Suspension - Front Audi S6 C5

DESCRIPTION

Front suspension is a MacPherson strut independent type suspension, with multiple links that connect strut to body and wheel bearing housing. (Scheme 1) This article covers vehicles equipped with conventional gas charged struts.

Various suspensions are offered as options. Coil spring/shock absorber combination is documented through the corresponding part number on vehicle data sticker. These are identified by Part numbers. Suspension version installed in vehicle is indicated by factory weight code on Vehicle Data Sticker (arrow). (Scheme 2) Vehicle Data Sticker is located at rear in spare tire well, and in Maintenance manual. Standard suspension installed is 1BA. For optional suspensions, see VEHICLE SUSPENSION IDENTIFICATION table.

VEHICLE SUSPENSION IDENTIFICATION

Scheme 1

Scheme 2

SHOCK ABSORBER LEAKS

Shock absorbers are often thought to be leaking and are unnecessarily replaced. Tests on test stands and on vehicles have determined that very often replacement was not necessary. Slight oil escape ("sweating") at the piston rod seal is not a legitimate reason to replace a shock absorber. An oil moistened shock absorber is OK under the following conditions.

1. Oil excretion (shaded area in illustration) is visible, but dull, matte and possibly dry due to dust.
2. Oil escape extends from upper strut connection (piston rod oil seal) no further than the lower spring seat (arrow).

Note. Minor oil excretion is advantageous since the piston rod oil seal gets lubricated, which increases service life. This is true for front and rear shock absorbers.

SHOCK ABSORBERS (REMOVED FROM VEHICLE)

Malfunctioning shock absorbers are noticeable during driving due to loud rattling noises caused by wheel bouncing, particularly on rough driving surfaces. They can also be externally identified by large oil loss.

Note. Shock absorbers are maintenance-free, shock absorber oil cannot be refilled.

A shock absorber that has been removed from the vehicle can be checked by hand as follows. Compress shock absorber by hand. The piston rod must move evenly and smoothly over the entire stroke. Release the piston rod. For shock absorbers with sufficient gas pressure, piston rod returns to initial position on its own.

If this is not the case, the shock absorber does not necessarily have to be replaced. As long as a large amount of oil has not escaped, the shock will continue to function same as a conventional shock absorber.

The shock absorption function is fully present without gas charge as long as a large amount of oil has not escaped. However noisy operation can worsen.

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

Note. See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

BALL JOINT CHECKING

Raise and support vehicle. Inspect ball joints for damaged rubber boots and vertical ball joint play. Procedure and wear tolerance are not available from manufacturer. When servicing ball joints, mark ball joint mounting position before removing to avoid changing camber setting.

BONDED RUBBER BUSHINGS

Bonded rubber bushings can only be turned to a limited extent. The bolted connections on suspension links should only be tightened when vehicle is standing on the ground.

WHEEL BEARING

Wheel bearing is pressed into bearing housing. No adjustment is required.

LONGMEMBER THREAD REPAIR

Servicing thread in weld nuts in longmember is possible under certain circumstances

1. Servicing must only be performed once per thread.
2. If secondary servicing is required, the weld nut must be replaced.

Thread insert must have same length as thread in body.

THREAD REPAIR - SUBFRAME MOUNT TO CHASSIS

Damaged threads can be repaired using wire inserts (Heli-coil). Wire inserts must have a zinc-nickel coating. Shavings that remain in chassis must be embedded in wax.

WELDING SUSPENSION PARTS

Load bearing components and parts of the suspension must not be welded or straightened.

WHEEL BEARINGS

Vehicles without drive axle must not be moved, or wheel bearing will be damaged. If vehicle does have to be moved, always note the following points

1. Install an outer joint in place of the drive axle.
2. Tighten outer joint to 85 ft. lbs. (115 N.m) for M14 bolt, or 140 ft. lbs. (190 N.m) for M16 bolt.

GUIDE LINK (ALUMINUM WHEEL BEARING HOUSING)

Note. During installation, replace all bolts and nuts that are removed.

Scheme 3

1. Raise and support vehicle. Remove wheel assembly.
2. Remove bolts securing brake caliper, and wire caliper aside. Secure brake disc rotor, by installing a wheel lug bolt.
3. Remove guide link ball joint nut. Counter-hold joint bolt using a 4 mm hex socket insert. Using Press Tool (T40010) or equivalent, press guide link from wheel bearing housing. Be careful not to damage CV boot. (Scheme 3)
4. Remove bolt (1) securing lower guide link. (Scheme 4) Lower subframe in back, if necessary. Remove bolts (2 and 3) securing guide link.
5. To install, reverse removal procedure. Tighten all bolts and nuts to specification. Parts that have bonded rubber bushing should be torqued only when vehicle is standing on ground. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).
6. Check wheel alignment. See «SPECIFICATIONS & PROCEDURES»(/audi/s6/c5-1999-2004/remont/wheel-alignment/#specifications-procedures) article in WHEEL ALIGNMENT.

GUIDE LINK & BUSHINGS (STEEL WHEEL BEARING HOUSING)

Note. Bonded rubber bushings can only be turned to a limited extent. Bolted connections should only be torqued to specification once vehicle is resting on its own weight.

Note. During installation, replace all bolts and nuts that are removed.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

1. Raise and support vehicle. Remove wheel assembly.
2. Remove guide link ball joint nut. Using Press Tool (3287A) or equivalent, press guide link from wheel bearing housing. Be careful not to damage CV boot. (Scheme 5)
3. Remove guide link-to-subframe nut and bolt. (Scheme 6) Remove guide link. Lower subframe if necessary.
4. Mount guide link in soft jawed vise. Using Bushing Remover/Installer Kit (3346, 3347 & 3301) or equivalent, remove and install bushings as shown in illustrations. (Scheme 7)and (Scheme 8).
5. Installation is reverse of removal procedure. Tighten all bolts and nuts to specification. Parts that have bonded rubber bushing should be torqued only when vehicle is standing on ground. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).
6. Check wheel alignment. See «SPECIFICATIONS & PROCEDURES»(/audi/s6/c5-1999-2004/remont/wheel-alignment/#specifications-procedures) article in WHEEL ALIGNMENT.

Scheme 8

1. Raise and support vehicle. Remove wheel assembly. On vehicles equipped with headlight vertical aim control, disconnect coupling rod from vehicle level sensor. (Scheme 24)
2. Remove clip (1) with pliers. (Scheme 9) This clip does not have to be reused. Remove nut (2) and hex bolt, and lift out both links from wheel bearing housing.
3. To avoid damaging steering rack boot, cover boot with Protective Sleeve (893 512 137) or equivalent.
4. To unscrew hex bolt from suspension strut/track control link, you must detach guide link from wheel bearing housing. Use 4 mm socket wrench to hold joint bolt, if necessary. Unscrew nut from joint bolt of guide link, then press off joint bolt. Be careful not to damage CV boot in the process! (Scheme 5)
5. Remove ABS wheel speed sensor from wheel bearing housing.
6. Unscrew hex bolt (1) from suspension strut/track control link. (Scheme 10) Swing wheel bearing housing away to the side.
7. Unscrew mounting bracket hex bolts (1) in plenum chamber. (Scheme 15) Remove suspension strut with mounting bracket. Be careful not to damage CV boot in the process!
8. Place strut assembly in a soft jawed vise. Remove bolts securing both links. (Scheme 11) Remove nuts securing mounting bracket. Remove bracket.
9. To replace mounting bracket bushings, refer to illustrations. (Scheme 12)- (Scheme 14).

Scheme 9

Scheme 10

Scheme 11

1. Install strut assembly so that hole in lower spring seat faces inside of vehicle. See arrow in (Scheme 10).
2. Install mounting bracket to suspension strut in correct position. (Scheme 16)
3. Install upper links to mounting bracket using NEW nuts and bolts. Align links to mounting bracket in specified position. (Scheme 17) With upper links in correct, position, final tighten link-to-mounting bracket bolts. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).
4. Insert suspension strut with mounting bracket into suspension strut tower. Ensure washers are correctly seated. Tighten strut tower bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).
5. Install lower strut assembly-to-track control link nut and bolt. Remove any adhesive remaining on thread of joint bolt. Finger tighten fasteners only. Final tighten lower strut mounting bolt after vehicle is resting on ground in normal ride height position.
6. Insert both upper links into wheel bearing housing. Press upper links down as far as possible when tightening nuts!
7. Insert cable of ABS wheel speed sensor into bracket on brake caliper.
8. Check wheel alignment. See «SPECIFICATIONS & PROCEDURES»(/audi/s6/c5-1999-2004/remont/wheel-alignment/#specifications-procedures) article in WHEEL ALIGNMENT.

SEPARATING UPPER LINKS (CONTROL ARMS) FROM WHEEL BEARING HOUSING

Note. This procedure applies to steel housing.

Note. This procedure is only necessary if the hex bolt for the connections between the upper control arms and the wheel bearing housing cannot be removed.

Scheme 12

Scheme 13

1. Raise and support vehicle. Remove wheel.
2. Disconnect ABS speed sensor wiring from retainer on brake caliper. Remove nut from upper control arm retaining bolt in wheel bearing housing (1). (Scheme 18) Do NOT loosen other bolts (3 or 4) in upper portion of wheel bearing housing. (Scheme 26)
3. Spread wheel bearing housing using Press Tool (VAS 6085), or equivalent. (Scheme 19) Position body tool on wheel bearing housing so recesses engage beneath joints of links.

Scheme 14

1. Raise and support vehicle. Remove engine sound proofing panel. Remove upper nut from coupling link (1) from left and right sides of stabilizer bar. (Scheme 20)
2. Remove stabilizer bar bracket bolts. Remove stabilizer bar.
3. When installing note that arrow on coupling link points to front of vehicle. On coupling with rubber bushings, ensure that spacing disc "A" is installed in proper position on stabilizer bar. (Scheme 23) When installing new bushings, do not use grease to mount bushings. Always replace bracket bolts with NEW.
4. To finish installation, reverse remaining installation procedure. Tighten all other bolts and nuts to specification. Parts that have bonded rubber bushing should be torqued only when vehicle is standing on ground. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).

Scheme 15

Scheme 16

Scheme 17

Scheme 18

1. Working under hood, remove plenum chamber/battery cover. Raise and support vehicle. Remove front wheel. On vehicles equipped with headlight vertical aim control, disconnect coupling rod from vehicle level sensor. (Scheme 24)
2. Working under hood, remove rubber grommets in plenum. (Scheme 25) Working through holes in body, remove upper strut mount bolts. Do not damage surface protection on brake lines when removing suspension strut nuts. Pull ABS wheel sensor cable out of bracket on brake caliper.
3. Remove upper control arm-to-wheel bearing housing nut (1). (Scheme 26)
4. Remove hex bolt and lift out control arms. Swing wheel bearing housing towards rear of vehicle. If upper control arms will lift out easily, see «SEPARATING UPPER LINKS (CONTROL ARMS) FROM WHEEL BEARING HOUSING»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__separating-upper-links-control-arms-from).
5. To unscrew hex bolt from suspension strut/track control link, you must detach guide link from wheel bearing housing. Use 4 mm socket wrench to hold joint bolt, if necessary. On vehicles with an aluminum wheel bearing housing be careful removing and installing guide link. Unscrew guide link nut from joint bolt, then press off joint bolt. Be careful not to damage CV boot in the process. Using Press Tool (3287A) or equivalent, press guide link from wheel bearing housing. (Scheme 5)
6. Remove lower strut assembly-to-track control link nut and bolt (1). (Scheme 27) Being careful not to damage CV boot, remove strut assembly from vehicle.

Scheme 19

Scheme 20

Scheme 21

Scheme 22

1. Clamp Suspension Strut Mount (VAG 1752/2) into vise. Clamp suspension strut into Suspension Strut Mount (VAG 1752/2) at clevis. (Scheme 28) Compress coil spring with Spring Compressor (VAG 1752/1) and Adapters (VAG1752/7) until upper spring retainer is free. Using Socket Wrench Insert (3353) remove piston rod nut. Counter-hold piston rod as necessary.
2. Slowly release tension on spring and remove upper strut mount, mounting bracket and coil spring. Remove protective cap, lower spring support and lower spring plate. Use a plastic hammer to loosen and remove lower spring plate. (Scheme 29)
3. Remove old strut from strut mount. Place new strut into strut mount. Install lower spring retainer. Ensure that hole in spring retainer is installed properly. (Scheme 30) Install lower spring base, protective cap and coil spring. Verify that coil spring rests against stop.
4. Install top spring seat, washer, and shock absorber mount. Adjust angle scale of Clamping Device (1752/2) to zero. Bring upper spring seat into 11° position using Adjusting Gauge (1752/8). (Scheme 31) On adjusting gauge, the 11° setting has "left front" or "right front" markings, ensure that left and right side 11° positions of spring seat are symmetrical. (Scheme 32)
5. Top end of coil spring must rest against stop of top spring washer. Tighten NEW piston rod nut to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications). If coil spring is correctly installed, top and bottom spring seats should be parallel to one another.
6. Remove strut assembly from strut mount.

Scheme 23

Scheme 24

Installation

1. Install strut assembly so that hole in lower spring seat faces inside of vehicle. See arrow in (Scheme 10). Install lower strut assembly-to-track control link nut and bolt. Finger tighten fasteners only.
2. Bonded rubber bushings can only be turned to a limited extent. The suspension strut/track control link bolt connection should only be tightened when vehicle is standing on ground. Use NEW nut.
3. Insert upper links (control arms) in wheel bearing housing and tighten NEW nuts. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).
4. Press upper links down as far as possible when tightening! Tighten nut on joint bolt. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications). Use 4 mm socket wrench to hold joint bolt, if necessary.
5. Insert cable of ABS wheel speed sensor into bracket on brake caliper. Screw on NEW nuts for suspension strut and tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications). Be careful not to damage surface of brake lines! Put rubber grommets in plenum. Mount wheel and tighten to specification.
6. Check wheel alignment. See «SPECIFICATIONS & PROCEDURES»(/audi/s6/c5-1999-2004/remont/wheel-alignment/#specifications-procedures) article in WHEEL ALIGNMENT.

Removal & Installation

Remove strut assembly and disassemble. See STRUT ASSEMBLY .

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

1. Support engine with supporting device. (Scheme 33)
2. Remove hubcap, for light-alloy wheels pull off center cap (use pulling hook in vehicle tools). Remove wheels.
3. Remove sound-deadening pan.
4. Before loosening subframe, special tool 3393 must be used to check whether holes (1) and (2) line up. (Scheme 34) If this is not the case, an axle alignment must be performed after the subframe is installed.
5. In order not to damage the joints of the upper links, it is necessary to use (engine/transmission jack for example), to brace against too strong rebound. Unscrew hex nuts (3). (Scheme 35) Remove hex bolt (1) and guide link to subframe.
6. Unscrew hex bolts (1). (Scheme 36) Remove hex bolts (2) and lower subframe in back.
7. Pull out hex bolts of guide links. Pull guide links out of subframe. Unscrew hex bolt (5). (Scheme 35)
8. On vehicles equipped with headlight vertical aim control, disconnect coupling rod from vehicle level sensor. (Scheme 24)
9. Remove hex nut (2), track control link to subframe, and remove hex bolt. (Scheme 35)
10. Pull cable of ABS wheel speed sensor out of bracket on brake caliper.
11. Pull track control links out of carrier. (Scheme 37)
12. Unscrew hex nuts (3) and (4). (Scheme 36) Remove hex bolts (5). Loosen hex bolt (6) until subframe can be removed. (Scheme 36)

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

1. Pull out rear bonded rubber bushings. Make sure that 3372 installation device is securely seated and cannot tilt off. (Scheme 38)
2. Pulling out bonded rubber bushings. All bonded rubber bushings on the subframe are pulled out with the same tool. (Scheme 39)
3. Assembly preparation for pulling in bushing for subframe. Apply 3372 installation device and insert 3372/2 split bushings. (Scheme 40)
4. The bonded rubber bushings must be aligned with a long rectangular tube or straightedge. Angle A = 90 +/- 5 degrees. (Scheme 41) Clamp subframe in vise only with protective pads!
5. Pull in rear bonded rubber bushings using G 294 421 A1 installation lubricant. Pull in bushing (A) until 3372/1 thrust piece is flush with upper edge of 3372 installation device. (Scheme 42) Remove 3372 installation device and 3372/2 split bushings upward. Insert 3372/2 split bushings between 3351/4 bridge and subframe. see scheme 43 Pull in bushing until it stops. If paint on surface of unit should be damaged, the surface should be protected against corrosion.
6. Pull in front bonded rubber bushings using G 294 421 A1 installation lubricant. Insert 3372/2 split bushings in 3372 installation device. (Scheme 40) Pull in bushing (A) until 3372/1 thrust piece is flush with upper edge of 3372 installation device. (Scheme 43)
7. Raise pipe (3372) and remove bushing (3372/2). (Scheme 44) Replace bridge (3351/4) by thrust piece (3351/1) and then pull in bushings until they stop. If paint on surface of unit should be damaged, the surface should be protected against corrosion.

Note. Replace all bolts and nuts.

Scheme 38

1. Insert subframe and thread hex bolts (5) and (6) partially. (Scheme 36) Start hex bolt for suspension strut to track control link.
2. Guide bearing and guide links into subframe. Put bolts in outside holes (arrows). (Scheme 45)
3. Holes (1) and (2) of subframe and hole (3) of aluminum bracket must line up on both sides. Fixing subframe in this way is a substitute for a subsequent axle alignment only when: Subframe has been removed and reinstalled; holes (1) and (2) line up before repair.
4. Start hex bolts (1) and (2). (Scheme 36) Start hex nuts (3) and (4). Protect drilled hole in body for special tool 3393 against corrosion.
5. Turn hex bolts (2) and (5) to 81 ft. lbs. (110 N.m) plus an additional 1/4 turn. (Scheme 36) Tighten hex bolts (6) to 52 ft. lbs. (70 N.m). Tighten hex bolt (1). Note different bolt versions. See «BOLT VERSIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__bolt-versions). Tighten hex nuts (3) and (4) to 30 ft. lbs. (40 N.m).
6. Tighten hex bolts for guide link. Suspension strut to track control link. Tighten coupling bolts to stabilizer bar using NEW ribbed nuts. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications)
7. Insert cable of ABS wheel speed sensor into bracket on brake caliper. Mount wheels.
8. Lower vehicle and final tighten bolts/nuts on bonded rubber bushings.

Scheme 39

Scheme 40

Scheme 41

1. Raise and support vehicle. Remove wheel assembly. On vehicles equipped with headlight vertical aim control, disconnect coupling rod from vehicle level sensor. (Scheme 24)
2. Secure brake disc using a wheel bolt. Detach brake caliper and fasten to body without disconnecting brake line. Protect CV boot from damage (e.g. place a leather cloth in between).
3. Be sure that both lever arms are parallel to each other during greatest applied pressure, adjust if necessary. Use a jack to compress front suspension. Remove ball joint nut and press ball joint out of track control link conical seating. (Scheme 47) For safety reasons, put collar nut back on joint bolt of track control link with about 4 turns, so that it is flush.
4. To remove suspension strut-to-track control link, guide link must be detached from wheel bearing housing. Unscrew nut from guide link ball joint in wheel bearing housing. Use 4 mm wrench to hold ball joint, if necessary.
5. For safety reasons, put collar nut back on ball joint of guide link with about 4 turns, so that it is flush. Be sure that both lever arms are parallel to each other during greatest applied pressure, adjust if necessary (use jack to compress suspension strut). Press guide link ball joint from wheel bearing housing. (Scheme 48) Be careful not to damage CV boot in the process!
6. Unscrew hex bolt (1). (Scheme 49) Unscrew ribbed nuts (2) and (3), and take off coupling. Unscrew hex bolt (4). Remove track control link.

Installation (Aluminum Wheel Bearing Housing)

Note. Bonded rubber bushings can only be turned to a limited extent. The bolted connections on the suspension links should therefore only be tightened when the vehicle is standing on the ground at normal ride height.

1. Replace all bolts and nuts before installation.
2. Put in new hex bolt (4) and new hex nut. (Scheme 49) Final tighten to specification with vehicle standing on ground at normal ride height. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).
3. Tighten nuts on ball joint bolts (guide link/track control link) to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications). Tighten hex nut (1) to specification with vehicle standing on ground at normal ride height. (Scheme 49) See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).
4. The arrow on the stabilizer bar coupling points in the direction of travel. Tighten nut (2) and (3) to specification. (Scheme 49) See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).
5. Mount brake disc, screw on brake caliper. Install wheels and tighten lug bolts. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).

Scheme 42

Scheme 43

1. Remove hubcap, for light-alloy wheels pull off center cap (use pulling hook in vehicle tools). Remove wheel.
2. On vehicles equipped with headlight vertical aim control, disconnect coupling rod from vehicle level sensor. (Scheme 24)
3. Protect CV boot from damage (e.g. place a leather cloth in between). Unscrew nut from ball joint bolt of track control link, then press joint bolt off conical seating. (Scheme 50)
4. To unscrew hex bolt from suspension strut/track control link, you must detach guide link from wheel bearing housing. Unscrew nut from ball joint bolt of guide link. Use 4 mm socket wrench to hold joint bolt, if necessary. Press off ball joint from wheel bearing housing. (Scheme 51) Be careful not to damage CV boot in the process.
5. Unscrew hex bolt (1). (Scheme 52) Unscrew ribbed nuts (2) and (3), and take off coupling.
6. In order not to damage the joints of the upper links, it is necessary to use engine/transmission jack (VAG1383-A, for example) to brace against too strong rebound. Unscrew hex bolt (4). (Scheme 52) Remove track control link.

Replacing Track Control Link Bushings (Steel Wheel Bearing Housing)

For removal and installation procedures (Scheme 53)- (Scheme 55).

Scheme 44

Scheme 45

Scheme 46

Installation (Steel Wheel Bearing Housing)

1. Replace all bolts and nuts. Only use the outside holes (arrow). (Scheme 45)
2. Put in new hex bolt (4) and new hex nut. (Scheme 52) Final tighten with vehicle at normal ride height.
3. Install and tighten ball joint nuts on guide link and track control link. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).
4. Install stabilizer bar coupling on track control link. The arrow on coupling points in direction of travel. Tighten nut (2). (Scheme 52) See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).
5. On vehicles equipped with headlight vertical aim control, connect coupling rod from vehicle level sensor. (Scheme 24)
6. Continue installation in reverse of removal procedure. Final tighten all bonded rubber bushings with vehicle resting on ground (normal ride height).

Scheme 47

Scheme 48

1. Remove mounting bracket. See «MOUNTING BRACKET»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front).
2. Mount strut assembly in vise. Remove control arms from mounting bracket. (Scheme 56)
3. Mount upper control arm in soft jawed vise. Using Bushing Remover/Installer Kit (3348 & 3301) or equivalent, pull bushing from control arm. (Scheme 57)
4. Install bushing to control arm. Check bushing installation position. (Scheme 58)
5. Install upper control arms to mounting bracket. Ensure control arms are mounted in specified position. (Scheme 59) Reinstall mounting bracket. Tighten all bolts and nuts to specification. Parts that have bonded rubber bushing should be torqued only when vehicle is standing on ground. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).

Scheme 49

WHEEL BEARINGS (STEEL WHEEL BEARING HOUSING REMOVED)

Note. Wheel bearing MUST be replaced if removed, as removal will damage bearing. During any removal and installation procedure, if axle nut/bolt is removed or installed, do so with vehicle resting on floor at full curb weight. Always replace axle shaft self-locking nut/bolt with NEW.

Removal & Installation (Steel Wheel Bearing Housing Removed From Vehicle)

Remove wheel bearing housing. See WHEEL BEARING HOUSING. To replace wheel bearing with wheel bearing housing removed from vehicle, use following illustrations. (Scheme 60)- (Scheme 65).

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

WHEEL BEARINGS (STEEL WHEEL BEARING HOUSING ON VEHICLE)

Note. This procedure applies to vehicles equipped with steel wheel bearing housing only.

Note. Wheel bearing MUST be replaced if removed, as removal will damage it. During any removal and installation procedure, if axle nut/bolt is removed or installed, do so with vehicle resting on floor at full curb weight. Always replace axle shaft self-locking nut/bolt with NEW parts when removed.

Removal & Installation (Steel Wheel Bearing Housing Installed In Vehicle)

Wheel bearing can be replaced without removing wheel bearing housing from vehicle. Using Wheel Bearing Tool (VAG1459B with VAG1459B/2 and VAG1389A/1) or equivalent, follow manufactures instructions to remove and install wheel bearing. To replace wheel bearing, use following illustrations. (Scheme 66)- see scheme 71.

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Removal & Installation (Aluminum Wheel Bearing Housing)

Note. On vehicles equipped with aluminum housing, housing only has to be removed to the point where drive axle can be removed from hub.

Note. During any removal and installation procedure, if axle nut/bolt is removed or installed, do so with vehicle resting on floor at full curb weight. Always replace axle shaft self-locking nut/bolt with NEW.

1. With vehicle resting on ground, remove hubcap. Loosen drive axle bolt, but do not remove. Raise and support vehicle. Remove wheel(s). Loosely install wheel lugs.
2. Remove ABS wheel speed sensor from wheel bearing housing. Remove brake caliper (without disconnecting brake hose), brake pads and brake pad carrier. Support brake caliper with mechanics wire. Remove lug bolts and slide rotor from hub.
3. Remove bolts from backing plate, and remove backing plate. On vehicles equipped with headlight vertical aim control, disconnect coupling rod from vehicle level sensor. (Scheme 24) Remove drive axle nut completely.
4. Remove nut (1) and hex bolt, and lift out both upper links (2). (Scheme 26) Slits in wheel bearing housing may not be widened with a chisel or similar tool! See «SEPARATING UPPER LINKS (CONTROL ARMS) FROM WHEEL BEARING HOUSING»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__separating-upper-links-control-arms-from).
5. Swing wheel bearing housing away and towards rear of vehicle, while pulling axle shaft from housing. Remove spherical cap bolts. see scheme 72
6. To replace wheel bearing, see «REPLACING WHEEL BEARING (ALUMINUM WHEEL BEARING HOUSING)»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__replacing-wheel-bearing-aluminum-wheel-bearing).
7. Install NEW wheel bearing assembly to housing. Tighten NEW bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).
8. Push drive axle into wheel hub. Using NEW bolt, hand-tighten axle shaft bolt.
9. Insert both ball joint bolts of top control arm (links) into wheel bearing housing. Remove any glue remaining on thread of ball joint bolt. Install and tighten NEW self-locking nuts. Press upper control arm down as far as possible when tightening!
10. Install ABS wheel speed sensor.
11. Mount brake disc, screw on brake caliper, and tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications). Mount wheel and tighten. Tighten hex bolt for axle shaft.
12. Check wheel alignment. See «SPECIFICATIONS & PROCEDURES»(/audi/s6/c5-1999-2004/remont/wheel-alignment/#specifications-procedures) article in WHEEL ALIGNMENT.

Scheme 61

Replacing Wheel Bearing (Aluminum Wheel Bearing Housing)

To replace wheel bearing, use following illustrations. see scheme 73- see scheme 75.

Scheme 62

Scheme 63

Scheme 64

WHEEL BEARING HOUSING

Note. Wheel bearing housing can be manufactured from either steel or aluminum. Removal and installation procedure is same except for wheel bearing replacement.

Note. During any removal and installation procedure, if axle nut/bolt is removed or installed, do so with vehicle resting on floor at full curb weight. Always replace axle shaft self-locking nut/bolt with NEW parts when removed.

Scheme 65

1. With vehicle resting on ground, remove hubcap. Loosen drive axle bolt, but do not remove. Raise and support vehicle. Remove wheel(s). Loosely install wheel lugs.
2. Remove ABS wheel speed sensor from wheel bearing housing. Remove brake caliper, brake pads and brake pad carrier. Support brake caliper with mechanics wire. DO NOT allow caliper hang by brake hose. Remove lug bolts and slide rotor from hub.
3. Remove bolts from backing plate, and remove backing plate. Remove rubber grommet and disconnect ABS speed sensor harness connector. see scheme 76 Remove speed sensor cable from guides, and guide cable through openings in wheel bearing housing and remove speed sensor.
4. On vehicles equipped with headlight vertical aim control, disconnect coupling rod from vehicle level sensor. (Scheme 24)
5. Unscrew hex bolt (3) and nut (4). Pull out tie rod end. (Scheme 26)
6. Unscrew nut from guide link ball joint bolt. Use 4 mm socket wrench to hold joint bolt, if necessary. Being careful not to damage CV boot, use Press Tool (3287A) to press guide link joint from wheel bearing housing. Also, press track control link joint from housing. (Scheme 46) Loosely install track control link and thread nut back onto joint by about 4 turns.
7. Remove nut (1) and hex bolt, and lift out both upper links (2). (Scheme 26) Slits in wheel bearing housing may NOT be widened with a chisel or similar tool! Swing away wheel bearing housing toward side (in direction of arrow in (Scheme 26) ) while pulling axle shaft end out of wheel hub. Unscrew nut from joint bolt of track control link. Remove wheel bearing housing.

1. Insert wheel bearing housing in vehicle. Push outer joint of axle shaft into wheel hub and hand-tighten NEW hex bolt or nut.
2. Remove any adhesive remaining on thread of joint bolt. Insert joint bolt of track control link and guide link into wheel bearing housing. Thread NEW self-locking nuts and tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications). Use 4 mm socket wrench to hold joint bolt, if necessary.
3. Insert both joint bolts of top control arm into wheel bearing housing. Tighten NEW self-locking nuts. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications). Press upper links down as far as possible when tightening!
4. Insert tie rod into wheel bearing housing. Screw on NEW self-locking nuts (4) and tighten to specification. (Scheme 26) Tighten hex bolts (3) to a maximum of 44 INCH lbs. (5 N.m). (Scheme 26)
5. Install ABS wheel speed sensor. Mount linkage for headlight vertical aim control (if equipped). Screw on brake disc backing plate. Mount brake disc, screw on brake caliper. Mount wheel. Tighten hex bolt for axle shaft. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications).
6. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/suspension-front/#suspension-front__torque-specifications). Check wheel alignment. See «SPECIFICATIONS & PROCEDURES»(/audi/s6/c5-1999-2004/remont/wheel-alignment/#specifications-procedures) article in WHEEL ALIGNMENT.

WHEEL HUB (LIGHT CONSTRUCTION)

Light construction wheel hub can be differentiated from traditional wheel hubs by spinning washer (1) and sleeve (2). see scheme 77 Light construction wheel hub must only be used in connection with respective wheel bearing. It must only be used on vehicles with light construction wheel hub, on which they are already factory installed. Spinning washer is deformed when removing wheel bearing and must be replaced!

Scheme 66

Disassembly & Reassembly

1. Carefully pry off old spinning washer (1). see scheme 77 Position spinning washer on wheel hub.
2. Drive spinning washer on as shown. see scheme 78 Spinning washer must be flush with wheel bearing shoulder.

Scheme 67

BOLT VERSIONS

Three different 8 mm bolt versions are used on Audi suspensions. see scheme 79 All bolts should only be used once. Bolts are as follows

1. Bolt "A" without ribbing. Tightening torque 18 ft. lbs. (25 N. m).
2. Bolt "B" with ribbing. Tightening torque 55 ft. lbs. (75 N. m).
3. Bolt "C" with screw head and washer ribbing. Tightening torque 22 ft. lbs. (30 N.m) plus an additional 90°.

Scheme 68

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• SPECIFICATIONS & PROCEDURES
• VEHICLE SUSPENSION IDENTIFICATION
• TORQUE SPECIFICATIONS
• SEPARATING UPPER LINKS (CONTROL ARMS) FROM WHEEL BEARING HOUSING
• BOLT VERSIONS
• WHEEL BEARING HOUSING
• REPLACING WHEEL BEARING (ALUMINUM WHEEL BEARING HOUSING)