brass drift on CV joint inner race with a hammer.
2. Remove joint

Outer CV joint, installing

1. Slide joint protective boot onto drive axle.
2. Insert new circlip

Circlip (snap ring) must be replaced

1. Pack 80 g joint grease in inside of joint.

1. Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.
2. Screw old drive axle bolt into joint as shown in illustration.

1. Drive joint onto drive axle with plastic hammer until circlip engages.
2. Apply 40 g joint grease in boot side of joint.
3. Bleed protective joint boot.
4. Close clamp.

In order to replace grease in case of strong soiling, joint must be disassembled or if journal surface of balls must be checked for wear and damage.

Disassembling

Scheme 168

1. Before disassembling mark ball hub position in relation to the ball cage and housing with an electric scriber or oil stone. (see - arrow -)
2. Swivel ball hub and ball cage.
3. Remove balls one after another.

Scheme 169

1. Turn cage until two cage windows - arrow - rest on joint body.
2. Lift out cage together with hub.

Scheme 170

1. Swing a hub segment in a cage window.
2. Tilt hub out of cage.

Checking

6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small indentations (pitting) and signs of seizure. Excessive backlash in the joint will cause knocking or jolts under load change. In such cases joint should be replaced. Flattening and running marks of balls are no reason to replace joint.

Assembling

1. Install cage with hub in joint housing.

Note. Cage must be installed laterally correct.

1. Press in opposing balls in sequence, during this, previous position of ball hub to ball cage and to joint body must be re-established.
2. Pack grease into joint body, grease quantity and type «Grease quantity and type»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

In order to replace grease in case of strong soiling, joint must be disassembled and if journal surfaces and balls must be checked for wear and damage.

Disassembling

Note. Ball hub and joint are paired and should be identified before removal. Do not interchange cage allocation.

1. Swing ball hub and ball cage and pull out of joint in direction of - arrow -.
2. Press balls out of cage.

1. Flip out ball hub from ball cage via running path of ball - arrows -.

Checking

1. Check joint housing, ball hub, ball cage and balls for indentations (pitting) and signs of seizure.

Note. Excessive backlash in the joint will cause knocking or jolts under load change. In such cases the joint must be replaced. Flattening and running marks of balls are no reason to replace joint.

Assembling

1. Insert ball hub into ball cage via two chamfers. The hub can be installed in any position. Press balls into cage.
2. Insert hub with cage and balls at right angle to joint.

Scheme 171

Note. When inserting make sure that the wide space - a - on joint housing is aligned with the narrow space - b - on the hub after swiveling in.

1. Install ball hub, whereby the hub must be swiveled out of the cage - arrows - far enough to allow the balls to fit into the ball tracks.

1. Press cage firmly - arrow - until hub swings fully in position.

Constant velocity joint, checking for function

Constant velocity joint is properly assembled, if ball hub can be slid back and forth by hand over whole compensation length.

When installing waxed components, contact surfaces must be cleaned. Contact surfaces must be free of wax and grease.

Torque specifications for unoiled bolts and nuts are given.

Welding or straightening operations are not permitted on load-bearing or wheel-controlling components.

Always avoid the following actions with coil springs: Hammer stroke, welding beads, applying color identification later.

Do not perform any welding or grinding (separating work) in coil spring or suspension strut area! Cover coil spring or suspension struts if necessary.

Vehicles without drive axle must not be moved, otherwise wheel bearing will be damaged. If vehicle must be moved, observe the following

1. Install an outer joint in place of drive axle.
2. Tighten outer joint to 115 Nm (bolt M14) or 200 Nm (bolt M16).

Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms if vehicle is in curb weight position --> Wheel bearing, lifting to curb weight position

If the vehicle must still be aligned, every bolt and nut that must be loosened for adjustment is only tightened to torque specification. After measurement/adjustment is complete, tighten bolt and nuts to prescribed additional torque angle.

Wheel bearing, lifting to curb weight position

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A
2. Tensioning strap T10038
3. Wheel hub support T10149

Note. All bolts on suspension parts with bonded rubber bushings must always be tightened in curb weight position (unloaded condition).

Bonded rubber bushings have a limited torsional range.

Parts with bonded rubber bushings must be brought into a position that corresponds to the position in driving mode before being tightened (curb weight position)

Otherwise, bonded rubber bushing will be stressed resulting in a shortened service life.

By raising appropriate suspension using engine/transmission jack V.A.G 1383 A and Wheel Hub Support T10149 , this position can be simulated on hoist.

1. Before starting work, take measurement - a - , e.g. with tape measure, from center of wheel to lower edge of wheelhousing.

The measurement must be taken in curb weight position (unloaded).

1. Make a note of measurement. It will be needed for tightening bolts/nuts.

Before appropriate suspension is raised, vehicle must be strapped to lift arms of hoist using tensioning straps T10038.

If a vehicle is not secured, there is danger that the vehicle could slip off the lift!

1. Turn wheel hub until one of the holes for the wheel bolts is at the 12 o'clock position.
2. Install wheel hub support T10149 with wheel bolt on wheel hub.

1. Using engine/transmission jack V.A.G 1383 A , lift wheel bearing housing until dimension - a - is reached.

Tightening of the respective bolts/nuts must then only occur after dimension - a - , which was measured before installation between the wheel hub center and the lower edge of wheelhousing, has been attained

1. Tighten respective bolts/nuts.
2. Lower steering knuckle.
3. Move engine/transmission jack away from under vehicle.
4. Remove wheel hub support T10149.

Scheme 172

I - Subframe - front wheel drive --> Part I, Subframe - front wheel drive

II - Subframe - all wheel drive --> Part II, Subframe - all wheel drive

III - Trapezoidal control arm, transverse link, tie rod --> Part III, Trapezoidal control arm, transverse link, tie rod

IV - Stub axle carrier - front wheel drive --> Part IV, Stub axle carrier - front wheel drive

V - Wheel bearing housing (steel) - all wheel drive --> Part V, wheel bearing housing (steel) - all wheel drive

VI - Stabilizer bar --> Part VI, Stabilizer bar

Scheme 173

Wheel bearing housing (aluminum) - all wheel drive

VII - Wheel bearing housing aluminum - all wheel drive --> Part VII, Wheel bearing housing (aluminum) - all wheel drive

Scheme 174

1 - Subframe

1. Removing and installing --> «Subframe, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Subframe bushings, replacing --> «Subframe bushings, replacing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

2 - Plastic insert

1. Part of purchased bushing assembly

3 - Washer

1. Always replace

4 - Combi-bolt

1. Always replace
2. Tighten to 110 Nm plus an additional 90° turn
3. Threads in body can be repaired according to DIN 8140 using wire thread inserts (Heli-Coil). Thread insert must be same length as thread in body.

5 - Washer

1. Front only
2. Corrugation face toward body
3. Only installed with hydraulic mounting 8E0 505 145 AQ
4. Discontinued from KW 48/00 with introduction of new hydraulic bushing

Scheme 175

1 - Subframe

1. Removing and installing --> «Subframe, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Subframe bushings, replacing --> «Subframe bushings, replacing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Rear differential bushing, replacing --> «Rear differential bushing, replacing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__rear-differential-bushing-replacing)

2 - Combi-bolt, 55 Nm

3 - Washer

4 - Hex nut

5 - Plastic insert

1. Part of purchased bushing assembly

6 - Washer

1. Always replace

7 - Combi-bolt

1. Always replace
2. Tighten to 110 Nm plus an additional 90° turn
3. Threads in body can be repaired according to DIN 8140 using wire thread inserts (Heli-Coil). Thread insert must be same length as thread in body.

8 - Washer

1. Front only
2. Corrugation face toward body
3. Only installed with hydraulic mounting 8E0 505 145 AQ
4. Discontinued from KW 48/00 with introduction of new hydraulic bushing

9 - Front transmission support

10 - Combi-bolt, 40 Nm

11 - Cover

12 - Combi-bolt, 25 Nm

13 - Rear final drive

14 - Rear crossmember

15 - Combi-bolt, 40 Nm

16 - Hex nut, 40 Nm

17 - Washer

18 - Combi-bolt

Scheme 176

1 - Trapezoidal control arm

1. Various versions --> «Trapezoidal control arm»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Mixed installation not permissible
3. Removing and installing --> «Trapezoidal control arm»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Trapezoidal control arm bushings must not be replaced, if bushing is damaged, replace trapezoidal control arm

2 - Eccentric bolt

1. Vehicle alignment must be performed after loosening. --> «Wheel alignment»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Do not turn more than 90° left or right (that is, smallest to largest possible adjustment)

3 - Eccentric washer

1. Inner bore with tab

4 - Hex nut, self-locking, 95 Nm

1. Always replace
2. Tighten bolts only in curb weight position

5 - Combi-bolt

1. Always replace
2. Tighten to 85 Nm plus an additional 90° turn

6 - Lower spring support

1. End of spring turned to stop

7 - Coil spring

1. Note different vehicle versions, see vehicle data plate. «Clarification of Production Control numbers (PR No.)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__clarification-of-production-control-numbers-pr)
2. Removing and installing --> «Rear coil spring»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

8 - Upper spring support

9 - Upper spring support

10 - Combi-bolt

1. Always replace
2. Tighten to 85 Nm plus an additional 90° turn

11 - Transverse link

1. Removing and installing --> «Transverse link»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Replace bearing --> «Transverse link bracket, replacing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__transverse-link-bracket-replacing)

12 - Eccentric bolt

1. Vehicle alignment must be performed after loosening. --> «Wheel alignment»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Do not turn more than 90° left or right (that is, smallest to largest possible adjustment)

13 - Washer

14 - Nut, self-locking

1. Always replace
2. Tighten to 85 Nm plus an additional 90° turn
3. Tighten bolts only in curb weight position

15 - Tie rod

1. Various versions
2. Removing and installing --> «Tie rod»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Vehicle alignment must be performed after installing. --> «Wheel alignment»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

16 - Stone protection plate

1. Various versions
2. Only for heavy duty suspension
3. Removing and installing (old version 8E0 501 561) --> «Tie rod (three-piece version) stone protection 8E0 501 561 (old version), removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__tie-rod-three-piece-version-stone-protection)

1. Removing and installing (new version) --> «Tie rod»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) and --> «Tie rod (one-piece version) stone protection (new version), removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__tie-rod-one-piece-version-stone-protection)

17 - Collar nut, self-locking

1. Always replace
2. Tighten bolts only in curb weight position

18 - Trapezoidal control arm stone protection

1. Only for heavy duty suspension

19 - Collar bolt, 25 Nm

20 - Bracket

1. For parking cable

Scheme 177

1 - Stub axle carrier

1. Vehicles with front wheel drive
2. Removing and installing --> «Stub axle carrier/wheel bearing housing and wheel bearing unit»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Servicing --> «Stub axle carrier - front wheel drive, servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__stub-axle-carrier-front-wheel)

2 - Wheel bearing unit

1. Removing and installing --> «Stub axle carrier/wheel bearing housing and wheel bearing unit»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. The wheel bearing and wheel hub are installed together in a housing.
3. This wheel bearing/hub unit is maintenance and adjustment free. Adjusting and servicing is not possible!
4. Does not need to be replaced

1. If wheel bearing unit can be removed from stub axle carrier by hand, wheel bearing unit is OK and can be reinstalled.
2. If it cannot be removed by hand, wheel bearing unit must be replaced.
3. Replace only as a unit

3 - Collar screw

1. Always replace
2. Tighten to 200 Nm plus 180° additional turn
3. Tighten to 200 Nm, if vehicle is raised, only tighten with additional turn when vehicle is on floor
4. If vehicle is resting on floor, do not loosen more than 90°

4 - Dust cap

1. Always replace if removed
2. An appropriate seal can only be achieved with a new dust cap.
3. Only then is an optimum function and long service life guaranteed.

5 - Speed sensor

1. Wire routing «Speed sensor wire routing on trapezoidal control arm»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

6 - Hex socket head bolt, 10 Nm

7 - Nut, self-locking

1. Always replace

8 - Washer

9 - Strut

1. On vehicles with Dynamic Ride Control (DRC II), empty and fill system --> «Dynamic Ride Control (DRC II), emptying and filling»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__dynamic-ride-control-drc-ii-emptying)
2. Removing and installing --> «Strut»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Observe installed location «Strut location»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Note different vehicle versions, see vehicle data plate. «Clarification of Production Control numbers (PR No.)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__clarification-of-production-control-numbers-pr)

1. Faulty struts must be vented and emptied before disposal --> «Rear gas-filled strut, venting»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__rear-gas-filled-strut-venting)
2. Check removed strut --> «Strut, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

10 - Combi-bolt, 36 Nm

11 - Combi-bolt

1. Always replace
2. Tighten to 150 Nm plus an additional 90° turn
3. Tighten bolts only in curb weight position

Scheme 178

1 - Screw with cylindrical shoulder, 10 Nm

2 - Collar bolt, 10 Nm

3 - Cable guide

To remove, remove collar bolt - 2 - and carefully slide cable guide off of screws - 1 - - arrow A -.

To remove complete wiring, unclip at subframe - arrow B -.

Scheme 179

Longer collar on strut - arrow A - must sit in centering seat on stub axle carrier/wheel bearing housing - arrow B -.

Scheme 180

1 - Wheel bearing housing

1. Vehicles with all-wheel drive
2. Removing and installing --> «Stub axle carrier/wheel bearing housing and wheel bearing unit»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Servicing --> «Wheel bearing housing (steel) - all wheel drive, servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__wheel-bearing-housing-steel-all)

2 - Wheel bearing

1. Removing and installing with wheel bearing housing removed --> «Wheel bearing housing (steel) - all wheel drive, servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__wheel-bearing-housing-steel-all)
2. Removing and installing in vehicle --> «Wheel bearing (with wheel bearing housing (steel) installed - all wheel drive), removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__wheel-bearing-with-wheel-bearing-housing)

3 - Wheel hub

1. Removing and installing with wheel bearing housing removed --> «Wheel bearing housing (steel) - all wheel drive, servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__wheel-bearing-housing-steel-all)
2. Removing and installing in vehicle --> «Wheel bearing (with wheel bearing housing (steel) installed - all wheel drive), removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__wheel-bearing-with-wheel-bearing-housing)

4 - Collar bolt

1. Always replace
2. Tighten to 200 Nm plus an additional 180° turn
3. Tighten to 200 Nm, if vehicle is raised, only tighten with additional turn when vehicle is on floor
4. If vehicle is resting on floor, do not loosen more than 90°

5 - Drive axle

1. Removing and installing --> «Drive axles, removing and Installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__drive-axles-removing-and-installing)
2. Servicing (with inner joint 100 mm dia.) --> «Drive axle with constant velocity inner joint (diameter 100 mm), servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Servicing (with inner joint dia. mm 108) --> «Driveshaft with constant velocity inner joint (diameter 108 mm), servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__driveshaft-with-constant-velocity-inner-joint)

6 - Speed sensor

1. Wire routing «Speed sensor wire routing on trapezoidal control arm»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

7 - Hex socket head bolt, 10 Nm

8 - Washer

9 - Nut, self-locking

1. Always replace

10 - Strut

1. Removing and installing --> «Strut»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Observe installed location «Strut location»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Note different vehicle versions, see vehicle data plate. «Clarification of Production Control numbers (PR No.)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__clarification-of-production-control-numbers-pr)
4. Faulty struts must be vented and emptied before disposal --> «Strut, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

1. Check removed strut --> «Strut, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

11 - Combi-bolt, 36 Nm

12 - Combi-bolt

1. Always replace
2. Tighten to 150 Nm plus an additional 90° turn
3. Tighten bolts only in curb weight position

Scheme 181

1 - Stabilizer bar

1. Be aware of the various suspension versions, «Clarification of Production Control numbers (PR No.)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__clarification-of-production-control-numbers-pr) Vehicle data plate.
2. Removing and installing --> «Stabilizer bar, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Replace bearing --> «Stabilizer bushings, replacing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__stabilizer-bushings-replacing)
4. Always replace mounts on both sides of vehicle

2 - Clamp

3 - Collar bolt, 25 Nm

4 - Bushing

1. Replacing --> «Stabilizer bushings, replacing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__stabilizer-bushings-replacing)
2. Always replace mounts on both sides of vehicle

5 - Coupling rod

1. Connects stabilizer with trapezoidal control arm

6 - Collar bolt, 25 Nm

7 - Collar bolt, 45 Nm

Scheme 182

1 - Wheel bearing housing

1. Vehicles with all-wheel drive
2. Removing and installing --> «Stub axle carrier/wheel bearing housing and wheel bearing unit»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Servicing --> «Wheel bearing housing (steel) - all wheel drive, servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__wheel-bearing-housing-steel-all)

2 - Wheel bearing

1. Removing and installing --> «Bolted wheel bearing unit, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

3 - Wheel hub

1. Removing and installing --> «Bolted wheel bearing unit, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

4 - Collar bolt

1. Always replace
2. Tighten to 200 Nm plus an additional 180° turn
3. Tighten to 200 Nm, if vehicle is raised, only tighten with additional turn when vehicle is on floor
4. If vehicle is resting on floor, do not loosen more than 90°

5 - Drive axle

1. Removing and installing --> «Drive axles, removing and Installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__drive-axles-removing-and-installing)
2. Servicing (with inner joint 100 mm dia.) --> «Drive axle with constant velocity inner joint (diameter 100 mm), servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Servicing (with inner joint 108 mm dia.) --> «Driveshaft with constant velocity inner joint (diameter 108 mm), servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__driveshaft-with-constant-velocity-inner-joint)

6 - Washer

7 - Nut, self-locking

1. Always replace

8 - Strut

1. Removing and installing --> «Strut»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Observe installed location «Strut location»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Note different vehicle versions, see vehicle data plate. «Clarification of Production Control numbers (PR No.)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__clarification-of-production-control-numbers-pr)
4. Faulty struts must be vented and emptied before disposal --> «Strut, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

1. Check removed strut --> «Strut, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

9 - Combi-bolt, 36 Nm

10 - Hex socket head bolt, 10 Nm

11 - Speed sensor

1. Wire routing «Speed sensor wire routing on trapezoidal control arm»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) , «Speed sensor wire routing on trapezoidal control arm»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

12 - Cap bolts (4x) 80 Nm plus an additional 90° turn

1. Always replace

13 - Combi-bolt

1. Always replace
2. Tighten to 150 Nm plus additional 90° turn
3. Tighten bolts only in curb weight position

Vehicle level sensor in vehicles with automatic headlight vertical aim control

Note. General information --> Vehicles with automatic headlight vertical aim control, vehicle level sensor . As a replacement part, vehicle level sensor is only available together with coupling rod and lower retaining plate. To remove it completely, subframe must be removed. Replacing with subframe installed --> Vehicle level sensor in vehicle, replacing . Headlamp Range Control Module J431 --> 94 LIGHTS, SWITCHES - EXTERIOR 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET

Scheme 183

1 - Combi-bolt

1. Always replace
2. Tighten to 85 Nm plus an additional 90° turn

2 - Left Rear Level Control System Sensor G76 or G77 Right Rear Level Control System Sensor G77

1. Complete with components
2. Lever - arrow - must face toward center of vehicle
3. Replace in vehicle --> «Vehicle level sensor in vehicle, replacing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__vehicle-level-sensor-in-vehicle-replacing)
4. After replacing, perform headlight basic setting --> «94 LIGHTS, SWITCHES - EXTERIOR»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET

3 - Collar bolt, 10 Nm

4 - Trapezoidal control arm

Vehicle level sensor in vehicle, replacing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

1. Remove tire.

Scheme 184

1. Remove bolt - 1 -.
2. Remove bolts - 2 - with angled wrench. When doing so, do not bend upper retaining plate.

Transverse control arm is not shown.

1. Adapt replacement part accordingly and install.

Note. Hold Level Control System Sensor securely when tightening bolts - 2 -.

Torque specifications

Item 1: 10 Nm

Item 2: 5 Nm

1. After replacing, perform basic setting for headlights. --> «94 LIGHTS, SWITCHES - EXTERIOR»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET
2. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

Coil spring, removing and installing

Special tools, testers and auxiliary items required

1. Spring compressor V.A.G 1752/1
2. Adapter V.A.G 1752/9
3. Spring holder A4, rear axle V.A.G 1752/16

Removing

1. Remove wheel.

Scheme 185

1. Insert spring compressor V.A.G 1752/1 with adapter V.A.G 1752/9 and spring holder A4, rear axle V.A.G 1752/16 in coil spring; if necessary, guide spring holder individually into windings and then fasten to spring compressor. When doing so, do not damage trapezoidal control arm.

It must be compressed 4 turns.

If this is not possible, compress only 3 turns and turn coil spring until 4 turns prescribed can be compressed.

1. Compress spring compressor to stop and remove spring.

Installing

Note. When installing new spring, ensure conical end points downward. - Arrow B - : Colored markings must be at bottom.

1. Lower spring seat - 1 - has a pin.
2. Insert this pin in trapezoidal control arm hole - 2 -.
3. Turn ends of coil spring so that it rests on spring seat stop - arrow A -.
4. Insert upper spring seat (not in illustration) in upper spring end.

1. Tension spring. Align upper spring seat in body hole.
2. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

Strut, removing and installing

Special tools, testers and auxiliary items required

1. Spring compressor V.A.G 1752/1
2. Adapter V.A.G 1752/9
3. Spring holder A4, rear axle V.A.G 1752/16
4. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332

Removing

On vehicles with Dynamic Ride Control (DRC II), empty and fill system --> Dynamic Ride Control (DRC II), emptying and filling

1. Remove tire.
2. Remove coil spring --> «Rear coil spring»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 186

1. Remove nut - 1 - and remove bolt (Illustration without cover plate).
2. Remove bolts - 2 -.

Note. Wheel housing liner remains installed.

1. Remove strut.

Installing

Note. Replace bolts and self-locking nuts --> Notes in exploded view diagrams at --> Part V, wheel bearing housing (steel) - all wheel drive

1. Tighten bolts - 2 -.

Note location of lower mounting Strut location

1. Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms if vehicle is in curb weight position --> «Wheel bearing, lifting to curb weight position»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Tighten connection - 1 - , (front wheel drive) or , (all wheel drive).
3. Install coil spring --> «Rear coil spring»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
4. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

Strut, servicing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

Scheme 187

1. Special wrench 3017 A

Scheme 188

1 - Hex nut, self-locking, 25 Nm

1. Always replace
2. Loosening and tightening «Loosening and tightening bolted connection for strut mount»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

2 - Strut mounting

3 - Buffer stop

4 - Protective sleeve

5 - Strut

1. Removing and installing --> «Strut»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Note different vehicle versions, see vehicle data plate. «Clarification of Production Control numbers (PR No.)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__clarification-of-production-control-numbers-pr)
3. Faulty struts must be vented and emptied before disposal --> «Strut, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Check removed strut --> «Strut, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

Scheme 189

Scheme 190

Special tools, testers and auxiliary items required

1. Grease cap puller VW 637/2
2. Fitting sleeve 3241/4
3. Torque wrench V.A.G 1332
4. Torque wrench V.A.G 1410

1. Bit XZN 18 T40027

Removing

1. Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).

Vehicles with front wheel drive

Note. If wheel bearing unit is not replaced, do not remove collar bolt and dust cap.

1. Remove wheel.

Scheme 191

1. Loosen dust cap from seat by lightly tapping on claws.

Scheme 192

1. Press of dust cap.
2. Mount wheel and place vehicle on wheels.

Continued for all vehicles

Scheme 193

1. Only loosen collar bolt - arrow - 90°, otherwise wheel bearing is damaged.

1. Remove tire.
2. Secure brake disc with a wheel bolt.

Scheme 194

1. Remove brake caliper - arrows -. To do so, use socket insert T40027.

Note. Secure brake caliper to body with wire. Do not allow brake caliper to hang from brake line.

1. Remove disc brake.
2. Remove coil spring --> «Rear coil spring»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 195

1. Remove collar bolt - 1 -.
2. Remove cover plate - 3 -.

Vehicles with front wheel drive

1. Remove wheel bearing unit - 2 -.

Note. If wheel bearing unit can be removed from stub axle carrier by hand, wheel bearing unit is OK and can be reinstalled.

Continued for all vehicles

Scheme 196

1. Remove speed sensor - 2 -.
2. Mark eccentric screw position - 1 - at top of stub axle carrier/wheel bearing housing, e.g. with a felt-tip pen.
3. Separate connections listed in sequence: Item 5, item 3, item 4, item 1.
4. Remove stub axle carrier or wheel bearing housing.

Note. Carefully press drive axle off on all wheel drive vehicles.

Installing

Note. Replace bolts and self-locking nuts --> Notes in exploded view diagrams at --> Part I, Subframe - front wheel drive .

Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms if vehicle is in curb weight position --> Wheel bearing, lifting to curb weight position

Vehicles with front wheel drive

1. Install new wheel bearing unit if necessary --> Note If wheel bearing unit can be removed from stub axle carrier by hand, wheel bearing unit is OK and can be reinstalled. under «Stub axle carrier/wheel bearing housing (steel), removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Continued for all vehicles

1. Tighten connections - 1 - , - 3 - , - 4 - and - 5 -.
2. Secure speed sensor - 2 - , (front wheel drive) or , (all wheel drive).
3. Install cover plate and brake caliper at stub axle carrier or wheel bearing housing. Refer to --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system) ; Rear brakes C38; Brake caliper, servicing

Vehicles with all-wheel drive

1. Tighten 5 wheel bolts and tighten parking brake.

Continued for all vehicles

1. First tighten collar screw - 1 - only to pre-tightening torque without additional turning (turn additionally when vehicle is resting on wheels), (front wheel drive) or (all wheel drive).
2. Install coil spring --> «Rear coil spring»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
3. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

Torque specifications

1. Tighten collar bolt - 1 - (Scheme 198), with prescribed additional turn, (front wheel drive) or (all wheel drive).

Vehicles with front wheel drive

1. Remove tire.

Scheme 197

1. Drive on a new dust cap.
2. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

Note. Damaged (dented) protective caps must be replaced. Damaged (dented) protective caps allow moisture to enter. Always use tool illustrated to reduce chance of damage to dust cap.

Continued for all vehicles

1. Perform vehicle alignment --> «Wheel alignment»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Alignment must take place on a VW/Audi recommended alignment stand.

Stub axle carrier - front wheel drive, servicing

Special tools, testers and auxiliary items required

1. Thrust plate VW 402
2. Punch VW 411
3. Punch VW 412
4. Sleeve VW 415 A

1. Press piece VW 434
2. Assembly tool VW 792
3. Assembly tool 3301/4

Scheme 198

1 - Stub axle carrier

1. Removing and installing --> «Stub axle carrier/wheel bearing housing and wheel bearing unit»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Front seal - arrow - must not grind against wheel bearing unit
3. Do not remove front seal

2 - Shield plate

3 - Wheel bearing unit

1. Does not need to be replaced
2. If wheel bearing unit can be removed from stub axle carrier by hand, wheel bearing unit is OK and can be reinstalled.
3. If it cannot be removed by hand, wheel bearing unit must be replaced.
4. Replace only as a unit

4 - Collar bolt

1. Always replace

5 - Torx bolt

1. Torque specification --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)

6 - Rubber bushing

1. Removing «Rubber bushing, removing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Installing «Rubber bushing, installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

Scheme 199

1. Continuously press out rubber bushing.

Note. Securely hold stub axle carrier/wheel bearing housing when pressing out.

Scheme 200

1. Clean bearing seat in stub axle carrier/wheel bearing housing.
2. Completely coat rubber bushing and stub axle carrier/wheel bearing housing bearing set using installation lubricant G 294 421 A1 (thin with water at a ratio of 1:100).
3. Position rubber bushing - A - so that wide collar faces downward - arrow -.

1. Continuously press rubber bushing into stub axle carrier or wheel bearing housing until rubber bushing collar rests on installation arbor VW 792 and is pressed (noticeable increase of pressure).

Note. If pressing process is interrupted, rubber expands and bushing cannot be pressed in farther without damaging it. Securely hold stub axle carrier/wheel bearing housing when pressing on.

Scheme 201

1. Press rubber bushing back again until dimension a = 10 ± 0.8 mm.

Wheel bearing housing (steel) - all wheel drive, servicing

Special tools, testers and auxiliary items required

1. Thrust plate VW 401
2. Punch VW 408 A
3. Punch VW 412
4. Sleeve VW 415 A

1. Press piece 2050
2. Thrust pad 3005
3. Assembly tool 3253/1
4. Press tool 3345

1. Press tube 30-100

Scheme 202

1 - Wheel bearing housing

1. Removing and installing --> «Stub axle carrier/wheel bearing housing and wheel bearing unit»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

2 - Wheel bearing

1. Interior diameter in tiered version
2. Installed location: Larger internal diameter of wheel bearing faces wheel hub
3. Pressing out «Pressing wheel bearing out of wheel bearing housing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Pressing in «Pressing wheel bearing into wheel bearing housing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

3 - Shield plate

4 - Wheel hub

1. Tiered version
2. Pressing out «Wheel hub, removing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Pressing in «Pressing wheel hub into wheel bearing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Light weight wheel hub --> «Light weight wheel hub»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

5 - Torx bolt

1. Torque specification --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)

6 - Rubber bushing

1. Removing «Rubber bushing, removing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Installing «Rubber bushing, installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

Scheme 203

Note. Wheel bearing housing must rest on machined screw hole surface.

Scheme 204

Note. Wheel bearing housing must rest on machined screw hole surface.

Scheme 205

1. Wheel bearing in tiered version

Note. Large internal diameter of wheel bearing faces wheel hub

1. Press wheel bearing - A - on to stop.

Scheme 206

1. Install wheel hub - B - and press on over wheel bearing inner race to stop.

Note. Tube VW 415 A must press onto center of bearing inner race.

Wheel bearing (with wheel bearing housing (steel) installed - all wheel drive), removing and installing

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A with universal transmission mount V.A.G 1359/2

Scheme 207

1. Foot pump with high pressure hose V.A.G 1389 A/1

If available in shop, hand pump V.A.G 1389/1 can also be modified for use as a foot pump.

To do so, use conversion kit V.A.G 1389/3.

Special tools, testers and auxiliary items required

Scheme 208

1. Wheel bearing tool V.A.G 1459B
2. Hollow piston cylinder HKZ-15 with hydraulic thrust piece E-0-204-T
3. Tie bolt E-0-217+218
4. Special nut E-8-214

1. Press piece E-5

Scheme 209

1. Supplementary set V.A.G 1459 B/2
2. Bell E-40
3. Press piece E-43
4. Thrust sleeve E-44-1

1. Remove brake caliper, brake disc and brake disc cover. --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)
2. Remove drive axle --> «Drive axles, removing and Installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__drive-axles-removing-and-installing) .

Place engine/transmission jack V.A.G 1383 A underneath (danger of accident from falling parts when removing the wheel hub and the wheel bearing).

Wheel hub, pulling out

Scheme 210

1. Attach bell - 1 - , hollow piston cylinder - 2 - with tie bolt, and special nut - 3 -.
2. Remove wheel hub by operating pump while holding tool securely.

1 - Bell E-40

2 - Hollow piston cylinder HKZ-15

3 - Special nut E-8-214 and tie bolt

Wheel bearing, pulling out

Scheme 211

1. Attach pressure piece - 1 - with collar to bearing, pressure sleeve - 2 - with four tiered interior diameters to wheel bearing housing, hollow piston cylinder - 3 - with tie bolt and special nut - 4 -.
2. Operate pump and remove wheel bearing.

1 - Thrust piece E-5

2 - Thrust sleeve E-44-1

3 - Hollow piston cylinder HKZ-15

4 - Special nut E-8-214 and tie bolt

Wheel bearing, pressing in

Installed location: Larger internal diameter of wheel bearing faces outward.

Scheme 212

1. Put wheel bearing - 1 - , pressure piece - 2 - (put collar into bearing), and hollow piston cylinder - 3 - with tie bolt on wheel bearing housing.
2. Attach pressure piece - 4 - with angles toward wheel bearing housing and special nut - 5 - from inside.
3. Press wheel bearing in by operating the pump.

1 - Wheel bearing

2 - Thrust piece E-14-1

3 - Hollow piston cylinder HKZ-15

4 - Thrust piece E-43

5 - Special nut E-8-214 and tie bolt

Wheel hub, pressing in

Scheme 213

1. Put wheel hub - 1 - and hollow piston cylinder - 2 - with tie bolt onto wheel bearing.
2. Attach pressure piece - 3 - with collar to special nut - 4 - from inside.
3. Press in hub by operating the pump.

1 - Wheel hub

2 - Hollow piston cylinder HKZ-15

3 - Thrust piece E-5

4 - Special nut E-8-214 and tie bolt

Installation is in reverse order of removal.

1. Install drive axle --> «Drive axles, removing and Installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__drive-axles-removing-and-installing) .
2. Install brake caliper, brake disc and brake disc cover. --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)

Scheme 214

Special tools, testers and auxiliary items required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Sleeve VW 416 B
4. Punch VW 412

1. Punch VW 407
2. Sleeve VW 519

1 - Wheel bearing housing

1. Wheel bearing housing, removing and installing --> «Wheel bearing housing (aluminum) - all wheel drive, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__wheel-bearing-housing-aluminum-all)

2 - Wheel bearing

3 - Wheel hub

1. Removing and installing --> «Bolted wheel bearing unit, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

4 - Collar screw

1. Always replace
2. Tighten to 200 Nm plus an additional 180° turn
3. Tighten to 200 Nm, if vehicle is raised, only tighten with additional turn when vehicle is on floor
4. If vehicle is resting on floor, do not loosen more than 90°

5 - Drive axle

1. Removing and installing --> «Drive axles, removing and Installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__drive-axles-removing-and-installing)
2. Servicing (with inner joint 100 mm dia.) --> «Drive axle with constant velocity inner joint (diameter 100 mm), servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Servicing (with inner joint 108 mm dia.) --> «Driveshaft with constant velocity inner joint (diameter 108 mm), servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__driveshaft-with-constant-velocity-inner-joint)

6 - Washer

7 - Nut, self-locking

1. Always replace

8 - Strut

1. Removing and installing --> «Strut»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Observe installed location «Strut location»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Note different vehicle versions, see vehicle data plate. «Clarification of Production Control numbers (PR No.)»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__clarification-of-production-control-numbers-pr)
4. Faulty struts must be vented and emptied before disposal --> «Strut, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

1. Check removed strut --> «Strut, checking»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

9 - Combi-bolt, 36 Nm

10 - Hex socket head bolt, 10 Nm

11 - Speed sensor

1. Wire routing «Speed sensor wire routing on trapezoidal control arm»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) , «Speed sensor wire routing on trapezoidal control arm»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)

12 - Cap bolts (4x) 80 Nm plus an additional 90° turn

1. Always replace

13 - Combi-bolt

1. Always replace
2. Tighten to 150 Nm plus an additional 90° turn
3. Tighten bolt only in curb weight position

Scheme 215

1. Puller 3- Kukko 15-17

1. Engine/transmission jack V.A.G 1383 A

Removing

1. Drive axle, removing and installing --> «Drive axles, removing and Installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__drive-axles-removing-and-installing)

Scheme 216

1. Remove mounting bolts - 1 - from brake caliper.
2. Remove brake caliper and hang up on body.
3. Remove disc brake.

Scheme 217

1. Remove cap bolts - 1 - and - 2

Scheme 218

1. Pull wheel bearing unit outward.

Pressing wheel hub out of 82 mm diameter wheel bearing housing

Press bearing inner race from hub.

1. Insert separator into of bearing inner race ring groove - arrow - , and pre-tension with spindle.

Note. Use commercially available separating device e.g. Kukko 15-17.

1. Press bearing inner race off from wheel hub.

With light weight wheel hubs, slide washer must be replaced. --> Slide washer, removing and installing

Pressing wheel hub into 82 mm diameter wheel bearing

1. When pressing on, thrust piece VW 511 must bear only against inner race.

Installing

Installation is in reverse order of removal.

Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms if vehicle is in curb weight position --> Wheel bearing, lifting to curb weight position

1. Drive axle, removing and installing --> «Drive axles, removing and Installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__drive-axles-removing-and-installing)

Wheel bearing housing (aluminum) - all wheel drive, removing and installing

Removing

1. Remove drive axle hex socket head bolt --> «Rear drive axle, servicing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Remove wheels.

1. Remove mounting bolts - 1 - from brake caliper.
2. Remove brake caliper and hang up on body.
3. Remove disc brake.

Scheme 219

1. Remove hex socket head bolt - 1 -.
2. Remove ABS wheel speed sensor - 2 - from wheel bearing housing.

Scheme 220

1. Remove bolt - 1 - for coupling rod.

Scheme 221

1. Remove bolt - A - for tie rod.
2. Mark installation position of eccentric washer for bolt - B -.
3. Remove bolt - B -.

Scheme 222

1. Remove bolt - 2 - for transverse link - 1 -.
2. Pull wheel bearing housing off drive axle.

Installing

Installation is in reverse order of removal.

Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at links if vehicle is in curb weight position --> Wheel bearing, lifting to curb weight position

Otherwise rubber mounting will be stressed, resulting in a reduced service life.

1. Drive axle, removing and installing --> «Drive axles, removing and Installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering__drive-axles-removing-and-installing)
2. Perform vehicle alignment --> «Wheel alignment»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Alignment must take place on a VW/Audi recommended alignment stand.

Characteristics

The light weight wheel hub is different from the conventional wheel hub - 1 - due to the slide washer - 2 - and sleeve.

The light weight wheel hub must only be used in conjunction with the corresponding wheel bearing.

Slide washer - 1 - should be replaced if deformed or damage during wheel bearing removal.

Slide washer, removing and installing

Special tools, testers and auxiliary items required

1. Assembly tool T40089/1

1. Press piece VW 473

1. Thrust plate VW 401

Slide washer, replacing

1. Carefully pry off slide washer - 1 - , e.g. with a screwdriver.
2. Position slide washer on wheel hub.

1. Install special tools as shown in illustration.

1. Press piece VW 473
2. Assembly tool T40089/1
3. Slide washer
4. Wheel hub
5. Thrust plate VW 401

1. Press slide washer off using assembly tool T40089/1 as shown in illustration up to wheel bearing hub radius.

Note. Slide washer must be pressed on up to wheel bearing hub radius.

Transverse link, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331
2. Torque wrench V.A.G 1332

Scheme 223

Note. Because of poor accessibility to inner bolt - 1 - when vehicle is resting on wheels, transverse link can only be removed when subframe is removed. Align vehicle after repair --> Wheel alignment .

Removing

1. Remove subframe --> «Subframe, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Mark eccentric bolt - 2 - to stub axle carrier/wheel bearing housing, e.g. with a felt-tip pen.
3. Separate connections - 1 - and - 2 -.

Installing

Note. Replace bolts and self-locking nuts --> Notes in exploded view diagrams at --> Part I, Subframe - front wheel drive . Do not interchange right and left parts. "R" or "L" is marked on back of transverse link.

Scheme 224

Location of transverse link to subframe

1. Loosely bolt transverse link - 2 - to subframe.
2. Lay a ruler or straight edge - 1 - flat against stabilizer bar mounting bracket - arrow -.
3. Position transverse link so that dimension a = 142 ± 1 mm.
4. Fasten transverse link to subframe in this position.

1. Attach stub axle carrier or wheel bearing housing to transverse link and tighten new nuts to 20 Nm. Note location of eccentric bolt - 2 -.
2. Install subframe --> «Subframe, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
3. Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at links if vehicle is in curb weight position --> «Wheel bearing, lifting to curb weight position»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Loosen connection - 2 - and retighten.

1. Perform vehicle alignment --> «Wheel alignment»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Alignment must take place on a VW/Audi recommended alignment stand.

Transverse link bracket, replacing

Special tools, testers and auxiliary items required

1. Thrust plate VW 401
2. Punch VW 412
3. Sleeve 2040
4. Impact sleeve 41 - 501

Scheme 225

Removing bonded rubber bushing

Scheme 226

Installing bonded rubber bushing

1. Press bracket on until ends project evenly on both sides.

Nut for securing transverse link to subframe, replacing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1332

Note. Replace nut for securing transverse link to subframe if damaged. Because of poor accessibility to inner bolt - 1 - when vehicle is resting on wheels, transverse link can only be removed when subframe is removed. Align vehicle after repair --> Wheel alignment .

Removing

1. Remove subframe --> «Subframe, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Separate connection - 1 -.
3. Swing transverse link upward out of subframe console.

Note. When installing cylinder bolt, ensure transverse link is not damaged.

Scheme 227

1. Install, for example, a cylinder bolt with hex socket head M12x1.5 x 20 (ET No. N902 268 01) - 1 - in nut - 2 - up to stop.

As an emergency solution, you can also use hex head bolt M12.1.5 x 20.

1. Turn cylinder screw more until damaged nut unscrews from subframe console.

Installing

Note. Replace bolts and self-locking nuts --> Notes in exploded view diagrams at --> Part I, Subframe - front wheel drive .

1. Insert transverse link in subframe console.

Scheme 228

1. Insert replacement nut - 2 - in subframe console using new combi-bolt - 1 -.
2. Tighten combi-bolt - 1 -.
3. Install subframe --> «Subframe, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
4. Perform vehicle alignment --> «Wheel alignment»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Alignment must take place on a VW/Audi recommended alignment stand.

1. Modified trapezoidal links are installed in Audi A4 with front or all wheel drive.
2. A mixed installation between old and new trapezoidal control arms in a vehicle is not permitted.

Old trapezoidal control arm version

New trapezoidal control arm version

Note. Measure vehicle after repair --> Wheel alignment .

Trapezoidal control arm, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331
2. Torque wrench V.A.G 1332

Removing

1. Remove underbody trim in front of trapezoidal control arm.

Convertible only

Scheme 229

1. Remove diagonal braces - 1 - and - 2 - --> «Diagonal braces»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Continued for all vehicles

1. Remove coil spring --> «Rear coil spring»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Vehicles with heavy duty suspension

1. Remove stone protection from trapezoidal control arm.

Continued for all vehicles

1. Disengage parking brake cable from bracket under trapezoidal control arm. Loosen bolts to do this.

1. Remove bolt - 1 - on vehicles with headlight range control.

Scheme 230

1. Remove speed sensor cable guide - 2 - «Speed sensor wire routing on trapezoidal control arm»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. Remove bolt - 1 -. Counterhold joint with open-end wrench.
3. Mark eccentric bolt - 5 - to subframe.
4. Loosen trapezoidal control arm (items 3 to 6).

Note. On vehicle with all wheel drive and with right trapezoidal control arm on vehicles with front wheel drive, subframe should be lowered slightly before removing bolts.

Vehicles with all-wheel drive

1. Remove drive shaft from rear final drive. --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive-0ar)
2. Secure drive shaft to body with wire.
3. Remove strut from wheel bearing housing.
4. Disengage parking brake cable at fuel tank.

1. Remove brake caliper. --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)
2. Remove right drive axle cover (remove right trapezoidal control arm).
3. Lower subframe slightly --> «Subframe, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Vehicles with front wheel drive, removing left trapezoidal control arm

1. Remove heat shield from body eccentric bolt and press to side.

Vehicles with front wheel drive, removing right trapezoidal control arm

1. Remove strut from wheel bearing housing.
2. Remove brake caliper. --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)
3. Lower subframe slightly --> «Subframe, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Continued for all vehicles

1. Remove trapezoidal control arm (items 3 to 6).

Note. When doing so, ensure subframe is held securely.

Installing

Replace bolts and self-locking nuts --> Notes in exploded view diagrams at --> Part I, Subframe - front wheel drive .

1. Install subframe --> «Subframe, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Install strut --> «Strut»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
3. Install brake caliper. --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)
4. Install drive shaft to rear final drive. --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive-0ar)

1. Install driveshaft shield.

Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at links if vehicle is in curb weight position --> Wheel bearing, lifting to curb weight position

1. Tighten threaded connections - 3 - , - 4 - and - 6 - --> «Part III, Trapezoidal control arm, transverse link, tie rod»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Tighten nut - 5 - (bring eccentric bolt into previous position).
3. Install speed sensor cable guide - 2 - «Speed sensor wire routing on trapezoidal control arm»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Tighten bolt - 1 -.

1. Install coil spring --> «Rear coil spring»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Engage parking brake cable in bracket.

1. Tighten bolt - 1 - on vehicles with headlight range control
2. Perform vehicle alignment --> «Wheel alignment»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Alignment must take place on a VW/Audi recommended alignment stand.

Vehicles with heavy duty suspension

1. Install stone protection and tighten bolts.

Convertible only

1. Install diagonal braces - 1 - and - 2 - --> «Diagonal braces»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Continued for all vehicles

1. Install underbody trim.

Subframe, removing and installing

Note. The procedure steps show you how you can remove the subframe as a complete unit (that is, with rear final drive, stub axle carrier/wheel bearing housing, trapezoidal control arm). Align vehicle after repair --> Wheel alignment .

1. Loosen collar bolt - arrow - only 90° on vehicle resting on wheels if you want to remove components that require removal of collar bolt.

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A

1. Spring compressor V.A.G 1752/1
2. Adapter V.A.G 1752/9
3. Spring holder A4, rear axle V.A.G 1752/16
4. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332
2. Bit XZN 18 T40027

Removing

Convertible only

1. Remove diagonal braces - 1 - and - 2 - --> «Diagonal braces»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Continued for all vehicles

1. Remove rear and side underbody trim in front of subframe.
2. Dismount tires.
3. Secure brake discs with a wheel bolt.
4. Remove rear portion of exhaust system. --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278884-S01497083522008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

1. Remove coil spring --> «Rear coil spring»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Remove strut from wheel bearing housing - 1 -.

Vehicles with heavy duty suspension

1. Remove stone protection from trapezoidal control arm.

Continued for all vehicles

1. Disengage parking brake cable from bracket under trapezoidal control arm. To do this, loosen bolts.

1. Remove brake caliper - arrows -. To do so, use socket insert T40027.

Note. Secure brake caliper to body with wire. Do not allow brake caliper to hang from brake line.

1. Remove speed sensor and cable guide «Speed sensor wire routing on trapezoidal control arm»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
2. On vehicles with headlight range control, remove connector from level control system sensor.

Vehicles with all-wheel drive

1. Remove drive shaft from rear final drive. --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive-0ar)
2. Secure drive shaft to body with wire.
3. Disengage parking brake cable at fuel tank.

1. Remove bolts - 2 - and remove strut.
2. Remove brake disc and brake disc cover.

Continued for all vehicles

Scheme 231

1. Position engine and transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 and a corresponding wooden block at subframe or final drive (Fig. for vehicles with front wheel drive).
2. Tighten band around subframe or final drive.

1. Remove subframe bolts - arrows -.

Vehicles with front wheel drive

1. Lay parking brake cable with brake caliper over transverse link.
2. Carefully lower subframe. Guide subframe so it does not shift.

Vehicles with all-wheel drive

1. Carefully lower subframe approx. 15 cm. Guide subframe so it does not shift.
2. Slide subframe left so that right parking brake cable with brake caliper can be laid over transverse link.

Note. Ensure brake hose is not stretched.

1. Slide subframe right so that left parking brake cable with brake caliper can be laid over transverse link.
2. Lower subframe.

Installing

Note. Replace bolts and self-locking nuts --> Notes in exploded view diagrams at --> Part I, Subframe - front wheel drive .

Installation of subframe occurs in reverse order of removal.

1. Center subframe over four bearing holes to body.
2. Install new subframe bolts and washers and tighten --> «Part I, Subframe - front wheel drive»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) , and (front wheel drive) or and (all wheel drive).

Vehicles with all-wheel drive

1. Install brake disc cover. --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)
2. Install brake disc and secure with wheel bolt.
3. Install drive shaft to rear final drive. --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive-0ar)
4. Install strut on body.

1. Engage parking brake cable at fuel tank.

Continued for all vehicles

1. Install and align exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278884-S01497083522008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF
2. Place headlight range control connector on level control system sensor.
3. Install speed sensor and cable guide «Speed sensor wire routing on trapezoidal control arm»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Secure brake caliper to stub axle carrier or wheel bearing housing. --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/a4/b7-2004-2009/remont/anti-locktraction-control/#brake-system)

1. Install parking brake cable with bracket below trapezoidal control arm and tighten bolts.

1. First tighten strut nut - 1 - to 20 Nm.
2. Install coil spring --> «Rear coil spring»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Only when you have loosed collar bolt

Always use a new collar bolt!

1. On vehicles with all wheel drive, install 5 wheel bolts hand tight and apply parking brake.
2. Tighten collar bolt to specified torque without additional turning (front wheel drive) or (all wheel drive).
3. Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at links if vehicle is in curb weight position --> «Wheel bearing, lifting to curb weight position»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
4. Tighten connection - 1 - , (front wheel drive) or (all wheel drive).

1. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

Only when you have loosed collar screw

1. Tighten collar screw with specified additional turning (front wheel drive) or (all wheel drive).

1. Install rear and side underbody trim.
2. Perform vehicle alignment --> «Wheel alignment»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Alignment must take place on a VW/Audi recommended alignment stand.

Vehicles with heavy duty suspension

1. Install stone protection and tighten bolts

Convertible only

1. Install diagonal braces - 1 - and - 2 - --> «Diagonal braces»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A with universal transmission mount V.A.G 1359/2
2. Torque wrench V.A.G 1331
3. Torque wrench V.A.G 1332

1. Foot pump with high pressure hose V.A.G 1389 A/1

If available in shop, hand pump V.A.G 1389/1 can also be modified for use as a foot pump.

To do so, use conversion kit V.A.G 1389/4.

Special tools, testers and auxiliary items required

1. Wheel bearing tool V.A.G 1459 B
2. Hollow piston cylinder HKZ-15 mit Druckstuck E-0-204-T hydraulisch
3. Tie bolt E-0-217+218
4. Special nut E-8-214

1. Press piece E-5
2. Press piece T40033/1
3. Support ring T40033/2
4. Tube T40033/3

1. Wheel hub support T40033/4
2. Press piece T40033/5
3. Wheel hub support T40033/6
4. Spindle T40034

1. Nut T40034/1
2. Nut T40034/2

Note. The same special tools and workshop equipment can be used to replace subframe mounting on vehicles with front and all wheel drive. The subframe does not have the usual bonded rubber bushings, but rather has hydraulic bushings. The bushings can only be removed and installed with the subframe lowered. Identify bushing location to subframe before removing.

Remove front or rear hydraulic bushings

1. Remove wheels.
2. Remove left and right coil spring --> «Rear coil spring»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 232

1. Only remove rear left/right underbody trim if front hydraulic mounting will be replaced.

1 - Left underbody trim

1. If present, remove diagonal braces - 1 - and - 2 - --> «Diagonal braces»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Only with rear hydraulic bushing

1. Remove stabilizer bar --> «Stabilizer bar, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Procedure for front and rear hydraulic bushings

1. Position engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 and a corresponding wooden block at subframe or final drive (Fig. for vehicles with front wheel drive).
2. Tighten band around subframe or final drive.

Note. If a front hydraulic bushing is to be replaced, only loosen front subframe bolts. If a rear hydraulic bushing is to be replaced, only loosen rear subframe bolts. If you loosen an additional front or rear subframe bolt, a vehicle alignment will be necessary after installation.

1. Loosen front or rear subframe bolts.
2. Carefully lower subframe approx. 5 cm.
3. Only remove subframe bolt where hydraulic mounting must be replaced.

Scheme 233

1. Mark location of hydraulic mounting - 1 - to subframe - 2 - , e.g. with a felt-tip pen (Fig. shows subframe on front wheel drive vehicle).

Arrow A: Driving direction

Arrows B and C: Marking

Scheme 234

1. Install special tools as shown in illustration.

1 - Nut T40034/1 or T40034/2

2 - Press piece T40033/1

3 - Support ring T40033/2

4 - Tube T40033/3

5 - Wheel hub support T40033/4

6 - Hollow piston cylinder HKZ-15

7 - Press piece E-5

8 - Special nut E-8-214

9 - Spindle T40034

10- Subframe

1. Pretension special tool.
2. Remove hydraulic bushing by operating pump.

Note. When removing hydraulic bushing with special tool wheel bearing tool V.A.G 1459 B , you must cut back.

Pull in front or rear hydraulic bushing

Front and hydraulic bushings are different. Ensure correct allocation when installing.

Hydraulic bushing must be installed in correct direction, note marking on subframe.

Scheme 235

1. Insert special tool with hydraulic bushing in subframe as shown.

Ensure correct location when inserting mount T40033/6.

1 - Nut T40034/1 or T40034/2

2 - Wheel hub support T40033/6

3 - Hydraulic mounting

4 - Press piece T40033/5

5 - Hollow piston cylinder HKZ-15

6 - Press piece E-5

7 - Special nut E-8-214

8 - Spindle T40034

9- Subframe

1. Pre-tension special tool with hydraulic bushing.
2. Completely coat hydraulic bushing with installation lubricant G 294 421 A1 -thin with water at a ratio of 1:100-.

1. Ensure ends of rubber beads on hydraulic bushing - 1 - align with markings - arrows B and C - on subframe - 2 -.

Arrow A - direction of travel

1. Pull in hydraulic pump to stop by operating pump.

Note. When pulling in hydraulic bushing with special tool V.A.G 1459 B you must cut back. Ensure hydraulic bushing does not tilt while it is being pulled in, otherwise outer ring could be damaged!

1. Raise subframe using engine/transmission jack V.A.G 1383 A.
2. Install new subframe bolts and washers and tighten and (front wheel drive) or and (all wheel drive).

Only rear hydraulic bushing

1. Install stabilizer bar --> «Stabilizer bar, removing and installing»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Procedure for front and rear hydraulic bushings

1. If present, install diagonal braces - 1 - and - 2 - --> «Diagonal braces»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
2. Install right and left underbody trim.
3. Install left and right coil spring --> «Rear coil spring»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .
4. Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide

1. Perform vehicle alignment if more than 2 hydraulic bushing bolts were loosened --> «Wheel alignment»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Alignment must take place on a VW/Audi recommended alignment stand.

Scheme 236

1 - Combi-bolt

2 - Rear differential mount

3 - Hex nut

4 - Subframe

5 - Hex nut

6 - Combi-bolt

7 - Final drive support

8 - Washer

9 - Rear crossmember

10 - Combi-bolt

11 - Combi-bolt

12 - Rear differential bushing web alignment

13 - Washer

Rear differential bushing, replacing

Special tools, testers and auxiliary items required

Scheme 237

1. Assembly tool T40032

1. Engine/transmission jack V.A.G 1383 A
2. Torque wrench V.A.G 1331
3. Torque wrench V.A.G 1332

Removing

1. Place engine/transmission jack V.A.G 1383 A with universal transmission support 1359/2 under rear final drive and secure rear final drive.

Scheme 238

1. Remove bolts from transmission supports and rear final drive - arrows -.
2. Remove drive shaft from rear final drive. --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive-0ar)
3. Secure drive shaft to body with wire.
4. Remove combi-bolts on differential bushing.

1. Remove rear crossmember/rear final drive bolts.

Note. Lower rear final drive enough so that upper bolt can be removed.

1. Remove rear crossmember downward.

Scheme 239

1. Use Removal And Assembly Tool T40032 as shown in illustration and remove differential bushing.

Note. To provide a better illustration, subframe is shown removed.

Installing

1. Align differential bushing as shown on.

Scheme 240

1. Use Removal And Assembly Tool T40032 as shown in illustration and remove differential mount - arrow -.

Note. Installation device from front. Bearing outer race flush with sleeve on subframe.

1. Place rear crossmember on rear final drive and tighten combi-bolts
2. Fasten rear crossmember with subframe.
3. Fasten front transmission support to rear final drive
4. Install drive shaft to rear final drive. --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/a4/b7-2004-2009/remont/differentials-drive-axles/#rear-final-drive-0ar)

1. Remove engine/transmission jack V.A.G 1383 A.

The three-part tie rod (old version) is replaced by a one-piece tie rod (new version) with or without stone protection.

A mixed installation of a three-piece and a one-piece tie rod on one vehicle is not permitted.

A mixed installation of tie rod (new version) with old stone impact protection (old version) or vice versa is not possible.

Stone protection 8E0 501 561 (old version) is now offered as a replacement part on finished vehicles with heavy duty suspension.

Tie rod, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1332

Note. Align vehicle after repair --> Wheel alignment .

Removing

1. Remove tire.
2. Remove coil spring --> «Rear coil spring»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 241

1. Remove threaded connections - 1 - and - 2 - and remove tie rod.

Installing

Note. Replace bolts and self-locking nuts --> Notes in exploded view diagrams at --> Part I, Subframe - front wheel drive .

1. First tighten threaded connections nuts - 1 - and - 2 - only to 20 Nm.
2. Install coil spring --> «Rear coil spring»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

1. Tighten threaded connections - 1 - and - 2 - and
2. Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at links if vehicle is in curb weight position --> «Wheel bearing, lifting to curb weight position»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering)
3. Perform vehicle alignment --> «Wheel alignment»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Alignment must take place on a VW/Audi recommended alignment stand.

Tie rod (three-piece version) stone protection 8E0 501 561 (old version), removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1410

Note. Tie rod stone protection suspension is only installed on vehicles with heavy duty suspension. Stone protection 8E0 501 561 (old version) can only be installed on vehicles with a three-piece tie rod (old version).

Stone protection, replacing with tie rod removed

Scheme 242

1. Loosen bolts - 2 -.
2. Slide clamping parts - 1 - inward.
3. Unclip stone protection from tie rod.

Installation is in reverse order of removal.

Torque specification item 2: 5 Nm

Stone protection, replacing with tie rod installed

Removing

1. Cut stone protection with a knife in threaded connection area at trapezoidal control arm. Do not damage tie rod.

1. Loosen bolts - 2 -.
2. Slide clamping parts - 1 - inward.
3. Unclip stone protection from tie rod.

Installing

Scheme 243

1. Cut in new stone protection at top - A -.
2. Slide clamping parts - 1 - inward.
3. Clip stone protection onto tie rod.
4. Slide clamping parts - 1 - outward and tighten bolts - 2 - to 5 Nm.

Tie rod (one-piece version) stone protection (new version), removing and installing

Note. Tie rod stone suspension is only installed on vehicles with heavy duty suspension.

Stone protection, replacing with tie rod removed

Scheme 244

1. Press clips - 1 - forward in direction of travel out of stone protection - 2 -.
2. Unclip stone protection - 2 - from tie rod - 3 -.

Installation is in reverse order of removal.

When installing stone impact protection, ensure it engages correctly with tie rod.

Stone impact protection, replacing with tie rod installed

Note. Replacement of stone protection on right side of vehicle is described and shown in illustration.

Removing

1. Cut stone protection with a knife in threaded connection area at trapezoidal control arm/tie rod. Do not damage tie rod or other suspension components.

Scheme 245

1. Press clip - 3 - forward in direction of travel out of stone protection - 2 -.
2. Press clip - 1 - forward in direction of travel out of stone protection - 2 - until head of clip rests on trapezoidal control arm.

4 - Tie rod

Scheme 246

1. Cut clip head - 1 - at --> area marked in illustration. Do not damage any other suspension components when doing this.

2 - Tie rod

3 - Stone protection plate

1. Pull rest of clips - 1 - back in direction of travel out of stone protection.
2. Unclip stone protection from tie rod.

Installing

Scheme 247

1. Cut new stone protection for right side at markings - A - and for left side at markings - B -.
2. First insert stone protection on interior side (side facing center of vehicle), then on exterior side.

Scheme 248

1. File clip off about 2 mm on interior side at both marks - arrows -.

Scheme 249

1. Press filed clip from behind in direction of - arrow - on vehicle interior side through tie rod and stone impact protection.
2. Clip stone impact protection onto tie rod. Ensure stone protection engages correctly.

1. Press clip - 1 - and - 3 - back in direction of travel in stone protection - 2 -.

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

Removing

1. Remove rear underbody trim.

Convertible only

1. Remove rear diagonal brace --> «Diagonal braces»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Vehicles with exhaust system with 2 rear mufflers

1. Remove rear portion of exhaust system. --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278884-S01497083522008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

Vehicles with heavy duty suspension

1. Remove stone protection from trapezoidal control arm.

Continued for all vehicles

Scheme 250

1. Remove bolts - 1 -.
2. Remove bolts - 2 -. Counterhold joint with open-end wrench.
3. Remove bolts - 3 -.
4. Remove stabilizer with bushing.

Installing

Scheme 251

1. Rubber bushing must rest on stabilizer bar collar - arrow -.

1. Install bolts - 3 - and only hand tighten for the time being.
2. Install and tighten bolt - 2 -.
3. Install and tighten bolt - 1 -.
4. Place vehicle on wheels and bounce several times.

1. Tighten bolts - 3 - to specified torque.

Vehicles with heavy duty suspension

1. Install stone protection and tighten bolts

Vehicles with exhaust system with 2 rear mufflers

1. Install and align exhaust system --> 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 26 EXHAUST SYSTEM, EMISSION CONTROLS for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278885-S34607538342008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-278884-S01497083522008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

Convertible only

1. Install rear diagonal brace --> «Diagonal braces»(/audi/a4/b7-2004-2009/remont/axle-shafts/#suspension-wheels-steering) .

Continued for all vehicles

1. Install rear underbody trim.

Stabilizer bushings, replacing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

Removing

1. Remove bolt - 1 -.
2. Remove clamp - 2 - and rubber bushing - 3 -.

Installing

1. Rubber bushing must rest on stabilizer bar collar - arrow -.
2. Only hand-tighten bolts - 1 - for the time being.
3. Place vehicle on wheels and bounce several times.
4. Tighten bolts - 1 -.

Coupling rod for stabilizer bar, removing and installing

Removing

1. Remove wheel.

1. Remove bolts - 1 -.
2. Remove bolts - 2 -. Counterhold joint with open-end wrench.
3. Remove connecting link.

Installing

Installation is in reverse order of removal.

Torque specifications --> Part VI, Stabilizer bar

Front or rear diagonal braces, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1332

Front and rear diagonal braces are only installed in the convertible.

Removing

1. Remove front underbody trim before removing front diagonal braces. --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

1. Remove rear underbody trim before removing rear diagonal braces - 1 -. --> «66 EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) «66 - EXTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET