Subframe, removing and installing Audi S4 B7

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/s4/b7-2004-2008/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»(ref-278881-S12387190922008020700000) 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»(ref-278883-S25168432662008020700000) 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»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

1. Remove coil spring --> «Rear coil spring»(/audi/s4/b7-2004-2008/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/s4/b7-2004-2008/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/s4/b7-2004-2008/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/s4/b7-2004-2008/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/s4/b7-2004-2008/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/s4/b7-2004-2008/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»(ref-278881-S12387190922008020700000) 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»(ref-278883-S25168432662008020700000) 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»(/audi/s4/b7-2004-2008/remont/cooling-fan/#42l-v8-5v-engine-mechanical-engine-codes-bhf) 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/s4/b7-2004-2008/remont/axle-shafts/#suspension-wheels-steering)
4. Secure brake caliper to stub axle carrier or wheel bearing housing. --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/s4/b7-2004-2008/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/s4/b7-2004-2008/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/s4/b7-2004-2008/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/s4/b7-2004-2008/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/s4/b7-2004-2008/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/s4/b7-2004-2008/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/s4/b7-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .

Only with rear hydraulic bushing

1. Remove stabilizer bar --> «Stabilizer bar, removing and installing»(/audi/s4/b7-2004-2008/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/s4/b7-2004-2008/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/s4/b7-2004-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Install right and left underbody trim.
3. Install left and right coil spring --> «Rear coil spring»(/audi/s4/b7-2004-2008/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/s4/b7-2004-2008/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