Suspension, Wheels, Steering Audi S6 C6

1 - Vehicles with "short" wheelbase.

2 - Vehicles with "long" wheelbase.

3 - Specifications correspond to a rim offset (ET) of 35 mm.

4 - Specified values correspond to the standard level on an air spring suspension.

5 - Specifications correspond to a rim offset (ET) of 38 mm.

Note. Specified values valid for all engine versions. Track widths change when using wheels with different rim offset.

* Vehicles with "short" wheelbase.

* Vehicles with "short" wheelbase.

Front gas-filled shock absorber, release gas and draining

A - Venting by drilling

1. Secure gas-filled strut vertically in vise, with piston rod facing down.

Scheme 1

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

Note. Gas will escape while drilling.

1. Continue to drill through inner tube (approx. 25 mm deep).
2. Drill a second hole 6 mm in diameter - arrow B - through outer and inner tubes of strut.
3. Hold strut over an appropriate container for catching oil and move piston rod repeatedly through its entire stroke until no more oil flows out.

B - Opening with a pipe cutter

Special tools, testers and auxiliary items required

1. Pipe cutter, commercially available

Scheme 2

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

Note. Gas will escape while drilling or cutting.

1. Attach a pipe cutter (commercially available), as shown in illustration, and cut through outer tube.
2. Pull piston rod upward, hold inner tube with pliers during this and press it downward so that it stays in outer tube when piston rod is pulled up slowly.
3. Remove piston rod from inner tube.
4. Empty strut tube.

Rear gas-filled struts, venting

A - Venting by drilling

1. Secure gas-filled strut vertically in vise, with piston rod facing down.

Scheme 3

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

Note. Gas will escape while drilling.

1. Continue to drill through inner tube (approx. 25 mm deep).
2. Drill a second hole 6 mm in diameter - arrow B - through outer and inner tubes of strut.
3. Hold strut over an appropriate container for catching oil and move piston rod repeatedly through its entire stroke until no more oil flows out.

B - Opening with a pipe cutter

Special tools, testers and auxiliary items required

1. Pipe cutter, commercially available

Scheme 4

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

Note. Gas will escape while drilling or cutting.

1. Attach a pipe cutter (commercially available), as shown in illustration, and cut through outer tube.
2. Pull piston rod upward, hold inner tube with pliers during this and press it downward so that it stays in outer tube when piston rod is pulled up slowly.
3. Remove piston rod from inner tube.
4. Empty strut tube.

Front suspension strut (air spring suspension), draining

Removing front suspension strut (air spring suspension) --> Suspension strut (air spring suspension) with mounting bracket, removing and installing .

Scheme 5

1. Slowly loosen residual pressure valve - 2 - on front suspension strut (air spring suspension) and allow air pressure to dissipate.

A - Opening by drilling

Illustration shows a conventional shock absorber. The procedure for the suspension strut (air spring suspension) is identical.

1. Secure suspension strut (air spring suspension) vertically in vise, with piston rod facing down.

1. Drill a 3 mm in diameter hole - arrow A - through outer tube of strut.
2. Continue to drill through inner tube (approx. 25 mm deep).
3. Drill a second hole 6 mm in diameter - arrow B - through outer and inner tubes of strut.
4. Hold strut over an appropriate container for catching oil and move piston rod repeatedly through its entire stroke until no more oil flows out.

Pressure reservoir, draining

1. Perform system bleed using VAS 5051 A --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .

Scheme 6

1. Slowly loosen air line - 1 - on pressure reservoir - 2 - and let air pressure dissipate. Once air pressure has dissipated, remove air line - 1 -.

Power steering gear, emptying

Note. Room temperature must be at least 20 ° C when emptying steering gear.

Scheme 7

1. Turn steering pinion in direction of - arrow - until stop.
2. Secure steering gear horizontally in a vise.
3. Place appropriate receptacle underneath steering gear.

Scheme 8

1. Cut through steering gear where indicated with - arrow A -.
2. Hold severed steering gear over oil receptacle and let hydraulic fluid run out. Turn steering pinion to stop in opposite direction if necessary.

Leakages at shock absorbers

Shock absorbers are frequently thought to be leaking and are replaced. Examinations of test conditions and on vehicles have revealed that a large number of shock absorbers are replaced without justification.

Minor fluid excretion ( "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 leakage (shaded in illustration) is visible, but dull, matte and possibly dry due to dust.

Scheme 9

1. Oil leakage extends from upper strut connection (piston rod oil seal) no further than 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 noises

Shock absorbers are frequently replaced due to rattling noises. Examinations of test conditions and on vehicles have revealed that 70% of the shock absorbers at blame did not have any problems and that replacement was not justified.

Proceed as follows for complaints involving rattling or cracking noises

1. Determine where, when and how noises develop during a road test with the customer - if possible road test vehicle on a dry, uneven driving surface.

Note. It is only in the rarest of cases that the shock absorber is at fault for the noises.

Shock absorbers (removed from vehicle), checking

Faulty 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

1. Press shock absorber together by hand.

1. Piston rod must move with even resistance throughout entire stroke and without jerking.

1. Release piston rod.

1. For shock absorbers with sufficient gas pressure, piston rod returns to initial position automatically.

Note. If this does not occur, the shock absorber must not necessarily be replaced. As long as oil loss is not large, the effectiveness represents that of a conventional shock absorber. The damping function is completely available even without gas pressure as long as there is not a large fluid loss. But the noisiness may worsen.

Shock absorbers on shock tester, testing

Shock absorbers can be tested while still installed in vehicle via shock tester (shock absorber test tool). The damping capacity can be judged via travel of a pointer or via a print-out.

Special tools, testers and auxiliary items required

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

Note. Temperature +10 ° C. to +40 ° C. Driver in vehicle. Tire pressure OK Vehicle driven onto center of wheel plates in straight-ahead position. Front wheels in "straight-ahead" position. Parking brake not engaged, foot brake not operated.

Tolerance values

Shock absorber condition can only be judged as follows

1. Damping effect sufficient

or

1. Damping effect insufficient

Note. Intermediate values for a reduced damping power cannot be read out. Predicting service life is not permitted. Measured values that involved a contribution of force by spring range end stop, are false.

The following values are valid only for the above mentioned test stands. If values specified are exceeded, the shock absorber has lost enough of its efficacy that a replacement is recommended.

Scheme 10

Example

Limit = 70

1. a = Larger than 70: Damping effect insufficient
2. a = Smaller than 70: Damping effect sufficient

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

Clarification of weight Production Relevant numbers (PR No.) --> Explanatory notes for Production Relevant numbers (PR No.) .

Limit values "a" in mm

Note. If the readout value is greater than the limit value "a" (table value): Damping effect insufficient. Replace shock absorber. If the readout value is less than the limit value "a" (table value): Damping effect sufficient. Shock absorber does not need to be replaced.

Raising and lowering with air spring suspension system opened and not opened

Raising with air spring suspension system not opened

1. Before raising vehicle with lifting platform, place vehicle on "Lift" (height adjustment) and switch on "vehicle jack mode" --> «Vehicle jack mode»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__vehicle-jack-mode) .

This ensures that lift arms of lifting platform can be swung under vehicle and no uncontrolled regulations of air spring suspension system are activated.

1. Position lift arms of lifting platform under designated take-up points on longitudinal members and lift vehicle.

Lowering with air spring suspension system not opened

1. Lower lifting platform and set vehicle on wheels.
2. Swing back lift arms of lifting platform.
3. Switch off "vehicle jack mode" and set desired driving mode --> «Vehicle jack mode»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__vehicle-jack-mode) .

Note. Deactivation (switching off) the "vehicle jack mode" is also performed automatically at a vehicle speed above 10 km/h.

Lowering with air spring suspension system opened

1. Perform system charging using VAS 5051 A --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .
2. Lower lifting platform and set vehicle on wheels.

If vehicle is not high enough to swing back lift arms of lifting platform (insufficient pressure in pressure reservoir), engine must be allowed to run at idle. This switches on compressor of air supply unit.

1. Switch off "vehicle jack mode" and set desired driving mode --> «Vehicle jack mode»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__vehicle-jack-mode) .

General notes

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

The tightening torques stated apply to non-oiled nuts and bolts.

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

Always prevent the following effects at coil springs: Hammer blows, weld splashes, apply new color markings.

Do not perform welding or cutting operations (separating work) in area of coil springs or suspension struts! If necessary, cover coil springs or suspension struts.

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 drive axle.
2. Tighten outer joint to 200 Nm.

Bonded rubber bushings can only be turned to a limited extent. The bolted connections on suspension links should only be tightened when vehicle is in curb weight position or control position.

1. For vehicles with coil springs, lift wheel suspension in curb weight position --> «For vehicles with coil springs, lift wheel suspension in curb weight position»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__for-vehicles-with-coil-springs-lift)
2. For vehicles with air spring suspension, lift wheel suspension in control position --> «For vehicles with air springs, lift wheel suspension in control position»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__for-vehicles-with-air-springs-lift)

If the vehicle still needs to be aligned, the bolts and nuts which must be loosened during alignment work must only be tightened with tightening torque. After performing alignment/adjustment the bolts and nuts must be tightened with prescribed additional torque angle!

Contact corrosion!

Contact corrosion can occur if inappropriate connecting elements (bolts, nuts, washers, ) are used.

For this reason, only connecting elements with a special surface coating are installed (Dachromet). These elements are distinguished by their greenish hue.

Furthermore, all rubber, plastic and adhesive materials used are non-conductive.

If you have doubts about the reusability of parts, it is generally better to install new parts.

Note the following

Use only authorized parts! They have been tested and are aluminum compatible.

Additional equipment must be authorized by Audi AG!

Damage via contact corrosion is not covered by warranty!

Repairing damaged threads in longitudinal member (subframe to body)

Damaged threads can be repaired using wire inserts (heli-coil).

Component overview indicates which threads can be repaired.

Shavings that remain in the chassis must be embedded in wax.

Servicing thread in the weld nuts in long member 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.

1. Have responsible foreman or next superior check thread repair.
2. Thread insert must have same length as thread in body.
3. Repair any damage to underbody sealant.

Scheme 11

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 can only be turned to a limited extent.

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

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

This position can be simulated on lifting platform by raising corresponding wheel suspension using engine/transmission jack V.A.G 1383 A and wheel hub support T10149.

Scheme 12

1. For example, measure dimension - a - from center of wheel to lower edge of wheel housing using a tape measure before starting work.

Measurement must be performed in curb weight position (unloaded condition).

1. Note measured value. It will be required for tightening bolts/nuts.

Before lifting the corresponding wheel suspension, vehicle must be strapped down using tensioning straps T10038 at lift arms of lifting platform.

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

1. Remove wheel.
2. Turn wheel hub far enough until one of the holes for wheel bolts is on top.
3. Install wheel hub support T10149 with wheel bolt to wheel hub.

Tightening of the respective bolts/nuts must only occur if dimension - a - , measured before installation between wheel hub center and lower edge of wheel house, has been attained.

Scheme 13

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

1. Tighten respective bolts/nuts.
2. Lower wheel bearing housing.
3. Remove engine/transmission jack from below vehicle.
4. Remove wheel hub support T10149.

Scheme 14

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A
2. Torque wrench V.A.G 1783
3. Wheel hub support T10149

Special tools, testers and auxiliary items required

Scheme 15

1. Insertion tool 10 mm V.A.G 1783/1

Bonded rubber bushings can only be turned to a limited extent.

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

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

This position can be simulated on lifting platform by raising wheel bearing housing using engine/transmission jack V.A.G 1383 A and wheel hub support T10149.

Requirement

1. Engine must be installed.

1. Set vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Perform system bleed using VAS 5051 A --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .
3. Clean area of air connection.

1. Remove connecting piece - 1 - at residual pressure valve - 2 -. This dissipates air.

Note. In general, the residual pressure valve - 2 - must not be loosened or removed.

1. Seal both connections. When doing this, make sure that no particles of dirt penetrate into connections.
2. Turn wheel hub far enough until one of the holes for wheel bolts is on top.

Scheme 16

1. Install wheel hub support T10149 with wheel bolt.
2. Insert wheel hub support T10149 into engine/transmission jack V.A.G 1383 A and press wheel bearing housing far enough upward until control position, dimension - a - , is obtained.

Control position

1. Dimension - a - for vehicles with air suspension 386 mm
2. Dimension - a - for allroad vehicles with air spring 388 mm

Work operations after setting control position

1. Tighten respective bolts/nuts.
2. Lower wheel bearing housing.
3. Remove engine/transmission jack V.A.G 1383 A from below vehicle.
4. Remove wheel hub support T10149.

1. Bolt on connecting piece - 1 - to residual pressure valve - 2 -.
2. Install wheel and tighten --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Charge air spring suspension --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .

Scheme 17

I - Subframe, engine mount plate, stabilizer bar, cross member, steering rod --> Subframe, engine mount plate, stabilizer bar, cross member, coupling rod

II - Suspension strut (coil spring), mounting bracket, upper control arm --> Suspension strut (coil spring), mounting bracket, upper links

III - Suspension strut (air spring suspension), mounting bracket, upper control arm --> Suspension strut (air spring suspension), mounting bracket, upper links, assembly overview

IV - Track control arm, guide control arm, level control system sensor --> Control arm, guide link, level control system sensor

V - Wheel bearing housing, wheel bearing unit --> Wheel bearing housing, wheel bearing unit

VI - Tunnel cross member, dome brace --> Tunnel cross member, dome brace

Scheme 18

VII - "Drive axle" --> Drive axle

Scheme 19

1 - Subframe

1. Removing and installing --> «Subframe, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__subframe-removing-and-installing)

2 - Bonded rubber bushing

1. Hydraulic support
2. Removing and installing --> «Bonded rubber bushings for subframe, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__bonded-rubber-bushings-for-subframe-replacing)

3 - Hex nut

1. Always replace after removal

4 - Hex nut

1. Always replace after removal

5 - Hex bolt 60 Nm plus an additional 90 ° turn

1. Always replace after removal

6 - Transverse beam for subframe

7 - Hex bolt 70 Nm plus an additional 180 ° turn

1. Always replace after removal

8 - Support for subframe

9 - Hex bolt, 55 Nm

10 - Bolt 5 Nm

11 - Hex bolt 40 Nm plus an additional 90 ° turn

1. Always replace after removal

12 - Hex bolt 115 Nm plus an additional 90 ° turn

1. Always replace after removal
2. Thread in body can be repaired with thread insert made of wire according to DIN 8140 (Helicoil). Thread insert must have same length as thread in body.

13 - Hex bolt, 10 Nm

14 - Mounting bracket

15 - Left Front Level Control System Sensor G78 or Right Front Level Control Sensor G289

1. Removing and installing or replacing only as complete set --> «Front Vehicle Level Sensor , removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__front-vehicle-level-sensor-removing)
2. Sensor lever must point toward front
3. After loosening, check basic setting of headlamp adjustment --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .
4. After loosening, control position must be adapted again in vehicles with air spring suspension --> «Control position, adapting again»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-position-adapting-again) .

16 - Hex bolt 115 Nm plus an additional 90 ° turn

1. Always replace after removal
2. Thread in body can be repaired with thread insert made of wire according to DIN 8140 (Helicoil). Thread insert must have same length as thread in body.

17 - Guide control arm

18 - Hex nut

19 - Hex bolt 40 Nm plus an additional 90 ° turn

1. Always replace after removal

20 - Coupling rod

1. Removing and installing --> «Coupling rod, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coupling-rod-removing-and-installing)

21 - Track control arm

22 - Hex nut 8 Nm

23 - Stabilizer bar

1. Removing and installing --> «Stabilizer bar, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__stabilizer-bar-removing-and-installing)

24 - Clamp

25 - Hex nut 25 Nm

1. 2x

26 - Hex nut 40 Nm

1. 3x
2. Only on vehicles with 10-cyl. gas engine

27 - Hex bolt, 40 Nm

28 - Cross member

1. Only on vehicles with 10-cyl. gas engine
2. Removing and installing --> «Cross member, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__cross-member-removing-and-installing)

29 - Hex bolt

1. All engine versions, except vehicles with 10-cyl. gas engine: 40 Nm
2. Only on vehicles with 10-cyl. gas engine: 75 Nm

30 - Engine mount plate

1. Make sure parts fit correctly when assembling subframe and engine mount plate.

31 - Engine mount

32 - Bonded rubber bushing

1. Hydraulic support
2. All engine versions, except vehicles with 10-cyl. gas engine
3. Removing and installing --> «Bonded rubber bushings for subframe, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__bonded-rubber-bushings-for-subframe-replacing)

33 - Aluminum bushing

1. Only on vehicles with 10-cyl. gas engine
2. Removing and installing --> «Bonded rubber bushings for subframe, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__bonded-rubber-bushings-for-subframe-replacing)

34 - Hex bolt 70 Nm plus an additional 180 ° turn

1. Always replace after removal

35 - Hex nut 40 Nm

Subframe, removing and installing

Special tools, testers and auxiliary items required

Scheme 20

1. Engine support bridge 10-222 A

Scheme 21

1. Torque wrench V.A.G 1331

Scheme 22

1. Torque wrench V.A.G 1332

Scheme 23

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

Scheme 24

1. Vehicle Diagnostic, Testing and Information System VAS 5051 B with corresponding diagnostic cable.

Scheme 25

1. Tensioning strap T10038

Scheme 26

1. Wheel hub support T10149

Scheme 27

1. Engine Support Basic Set T40091

Scheme 28

1. Engine Support Supplement Set T40092

Scheme 29

1. Engine Support Supplement Set T40093

Removing

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Perform system bleed using VAS 5051 A --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .

Applies to all vehicles

1. Remove noise insulation --> «50 - BODY - FRONT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove decorative wheel cover, for light-alloy wheels pull off protective cap (use pulling hook in vehicle tool kit).
3. Remove wheels.

Relevant for vehicles with auxiliary heater

Scheme 30

1. Remove muffler - 1 - for auxiliary heater with exhaust pipe - 2 -.

Applies to all vehicles

1. Remove left and right coupling rods --> «Coupling rod, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coupling-rod-removing-and-installing) .
2. Remove stabilizer --> «Stabilizer bar, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__stabilizer-bar-removing-and-installing) .
3. Support engine completely using supporting device.

Scheme 31

1. Assemble engine support bridge 10-222 A using engine support basic set T40091 , engine support supplement set T40092 and engine support supplement set T40093 on suspension strut domes and long members, as shown in illustration.

Note. The exact description for engine support can be found in --> 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BAT, BNK 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA of the respective engine.

Scheme 32

1. Remove nuts - 1 - at left and right.

Scheme 33

1. In vehicles with level control system sensor, remove nut - 2 - on both sides.
2. Disconnect connector from level control system sensor on left and right sides.

1. Remove hex bolt - 1 - at left and right.

Scheme 34

1. Tie up both wheel bearing housings using tensioning straps T10038 as shown in the illustration.

Note. Wheel bearing housing must be supported to prevent damage to joints of upper control arm.

Scheme 35

1. Disconnect threaded connection from both guide control arms - 1 - and track control arms - 2 - on subframe side. Tie up guide control arm and track control arm using wire - arrows -.

Note. In order not to over bend the joints of track control arm and guide control arm, they must be fastened to the body with a tie wire or something like it.

1. Place engine/transmission jack V.A.G 1383 A with hard wood block under subframe and press lightly against.

Scheme 36

1. Remove hex bolts - 5 - and - 6 -.

1. Remove hex bolts - 7 - to - 12 - and lower rear subframe.
2. Loosen hex bolts - 1 - to - 4 - far enough until subframe can be removed.

Installing

Installation is in reverse order of removal. Note the following

Make sure parts fit correctly when assembling subframe and engine mount plate.

1. Drillings of subframe mounts must be aligned centered to bolt-on points on body.

Note. Bonded rubber bushings can only be turned to a limited extent. The bolted connections on the wheel suspension should therefore only be tightened when the vehicle is in curb weight position or control position. For vehicles with coil springs, lift wheel suspension in curb weight position --> For vehicles with coil springs, lift wheel suspension in curb weight position For vehicles with air spring suspension, lift wheel suspension in control position --> For vehicles with air springs, lift wheel suspension in control position

Tightening torques: --> Subframe, engine mount plate, stabilizer bar, cross member, coupling rod - assembly overview

1. Install wheels.
2. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Tighten wheels --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
4. Adapt control position again on vehicles with air spring suspension --> «Control position, adapting again»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-position-adapting-again) .

1. On vehicles with automatic headlamp range control system, perform basic setting of headlamps --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .
2. Perform vehicle alignment --> «Wheel Alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Suspension setting at front/rear axle must be performed on a VW/Audi approved alignment rack.

Bonded rubber bushings for subframe, replacing

Special tools, testers and auxiliary items required

Scheme 37

1. Thrust plate VW 401

Scheme 38

1. Thrust plate VW 402

Scheme 39

1. Punch VW 412

Scheme 40

1. Thrust piece 3416/1

Scheme 41

1. Shop press V.A.G 1290 A

Scheme 42

1. Assembly tool T10205

Scheme 43

1. Assembly tool T10301

1. Remove subframe --> «Subframe, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__subframe-removing-and-installing) .

Note. Pressing bearings out and in is performed using shop press V.A.G 1290 A. For pressing bearings out and in, a second technician is required to hold the subframe.

Pressing out front bearing (aluminum)

Scheme 44

1. Install tools at front bearing (aluminum) as shown in illustration.

1. Punch VW 412
2. Front bearing (aluminum)
3. Subframe
4. Sleeve T10205/5
5. Thrust plate VW 402
6. Thrust plate VW 401

Pressing in front bearing (aluminum)

1. Note installation position of front bearing

Scheme 45

Catch - 1 - of front bearing must align with recess - 2 -.

Scheme 46

1. Install tools at front bearing (aluminum) as shown in illustration.

1. Punch VW 412
2. Front bearing (aluminum)
3. Subframe
4. Sleeve T10205/5
5. Thrust plate VW 402
6. Thrust plate VW 401

1. Press front bearing (aluminum) into subframe until stop.

Pressing out front bearing (bonded rubber bushing)

Scheme 47

1. Install tools at front bearing (bonded rubber bushing) as shown in illustration.

1. Punch VW 412
2. Thrust piece 3416/1
3. Subframe
4. Sleeve T10205/5
5. Thrust plate VW 402
6. Thrust plate VW 401

Pressing in front bearing (bonded rubber bushing)

1. Note installation position of bearing.

Catch - 1 - of front bearing must align with recess - 2 -.

Note. Illustration shows aluminum bearing. Installation position is the same as for bonded rubber bushing.

Scheme 48

1. Install tools at front bearing (bonded rubber bushing) as shown in illustration.

1. Punch VW 412
2. Washer T10205/15
3. Front bearing (bonded rubber bushing)
4. Subframe
5. Sleeve T10205/5
6. Thrust plate VW 402
7. Thrust plate VW 401

1. Press front bearing (bonded rubber bushing) into subframe until stop.

Pressing out rear bearing

Scheme 49

1. Install tools at rear bearing as shown in illustration.

1. Punch VW 412
2. Thrust piece 3416/1
3. Subframe
4. Sleeve T10301/3
5. Thrust plate VW 402
6. Thrust plate VW 401

Pressing in rear bearing

1. Note installation position of bearing.

Scheme 50

Catch - 1 - of rear bearing must align with recess - 2 -.

Scheme 51

1. Install tools at rear bearing as shown in illustration.

1. Punch VW 412
2. Washer T10205/15
3. Rear bearing
4. Subframe
5. Sleeve T10205/5
6. Thrust plate VW 402
7. Thrust plate VW 401

1. Press rear bearing into subframe until stop.

Stabilizer bar, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

Removing

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

1. Remove noise insulation --> «50 - BODY - FRONT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

Relevant for vehicles with cross member

1. Remove cross member --> «Cross member, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__cross-member-removing-and-installing) .

Applies to all vehicles

Scheme 52

1. Remove bolt - 2 -.

Scheme 53

1. Remove hex nuts - 2 -.
2. Remove stabilizer bar.

Installing

Note. Note suspension version when replacing stabilizer bar. Stabilizer bar and bearing must be free of grease.

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

1. Tighten new bolt - 2 -.

1. Tighten nuts - 2 -.

Tightening torques: --> Subframe, engine mount plate, stabilizer bar, cross member, coupling rod - assembly overview

1. Install noise insulation --> «50 - BODY - FRONT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Cross member, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

Removing

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

1. Remove noise insulation --> «50 - BODY - FRONT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 54

1. Remove nuts - 1 - and bolts - 3 - for cross member - 2 - and remove cross member - 2 -.

Installing

Installation is in reverse order of removal. Note the following

1. Install new nuts - 1 - but do not tighten.
2. Tighten bolts - 3 -.
3. Tighten nuts - 1 -.

Tightening torques: --> Subframe, engine mount plate, stabilizer bar, cross member, coupling rod - assembly overview

1. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Coupling rod, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

Removing

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

1. Remove bolts - 2 - and - 4 -.
2. Remove coupling rod.

Installing

Installation is in reverse order of removal. Note the following

1. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Tightening torques: --> Subframe, engine mount plate, stabilizer bar, cross member, coupling rod - assembly overview

Scheme 55

1 - Collar nut, 50 Nm

1. Always replace after removal

2 - Shock absorber mount

3 - Washer

4 - Mounting bracket

1. Suspension strut with mounting bracket, removing and installing --> «Suspension strut (coil spring) with mounting bracket, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-coil-spring-with-mounting)
2. Servicing suspension strut with mounting bracket --> «Suspension strut (coil spring) with mounting bracket, servicing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-coil-spring-with-mounting)

5 - Hex bolt 50 Nm and turn an additional 90 °

1. Always replace after removal

6 - Upper rear link

1. Removing and installing --> «Upper link (coil spring), removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__upper-link-coil-spring-removing-and)
2. Removing and installing bearing --> «Bearing for upper front and rear link, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__bearing-for-upper-front-and-rear)

7 - Upper front link

1. Removing and installing --> «Upper link (coil spring), removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__upper-link-coil-spring-removing-and)
2. Removing and installing bearing --> «Bearing for upper front and rear link, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__bearing-for-upper-front-and-rear)

8 - Hex nut

9 - Wheel bearing housing

10 - Hex bolt, 45 Nm

11 - Spring plate

12 - Protective cap

13 - Protective sleeve

14 - Auxiliary spring

15 - Spring

16 - Hex bolt 40 Nm plus an additional 90 ° turn

1. Always replace after removal

17 - Hex nut

1. Always replace after removal

18 - Coupling rod

19 - Hex nut

1. Always replace after removal

20 - Stabilizer

21 - Control arm

22 - Hex bolt 40 Nm plus an additional 90 ° turn

1. Always replace after removal

23 - Hex bolt 90 Nm plus an additional 90 ° turn

1. Always replace after removal

24 - Shock absorbers

1. Suspension strut with mounting bracket, removing and installing --> «Suspension strut (coil spring) with mounting bracket, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-coil-spring-with-mounting)
2. Servicing suspension strut with mounting bracket --> «Suspension strut (coil spring) with mounting bracket, servicing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-coil-spring-with-mounting)
3. Note different types of suspension versions, see vehicle data plate --> «Explanatory notes for Production Relevant numbers (PR No.)»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__explanatory-notes-for-production-relevant-numbers) .
4. Always release gas and drain malfunctioning shock absorbers before disposal --> «Shock absorbers, checking»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

1. Checking removed shock absorbers --> «Shock absorbers, checking»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

25 - Hex bolt 50 Nm plus an additional 90 ° turn

1. Always replace after removal

26 - Hex nut

1. Always replace after removal

27 - Hex nut

1. Always replace after removal

28 - Hex bolt 50 Nm plus an additional 90 ° turn

1. Always replace after removal
2. Observe tightening sequence Tightening torque of threaded connection depicted as numbered is mandatory under «Suspension strut (coil spring) with mounting bracket, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-coil-spring-with-mounting)

Suspension strut (coil spring) with mounting bracket, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332

Scheme 56

1. Pliers T40067

Removing

1. Remove decorative wheel cover, for light-alloy wheels pull off protective cap (use pulling hook in vehicle tool kit).
2. Remove wheel.

1. In vehicles with level control system sensor, remove nut - 6 -.

Scheme 57

1. Remove clip - 1 - using pliers.

This clip does not have to be re-inserted.

1. Disconnect threaded connection - 2 - , remove hex bolt and pull out both control arms upward.

Slits in wheel bearing housing may not be widened with a chisel or similar tool!

Scheme 58

1. Remove hex bolt - arrow - suspension strut/control arm.
2. Pivot wheel bearing housing away to side and guide out fork head at control arm.

Scheme 59

1. Disengage mounting of coolant expansion tank - arrow - , unclip tank and set aside.
2. Remove plenum chamber cover if necessary.

Scheme 60

1. Remove cover - arrow - of bolt.

Scheme 61

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

Note. Be careful not to damage CV boot in the process!

Installing

1. Insert suspension strut with mounting bracket into suspension strut tower.

Note. Observe tightening sequence of threaded connections for mounting bracket with suspension strut to suspension strut dome.

Scheme 62

1. Tightening torque of threaded connection depicted as numbered is mandatory --> «Suspension strut (coil spring), mounting bracket, upper links, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Install cover - arrow - of bolt.
2. Install plenum chamber cover.

Note. The threaded connection must only be tightened when the vehicle is in curb weight position.

1. Insert fork head of suspension strut in control arm and tighten threaded connection - 1 - --> «Suspension strut (coil spring), mounting bracket, upper links, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Note. Bolt must be inserted in opposite direction of travel.

Scheme 63

1. Insert both linkage stubs of upper links in wheel bearing housing and tension as far as possible downward using pliers T40067.

1. Insert new bolt - 2 - and self-locking nut and tighten --> «Suspension strut (coil spring), mounting bracket, upper links, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. In vehicles with level control system sensor, install nut - 6 -.
2. Install wheel and tighten --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. On vehicles with automatic headlamp range control system, perform basic setting of headlamps --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .

Suspension strut (coil spring) with mounting bracket, servicing

Special tools, testers and auxiliary items required

1. Spring compressor V.A.G 1752/1

Scheme 64

1. Suspension strut mount V.A.G 1752/2

Scheme 65

1. Spring bracket V.A.G 1752/6

Scheme 66

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 67

1 - Collar nut, 50 Nm

1. Always replace after removal

2 - Shock absorber mount

3 - Washer

4 - Mounting bracket

1. Installed position «Installation position of mounting bracket»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

5 - Coil spring

1. Removing «Coil spring, removing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
2. Installing «Coil spring, installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-installing)
3. Note different types of suspension versions, see vehicle data plate --> «Explanatory notes for Production Relevant numbers (PR No.)»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__explanatory-notes-for-production-relevant-numbers) .
4. Allocation Parts catalog

6 - Auxiliary spring

7 - Protective sleeve

8 - Protective cap

9 - Bottom spring seat

10 - Lower spring plate

11 - Shock absorbers

1. Replace «Replacing shock absorbers»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
2. Note different types of suspension versions, see vehicle data plate --> «Explanatory notes for Production Relevant numbers (PR No.)»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__explanatory-notes-for-production-relevant-numbers) .
3. Always release gas and drain malfunctioning shock absorbers before disposal.
4. Allocation Parts catalog

Clarification of Production Relevant numbers (PR No.) --> Explanatory notes for Production Relevant numbers (PR No.)

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

Scheme 68

1. Clamp suspension strut in vise.
2. Preload coil spring using spring compressor V.A.G 1752/1 and spring holder V.A.G 1752/6 far enough until top spring plate is free.

Scheme 69

1. Make sure that coil spring is seated correctly in spring holder V.A.G 1752/6 - arrow -.

1. Remove collar nut of coupling rod using tools T10001/3 , T10001/11 and T10001/7.
2. Remove individual components of suspension strut and pre-loaded coil spring with spring compressor V.A.G 1752/1.

Scheme 70

1. Remove protective cap - 1 - and bottom spring washer - 2 -.
2. Loosen spring plate - 3 - using a plastic mallet and remove upward.
3. Tap spring plate onto new shock absorber using a plastic mallet.

Coil spring, installing

1. Install bottom spring washer and protective cap.
2. Install pre-loaded coil spring onto bottom spring washer. End of spring coil must rest against stop - arrow - (permissible play max. 2 mm).

Scheme 71

Install mounting bracket with spring washer onto pre-loaded spring so that spring washer makes contact on end of spring coil - arrow - (permissible play max. 2 mm).

1. Install individual components of suspension strut.
2. Tighten collar nut using special tools.
3. Do not yet release tension on spring.

Scheme 72

1. Assemble suspension strut mount V.A.G 1752/2 as depicted in the illustration.
2. Clamp suspension strut with spring compressor into suspension strut mount V.A.G 1752/2 vertically.

Scheme 73

1. Disengage locking lever and set pointer to 0 ° position - arrow - and seize locking lever.
2. Adjust mounting bracket so that adjusting gauge for suspension strut V.A.G 1752/18-4 for the respective vehicle side can be bolted to mounting bracket.

Left side of vehicle

Scheme 74

1. Bolt adjust gage for suspension strut V.A.G 1752/18-4 on to mounting bracket - arrows L -.

Right side of vehicle

Scheme 75

1. Bolt adjust gage for suspension strut V.A.G 1752/18-4 to mounting bracket - arrows R
2. Now release tension on spring compressor V.A.G 1752/1 and remove it.

Note. While releasing tension, make sure that ends of spring make contact at stops of spring washers in mounting bracket and bottom spring washer.

1. Check adjustment, and repeat procedure if necessary.

Permissible deviation: ± 2 °.

Upper link (coil spring), removing and installing

Removing

1. Remove suspension strut with mounting bracket --> «Suspension strut (coil spring) with mounting bracket, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-coil-spring-with-mounting) .

Scheme 76

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

Installing

Installation is in reverse order of removal. Note the following

1. Secure top links - 3 - and - 4 - via bolts - 2 - and nuts - 1 - only so that links can still change their positions.

Scheme 77

Upper front link

1. Set height - A -.

A = 94 mm ± 2 mm

Scheme 78

Upper rear link

1. Set height - A -.

A = 85 mm ± 2 mm

Continuation for upper front and rear links

1. Tighten new nuts - 1 - --> «Suspension strut (coil spring), mounting bracket, upper links, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Check position of upper links.
3. Repeat adjustment procedure, if necessary.
4. Reinstall suspension strut --> «Suspension strut (coil spring) with mounting bracket, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__suspension-strut-coil-spring-with-mounting) .

Bearing for upper front and rear link, replacing

Special tools, testers and auxiliary items required

Scheme 79

1. Assembly tool 3301

Scheme 80

1. Assembly tool 3348

Links must only be clamped in a vise with protective vise jaw lining!

Scheme 81

Pulling out bearing

Scheme 82

Installed position of bearing

A = ~ 90 ° ± 5 °

Scheme 83

Pulling in bearing

A = bearing

Note. Do not use lubricant!

Scheme 84

1 - Mounting bracket

1. Suspension strut with mounting bracket, removing and installing --> «Suspension strut (air spring suspension) with mounting bracket, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

2 - Hex bolt 50 Nm plus an additional 90 ° turn

1. Always replace after removal
2. Observe tightening sequence Tightening torque of threaded connections depicted as numbered is mandatory under «Suspension strut (air spring suspension) with mounting bracket, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

3 - Hex nut, 23 Nm

4 - Hex nut

5 - Wheel bearing housing

6 - Hex bolt, 45 Nm

7 - Residual pressure retaining valve

1. Must not be loosened under any circumstances.

8 - Connecting piece, 3 Nm

1. Always tighten to tightening torque!
2. Only remove if vehicle has been raised and air spring shock absorbers have been released of load (otherwise there is a danger of injury when lowering vehicle)
3. If leaking, service air pipe --> «Air line, servicing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) or replace connecting piece --> «Connecting piece, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__connecting-piece-replacing)
4. Clean line connection before loosening

1. Air dissipates when removing

9 - Air line

1. Colors: Left front - red; right front - green
2. Servicing air line --> «Air line, servicing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
3. If leaking, replace connecting piece --> «Connecting piece, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__connecting-piece-replacing)

10 - Left Front Dampening Adjustment Valve N336 or Right Front Dampening Adjustment Valve N337

1. Removing and installing --> «Dampening adjustment valve , replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__dampening-adjustment-valve-replacing)

11 - Hex nut

1. Always replace after removal

12 - Control arm

13 - Hex bolt 90 Nm and turn an additional 90 °

1. Always replace after removal

14 - Hex nut 8 Nm

15 - Left Front Level Control System Sensor G78 or Right Front Level Control Sensor G289

1. Removing and installing or replacing only as complete set --> «Front Vehicle Level Sensor , removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__front-vehicle-level-sensor-removing)
2. Sensor lever must point toward front
3. After loosening, check Basic Setting of head light adjustment --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment)
4. After loosening, control position must be adapted again --> «Control position, adapting again»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-position-adapting-again) in vehicles with air spring suspension

16 - Tension clamp

1. Only installed during a repair

17 - Boot

1. Replace --> «Boot, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__boot-replacing)

18 - Tension clamp

19 - Air spring shock absorbers

1. Removing and installing --> «Suspension strut (air spring suspension) with mounting bracket, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
2. Replacing dampening adjustment valve --> «Dampening adjustment valve , replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__dampening-adjustment-valve-replacing)

Scheme 85

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331
2. Torque wrench V.A.G 1332
3. Torque wrench V.A.G 1783
4. Insertion tool 10 mm V.A.G 1783/1

Special tools, testers and auxiliary items required

1. Vehicle Diagnostic, Testing and Information System VAS 5051 B with corresponding diagnostic cable.

1. Pliers T40067

Removing

Suspension strut (air spring suspension) is removed together with mounting bracket and upper links.

During assembly work, make sure that no indentations form on dust boot of suspension strut (air spring suspension)!

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Perform system bleed using VAS 5051 A --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .
3. Remove decorative wheel cover, for light-alloy wheels remove protective cap (use pulling hook in vehicle tool kit).
4. Remove wheel.

1. Clean area of air connection.

1. Remove connecting piece - 1 - on residual pressure valve - 2 - and unclip air line at suspension strut.

Note. In general, the residual pressure valve - 2 - must not be loosened or removed.

1. Seal both connections. When doing this, make sure that no particles of dirt penetrate into connections.

1. Remove clip - 3 - using pliers.

This clip does not have to be re-inserted.

Scheme 86

1. Remove nut - 1 - , remove bolt - 2 - and pull out both links - 3 - upward.
2. Slits in wheel bearing housing may not be widened using a chisel or similar tool!

1. Remove coupling rod of level control system sensor - 6 - from control arm.
2. Remove hex bolt - 1 - and guide suspension strut fork out of control arm.

Scheme 87

1. Carefully unclip and disconnect harness connector - 2 -.

1. Disengage mounting of coolant expansion tank - arrow - , unclip tank and set aside.
2. Remove plenum chamber cover if necessary.

1. Remove cover - arrow - of bolt.

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

Note. When removing suspension strut (air spring suspension), make sure that protective sleeves on steering, drive axle and air spring suspension strut are not damaged.

If suspension strut (air spring suspension) is to be replaced, observe --> Suspension strut (air spring suspension), charging .

Installing

Installation is in reverse order of removal. Note the following

During assembly work, make sure that no indentations form on dust boot of suspension strut (air spring suspension)!

1. Secure suspension strut (air spring suspension) to body first.

Guides of mounting bracket must sit in sockets of body.

1. Tightening torque of threaded connections depicted as numbered is mandatory.

Scheme 88

1. Insert both linkage stubs of upper links - 2 - into wheel bearing housing - 3 - and tension as far as possible downward using pliers T40067.
2. Tighten bolt - 1 -.

Note. Bonded rubber bushings can only be turned to a limited extent. The bolted connections on the wheel suspension should therefore only be tightened when the vehicle is in control position. For vehicles with air spring suspension, lift wheel suspension in control position --> For vehicles with air springs, lift wheel suspension in control position .

1. Install wheel.
2. Position vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Tighten wheel --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
4. Adapt control position again --> «Control position, adapting again»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-position-adapting-again) .

1. Install plenum chamber cover --> «92 - WINDSHIELD WIPER AND WASHER SYSTEM»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .

Tightening torques: --> Suspension strut (air spring suspension), mounting bracket, upper links, assembly overview

Dampening adjustment valve , replacing

Special tools, testers and auxiliary items required

Scheme 89

1. Kukko Separating Tool 5-60 mm Kukko 17/0 - 3

Removing

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Remove wheel.

Scheme 90

1. Mark cable connection position - 1 - of dampening adjustment valve at damper - arrow -.
2. Carefully disconnect harness connector and carefully pull connector - 2 - out of bracket by hand.

Scheme 91

1. Attach Kukko Separating Tool 5-60 mm Kukko 17/0 - 1 - to damper with smooth surface and pretension by hand. Attach gripping pieces - 3 - and - 4 - between dampening adjustment valve - 2 - and damper tube.
2. Tap dampening adjustment valve - 2 - at right angle using plastic hammer - 5 -. Tap on gripping piece - 4 - as close to valve housing as possible using a plastic hammer. Pull on gripping piece - 3 - in a right angle by hand.

Note. Dampening adjustment valve is destroyed when removed.

Scheme 92

1. Remove circlip - 1 -.
2. Remove coil - 2 - and sealing ring - 3 -.

Scheme 93

1. Check housing for dampening adjustment valve for deformation all around - arrows -. If necessary, flatten deformations using a small screwdriver.

Installing

1. Clean housing for dampening adjustment valve.

Scheme 94

1. Always replace sealing ring - arrow -.

Note. New sealing ring - 1 - is already installed on dampening adjustment valve. Sealing ring and valve are installed together - do not disconnect.

1. Attach new dampening adjustment valve and align cable connection - 1 - with your marking - arrow -.
2. Forcefully press on dampening adjustment valve by hand until sealing ring engages audibly.

Rest of installation is in reverse order of removal.

Boot, replacing

Special tools, testers and auxiliary items required

Scheme 95

1. Hose clamp pliers V.A.G 1275

Removing

Note. Replacement of boot is performed with suspension strut installed.

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Remove wheel.

1. Carefully unclip and disconnect harness connector - 2 -. Unhook wiring harness of harness connector - 2 - at suspension strut.

1. Remove coupling rod of level control system sensor - 6 - from control arm.
2. Remove hex bolt - 1 - and guide suspension strut fork out of control arm.

Scheme 96

1. Mark position of line retainer - 1 - at suspension strut.

Note. A line retainer - 1 - is installed at left suspension strut. Two line retainers - 1 - are installed at right suspension strut.

1. Remove clamp - 2 -.

If boot - 3 - was already replaced before, clamp at bottom of boot must also be removed.

1. Carefully cut boot - 3 - from top to bottom (do not damage suspension strut) and remove.

Installing

Installation is in reverse order of removal. Note the following

1. Carefully install new boot.
2. Install suspension strut at control arm.
3. Bring steering wheel into center position.
4. Lift wheel bearing in control position --> «For vehicles with air springs, lift wheel suspension in control position»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__for-vehicles-with-air-springs-lift) .

1. Slide boot - 3 - onto suspension strut housing.
2. Attach line retainer - 1 - onto clamp - 2 -.
3. Install clamp - 2 - only loosely.
4. Align line retainer - 1 - with your marking on suspension strut.

1. Install clamp from repair kit on lower boot only loosely.

Scheme 97

1. Measure dimension - a - between boot and lower edge of suspension strut housing. Distance - a - must be 70 mm.

Scheme 98

1. Align clamps - 2 - and - 3 - so that they align with residual pressure valve - 1 -.
2. Before tensioning clamps, make sure boot is not twisted, adjust if necessary.
3. Tension clamps using hose clamp pliers V.A.G 1275.

Suspension strut (air spring suspension), charging

Special tools, testers and auxiliary items required

Scheme 99

1. Adapter T10157/1

Scheme 100

1. Air spring charging unit VAS 6231
2. Steel gas cylinder filled with Argon or Corgon

Note. Suspension struts (air spring suspension) are supplied as replacement parts with a minimum pressure. This pressure may decrease contingent upon storage time (as for a tire). This minimum pressure must be checked and if necessary restored by recharging before suspension strut (air spring suspension) is removed from the packaging. If suspension strut (air spring suspension) is removed from the packaging without this checking/recharging, this can cause indentations or kinks to form in the dust boot before it reaches its normal shape. These indentations lead to preliminary damage and may lead to premature failure.

1. Remove cover of packaging.

Scheme 101

1. Remove union screw - arrow - from residual pressure valve.
2. Close valve of steel gas cylinder.
3. Make sure that you are familiar with the relevant safety instructions for the use of pressurized containers and industrial gases.

Scheme 102

1. Connect air spring charging unit VAS 6231 and adapter T10157/1 as depicted in the illustration.

1. Suspension strut (air spring suspension) in packaging
2. Steel gas cylinder for Argon, Corgon with fittings
3. Air spring charging unit VAS 6231
4. Adapter T10157/1

Scheme 103

1. Set flow quantity restrictor - arrow - on fitting to 2.0 L/min.
2. Fill gas into suspension strut (air spring suspension) using several individual pressure bursts.

Scheme 104

Indicator only shows a correct pressure once back pressure of residual pressure valve is overcome. The back pressure is approx. 3.5 bar. The suspension strut (air spring suspension) is charged sufficiently with gas when a pressure of 3.5 to 4.5 bar is reached.

1. When charging, make sure that pressure does not rise above 4.5 bar.
2. Remove air spring filler unit VAS 6231 from adapter T10157/1 , this dissipates the gas above a pressure of 3.5 bar.

The minimum pressure has now been reproduced. Suspension strut (air spring suspension) can be removed from packaging.

1. After installing, set first to high setting then to normal setting. Repeat this procedure once more.

Most of the gas will be replaced with the filtered air from the air supply unit once the suspension has twice moved up and down to these settings.

1. Install suspension strut (air spring suspension) --> Identifying «Suspension strut (air spring suspension) with mounting bracket, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Upper link (air spring suspension), removing and installing

1. Suspension strut (air spring suspension) with mounting bracket, removing and installing --> «Suspension strut (air spring suspension) with mounting bracket, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Further procedures as for removing and installing upper link (coil spring) --> Upper link (coil spring), removing and installing .

1. Suspension strut (air spring suspension) with mounting bracket, removing and installing --> «Suspension strut (air spring suspension) with mounting bracket, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Further procedures as for replacing upper link bearing at front and rear (coil spring) --> Bearing for upper front and rear link, replacing .

Scheme 105

1 - Hex bolt 70 Nm plus an additional 180 ° turn

1. Always replace after removal

2 - Guide link

1. Removing and installing --> «Guide link, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
2. Replace guide link bearings --> «Guide link bearing, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

3 - Wheel bearing housing

4 - Self-locking hex nut, 110 Nm

1. Always replace after removal
2. After loosening threaded connection of guide link to wheel bearing housing, adhesive residue must be removed on thread of linkage stub.

5 - Self-locking hex nut, 110 Nm

1. Always replace after removal
2. After loosening threaded connection of control arm to wheel bearing housing, adhesive residue must be removed on thread of linkage stub.

6 - Hex nut

1. Always replace after removal

7 - Hex bolt 40 Nm plus an additional 90 ° turn

1. Always replace after removal

8 - Shock absorbers

9 - Hex bolt 90 Nm and turn an additional 90 °

1. Always replace after removal

10 - Stabilizer

11 - Self-locking hex nut, 8 Nm

1. Always replace after removal

12 - Control arm

1. Removing and installing --> «Control arm, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-arm-removing-and-installing)
2. Replacing bearings for control arm --> «Control arm bearing, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-arm-bearing-replacing)

13 - Left Front Level Control System Sensor G78 or Right Front Level Control Sensor G289

1. Removing and installing or replacing only as complete set --> «Front Vehicle Level Sensor , removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__front-vehicle-level-sensor-removing)
2. Sensor lever must point toward front
3. After loosening, check basic setting of headlamp adjustment --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .
4. After loosening, control position must be adapted again in vehicles with air spring suspension --> «Control position, adapting again»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-position-adapting-again) .

14 - Bolt, 5 Nm

15 - Mounting bracket

16 - Bolt, 10 Nm

17 - Hex bolt, 40 Nm plus an additional 90 ° turn

1. Always replace after removal

18 - Coupling rod

19 - Hex nut

1. Always replace after removal

20 - Hex bolt 70 Nm plus an additional 180 ° turn

1. Always replace after removal

21 - Hex nut

1. Always replace after removal

22 - Hex nut

1. Always replace after removal

23 - Subframe

Control arm, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332

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

1. Vehicle Diagnostic, Testing and Information System VAS 5051 B with corresponding diagnostic cable.

Scheme 106

1. Ball joint puller T40042

Removing

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Perform system bleed using Diagnostic Operation System VAS 5051 A --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .

Applies to all vehicles

1. Remove decorative wheel cover, for light-alloy wheels pull off protective cap (use pulling hook in vehicle tool kit).
2. Remove wheel.
3. Remove noise insulation --> «50 - BODY - FRONT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

1. In vehicles with level control system sensor, remove nut - 6 -.
2. Remove nut from linkage stub of control arm far enough so that it is flush with thread of linkage stub. Use 6 mm socket wrench to counterhold linkage stub, if necessary.

Scheme 107

1. Press linkage stub of control arm off conical seating using ball joint puller T40042.

Note. Be sure that both lever arms of puller are parallel to each other during greatest applied pressure, adjust if necessary. In order not to damage the joints of the upper links, it is necessary to use engine/transmission jack V.A.G 1383 A , for example, to brace wheel bearing housing against too strong rebound.

1. Remove hex bolt - 1 -.
2. Remove bolt - 2 - and - 4 - , remove coupling.
3. Remove hex bolt - 3 -.
4. Remove control arm.

Installing

Installation is in reverse order of removal. Note the following

Note. Bonded rubber bushings can only be turned to a limited extent. The bolted connections on the wheel suspension should therefore only be tightened when the vehicle is in curb weight position or control position. For vehicles with coil springs, lift wheel suspension in curb weight position --> For vehicles with coil springs, lift wheel suspension in curb weight position For vehicles with air spring suspension, lift wheel suspension in control position --> For vehicles with air springs, lift wheel suspension in control position

1. Remove adhesive residue at stub thread of control arm.

1. In vehicles with level control system sensor, install nut - 6 -.
2. Install wheel and tighten --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Tightening torques: --> Control arm, guide link, level control system sensor, assembly overview

1. Install wheel.
2. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Tighten wheel --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
4. On vehicles with automatic headlamp range control system, perform basic setting of headlamps --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .

1. Adapt control position again on vehicles with air spring suspension --> «Control position, adapting again»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-position-adapting-again) .

Control arm bearing, replacing

Pressing out and in bearing for control arm (on wheel bearing housing side)

Scheme 108

Special tools, testers and auxiliary items required

1. Thrust plate VW 402
2. Punch VW 412
3. Tube VW 516
4. Tube 3296

1. Assembly paste G 052 109 A2

Note. Hold control arm firmly in position while pressing bearing out and in.

Pressing out bearing

1. Remove control arm --> «Control arm, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-arm-removing-and-installing) .

Scheme 109

1. Mark rim offset - arrow - on bearing - 1 -.

Use e.g. a waterproof felt marker for marking.

1. Arrange special tools as shown in illustration.
2. Press bearing - 1 - out of control arm - 2 -.

Pressing in bearing

1. Transfer marking of rim offset from old onto new bearing.
2. Coat bearing thinly with assembly paste G 052 109 A2 .

Scheme 110

1. Insert bearing - 1 - into control arm - 2 -.
2. Arrange special tools as shown in the illustration.

Note. When pressing in, make sure that bearing is not canted.

1. Press bearing - 1 - into control arm - 2 -.
2. When pressing in, note marking to rim offset - arrow -.

Scheme 111

1. Check rim offset of bearing - 1 - in control arm - 2 -.

Dimensions - a - and - b - must be identical.

1. If dimensions - a - and - b - are different, press bearing further - 1 -.
2. Install control arm --> «Control arm, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-arm-removing-and-installing) .

Bearing for control arm (on subframe side), pressing out and pressing in

Scheme 112

Special tools, testers and auxiliary items required

1. Thrust plate VW 402
2. Punch VW 412
3. Tube 3296
4. Assembly tool T40032

1. Assembly paste G 052 109 A2

Note. Hold control arm firmly in position while pressing bearing out and in.

Pressing out bearing

1. Remove control arm --> «Control arm, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-arm-removing-and-installing) .

Scheme 113

1. Mark rim offset - arrow - on bearing - 1 -.

Use e.g. a waterproof felt marker for marking.

1. Arrange special tools as shown in the illustration.
2. Press bearing - 1 - out of track control arm - 2 -.

Pressing in bearing

1. Transfer marking of rim offset from old onto new bearing.
2. Coat bearing thinly with assembly paste G 052 109 A2 .

Scheme 114

1. Insert bearing - 1 - into control arm - 2 -.
2. Arrange special tools as shown in the illustration.

Note. When pressing in, make sure that bearing is not canted.

1. Press bearing - 1 - into control arm - 2 -.
2. When pressing in, note marking to rim offset - arrow -.

Scheme 115

1. Check rim offset of bearing - 1 - in control arm - 2 -.

Dimensions - a - and - b - must be identical.

1. If dimensions - a - and - b - are different, press bearing further - 1 -.
2. Install control arm --> «Control arm, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-arm-removing-and-installing) .

Scheme 116

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1332
2. Ring insertion tool V.A.G 1332/7
3. Ball joint puller T40043

Removing

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

1. Remove decorative wheel cover, for light-alloy wheels pull off protective cap (use pulling hook in vehicle tool kit).
2. Remove wheel.
3. Remove noise insulation --> «50 - BODY - FRONT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Remove nut from linkage stub of guide control arm far enough so that it is flush with thread of linkage stub. Use 6 mm socket wrench to counterhold linkage stub, if necessary.

Scheme 117

1. Press linkage stub of guide link off conical seating using ball joint puller T40043.

Note. Be careful not to damage CV boot in the process! Be sure that both lever arms of puller are parallel to each other during greatest applied pressure.

Scheme 118

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

Installing

Installation is in reverse order of removal. Note the following

1. Remove adhesive residue at stub thread of guide link.

Note. Bonded rubber bushings can only be turned to a limited extent. The bolted connections on the wheel suspension should only be tightened when the vehicle is in curb weight position or control position. For vehicles with coil springs, lift wheel suspension in curb weight position --> For vehicles with coil springs, lift wheel suspension in curb weight position For vehicles with air spring suspension, lift wheel suspension in control position --> For vehicles with air springs, lift wheel suspension in control position

Tightening torques: --> Control arm, guide link, level control system sensor, assembly overview

1. Install wheel.
2. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Tighten wheel --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 119

Special tools, testers and auxiliary items required

1. Thrust plate VW 402
2. Punch VW 407
3. Press tool 3345
4. Assembly tool 3347/1

Note. Hold guide link firmly in position while pressing bearing out and in.

Pressing out bearing

1. Remove guide link --> «Guide link, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 120

1. Mark rim offset - arrow - on bearing - 1 -.

Use e.g. a waterproof felt marker for marking.

1. Arrange special tools as shown in the illustration.
2. Press bearing - 1 - out of control arm - 2 -.

Pressing in bearing

Scheme 121

1. Transfer marking of rim offset from old onto new bearing - arrow -.
2. Coat bearing thinly with assembly paste G 052 109 A2 .

Scheme 122

Installed position of bearing

A = ~ 90 ° ± 5 °

Arrows on bearing - B - points in opposite direction of ball stud.

1. Insert bearing - 1 - into guide link - 2 - , observe installation position.
2. Arrange special tools as shown in the illustration.

Note. When pressing in, make sure that bearing is not canted.

1. Press bearing - 1 - into guide link - 2 -.
2. When pressing in, note marking to rim offset - arrow -.

Scheme 123

1. Check installation position of bearing - 1 - in guide link - 2 -.
2. Check rim offset of bearing - 1 - in guide link - 2 -.

Dimensions - a - and - b - must be identical.

1. If dimensions - a - and - b - are different, press bearing further - 1 -.
2. Install guide control arm --> «Guide link, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Level control system sensor, removing and installing

1. Level control system sensor, removing and installing --> «Front Vehicle Level Sensor , removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__front-vehicle-level-sensor-removing) .

Scheme 124

1 - Wheel bearing housing

1. Removing and installing --> «Wheel bearing housing, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__wheel-bearing-housing-removing-and-installing)

2 - Hex nut

3 - Bolt

4 - Hex bolt, 7 Nm

1. For setting toe constants "S"

5 - Self-locking hex nut, 45 Nm

6 - Ball bearing

1. Removing and installing --> «Wheel bearing unit, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__wheel-bearing-unit-removing-and-installing)

7 - Wheel hub

1. Pressing out and pressing in --> «Wheel bearing unit, servicing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

8 - Collar bolt, 200 Nm plus an additional 180 ° turn

1. Always replace after removal
2. Observe work sequence with loosening and tightening collar bolt --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__collar-bolt-for-outer-joint-of)

9 - Hex bolt, 45 Nm

10 - Brake heat shield

11 - Socket-head bolt, 10 Nm

12 - Wheel speed sensor

13 - Socket-head bolt, 8 Nm

14 - Self-locking hex nut, 110 Nm

1. Always replace after removal
2. After loosening threaded connection of control arm to wheel bearing housing, adhesive residue must be removed on thread of linkage stub.

15 - Self-locking hex nut, 110 Nm

1. Always replace after removal
2. After loosening threaded connection of guide link to wheel bearing housing, adhesive residue must be removed on thread of linkage stub.

16 - Control arm

17 - Guide link

18 - Countersunk bolt, 80 Nm plus an additional 90 ° (1/4 turn)

1. Always replace after removal

19 - Twelve-point socket head bolt, 70 Nm

20 - Drive axle

Wheel bearing housing, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332

Scheme 125

1. Ring insertion tool V.A.G 1332/7

Scheme 126

1. Torque wrench V.A.G 1576

1. Vehicle Diagnostic, Testing and Information System VAS 5051 B with corresponding diagnostic cable.

1. Ball joint puller T40042

Scheme 127

1. Ball joint puller T40043

1. CV joint boot clamp tool T40067

Removing

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Perform system bleed using VAS 5051 B --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .

Applies to all vehicles

1. Remove decorative wheel cover, for light-alloy wheels remove protective cap (use pulling hook in vehicle tool kit).
2. Loosen collar bolt for outer joint of drive axle (only loosen when vehicle is standing on its wheels -danger of accident-) --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__collar-bolt-for-outer-joint-of) .
3. Pull cable of ABS wheel speed sensor out of bracket on wheel bearing housing.
4. Remove brake caliper and secure it to body so that the weight of the brake caliper does not stress or damage brake hose or brake line.

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

Scheme 128

1. Remove bolts - arrows - and remove shielding plate.

Scheme 129

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

Scheme 130

Note. Do not use a chisel or similar tool to press out tie rod between steering arm - 1 - and seal - 2 - on tie rod ball joint, otherwise seal will be damaged. Slits in wheel bearing housing may not be widened with a chisel or similar tool! Tie rod must only be pressed over joint end of tie rod ball joint out of steering arm or knocked using a wooden or rubber mallet. Perform vehicle alignment after a repair --> Wheel Alignment . Pull out or press out tie rod downward. Remove nut from linkage stub of guide link far enough so that it is flush with thread of linkage stub. Use 6 mm socket wrench to counterhold linkage stub, if necessary.

1. Press linkage stub of guide link off conical seating using ball joint puller T40043.

Note. Be careful not to damage CV boot in the process! Be sure that both lever arms of puller are parallel to each other during greatest applied pressure.

1. In vehicles with level control system sensor, remove nut - 6 -.
2. Remove nut from linkage stub of control arm far enough so that it is flush with thread of linkage stub. Use 6 mm socket wrench to counterhold linkage stub, if necessary.

1. Press linkage stub of control arm off conical seating using ball joint puller T40042.

Note. Be sure that both lever arms of puller are parallel to each other during greatest applied pressure.

1. Disconnect threaded connection - 1 - and pull out both links - 2 - upward.

Slits in wheel bearing housing may not be widened with a chisel or similar tool!

1. Swing away wheel bearing housing toward side while pulling drive axle end out of wheel hub.
2. Secure drive axle to body using e.g. wire.
3. Remove nut from linkage stub of control arm.
4. Remove wheel bearing housing.

Installing

Installation is in reverse order of removal. Note the following

1. Insert wheel bearing housing.
2. Push outer joint of drive axle into wheel hub and hand-tighten new collar bolt.
3. Insert linkage stub of control arm and guide link into wheel bearing housing.
4. Remove adhesive residue at stub thread of control arm and guide link.

1. Install new self-locking nuts on control arm and guide link and tighten --> «Wheel bearing housing, wheel bearing unit, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) linkage stubs, counterhold using 6 mm hex socket wrench if necessary.

1. Insert both linkage stubs of upper links in wheel bearing housing and tension downward as far as possible using pliers T40067.

1. Insert new bolt - 2 - and self-locking nut and tighten --> «Wheel bearing housing, wheel bearing unit, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Note. Tie rod (tie rod ball joint) must only be inserted by hand into steering arm - 1 -. Seal - 2 - must not be subjected to load under any circumstances.

1. Insert tie rod.

1. Install new self-locking nut - 4 - and tighten --> «Wheel bearing housing, wheel bearing unit, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Tighten hex bolt - 3 - --> «Wheel bearing housing, wheel bearing unit, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Install ABS wheel speed sensor --> «45 - ANTI-LOCK BRAKE SYSTEM»(/audi/s6/c6-2006-2008/remont/anti-locktraction-control/#brake-system) .

1. In vehicles with level control system sensor, install nut - 6 -.

1. Install cover plate and tighten --> «Wheel bearing housing, wheel bearing unit, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Install brake disc and install on brake caliper. --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/s6/c6-2006-2008/remont/anti-locktraction-control/#brake-system)
3. Install wheel.
4. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Tighten wheel --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Tighten collar bolt for outer joint of drive axle (only tighten when vehicle is standing on its wheels -danger of accident-) --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__collar-bolt-for-outer-joint-of) .
3. On vehicles with automatic headlamp range control system, perform basic setting of headlamps --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .
4. Adapt control position again on vehicles with air spring suspension --> «Control position, adapting again»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-position-adapting-again) .

1. Perform vehicle alignment --> «Wheel Alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Suspension setting at front axle must be performed on a VW/Audi approved wheel alignment stand.

Wheel bearing unit, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332

1. Torque wrench V.A.G 1576

1. CV joint boot clamp tool T40067

Removing

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

1. Remove decorative wheel cover, for light-alloy wheels pull off protective cap (use pulling hook in vehicle tool kit).
2. Loosen collar bolt for outer joint of drive axle (only loosen when vehicle is standing on its wheels -danger of accident-) --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__collar-bolt-for-outer-joint-of) .
3. Remove noise insulation --> «50 - BODY - FRONT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Remove brake caliper and secure to body so that the weight of the brake caliper does not stress or damage brake hose or brake line --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/s6/c6-2006-2008/remont/anti-locktraction-control/#brake-system) .

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

Scheme 131

1. Remove drive axle - 1 - from flange shaft/transmission.

1. Disconnect threaded connection - 1 - and pull out both links - 2 - upward.

Slits in wheel bearing housing may not be widened with a chisel or similar tool!

1. Swing away wheel bearing housing toward side while pulling drive axle end out of wheel hub.
2. Remove drive axle.

1. Insert both joint stubs of upper links - 2 - in wheel bearing housing and only insert bolt - 1 -.

Note. This work step is necessary to prevent damage to parts of suspension when loosening and tightening the countersunk bolts.

Scheme 132

1. Remove countersunk bolts - 1 -.
2. Remove wheel bearing unit.
3. Servicing wheel bearing unit --> «Wheel bearing unit, servicing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Installing

Installation is in reverse order of removal. Note the following

1. Insert both linkage stubs of upper links in wheel bearing housing and tension downward as far as possible using pliers T40067.

1. Insert new bolt - 2 - and self-locking nut and tighten --> «Wheel bearing housing, wheel bearing unit, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Tightening torques: --> Wheel bearing housing, wheel bearing unit, assembly overview

1. Install wheel.
2. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Tighten wheel --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 133

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

Special tools, testers and auxiliary items required

Scheme 134

1. Press tube 40-20

Scheme 135

1. Thrust piece VW 473

1. Separating tool 3 Kukko 17/2

Scheme 136

1. Assembly tool T40089/1 for wheel bearing with 85 mm diameter or assembly tool T40089/2 for wheel bearing with 92 mm diameter
2. Wheel bearing unit removed --> «Wheel bearing unit, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__wheel-bearing-unit-removing-and-installing)

Scheme 137

Pressing wheel hub out of wheel bearing with 85 mm diameter

Scheme 138

Pressing wheel hub out of wheel bearing with 92 mm diameter

Scheme 139

Pressing off bearing inner race of wheel hub with 85 mm diameter or 92 mm diameter

1. Insert separator between bearing inner race - 1 - and spinning washer - 2 - and preload spindle.

Note. Use a commercially available separator, e.g. Kukko 17/2.

This deforms the spinning washer and must then be replaced.

Scheme 140

1. Press off bearing inner race from wheel bearing with 85 mm diameter or 92 mm diameter of wheel hub.

Scheme 141

Replacing spinning washer of wheel bearing with 85 mm diameter or 92 mm diameter

1. Carefully pry off old spinning washer - 1 - using a screwdriver.
2. Position new spinning washer on wheel hub.

Scheme 142

1. Attach special tools as shown in figure.

1. Thrust piece VW 473
2. Assembly tool T40089/1 for wheel bearing with 85 mm diameter or assembly tool T40089/2 for wheel bearing with 92 mm diameter
3. Spinning washer
4. Wheel hub
5. Thrust plate VW 401

1. Press on spinning washer up to radius of wheel bearing hub using assembly tool T40089/1 or T40089/2 as shown in the illustration.

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

Scheme 143

Pressing wheel hub into wheel bearing with 85 mm diameter

1. When pressing in, pressure pad VW 511 may only lie against bearing inner race.

Scheme 144

Pressing wheel hub into wheel bearing with 92 mm diameter

1. When pressing in, sleeve 40-20 may only lie against bearing inner race.

Note. Machined surface of wheel bearing outer race points upward.

1. Install wheel bearing unit --> «Wheel bearing unit, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__wheel-bearing-unit-removing-and-installing) .

Scheme 145

1 - Tunnel cross member

1. Removing and installing --> «Tunnel cross member, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__tunnel-cross-member-removing-and-installing)

2 - Bolt and washer assembly, 50 Nm

3 - Combination nut, 23 Nm

4 - Multi-point socket head bolt, 25 Nm

5 - Dome brace

1. Removing and installing --> «Dome brace, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__dome-brace-removing-and-installing)

6 - Multi-point socket head bolt, 25 Nm

Tunnel cross member, removing and installing

Special tools, testers and auxiliary items required

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

1. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332

Removing

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

On vehicles with dual exhaust system, remove noise insulation and left or right exhaust pipe.

1. Remove noise insulation --> «50 - BODY - FRONT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove exhaust system --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281370-S23494820212008031100000) for 3.2 LITER V6 4V GENERIC SCAN TOOL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BAT, BNK 26 EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V GENERIC SCAN TOOL, ENGINE CODE(S): BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .
3. Support transmission using engine/transmission jack V.A.G 1383 A and a hard wood support.

Scheme 146

1. Remove bolts - 1 - and - 3 - , and nuts - 2 -.
2. Remove tunnel cross member.

Installing

Installation is in reverse order of removal. Note the following

Tightening torques: --> Tunnel cross member, dome brace, assembly overview

1. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Dome brace, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

Removing

Scheme 147

1. Remove rubber seal - 1 - for plenum chamber cover.
2. Remove plenum chamber cover see - arrows - toward front.

Scheme 148

1. Remove socket head bolts - 1 - and - 3 -.

Allocation of socket head bolts Electronic Parts Catalog "ETKA"

1. Remove dome brace - 2 - upward from plenum chamber.

Installing

Installation is in reverse order of removal. Note the following

Tightening torques: --> Tunnel cross member, dome brace, assembly overview

Drive axle, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1332

1. Torque wrench V.A.G 1576
2. Pliers T40067

Removing

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

1. Remove wheel.
2. Loosen collar bolt for outer joint of drive axle --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__collar-bolt-for-outer-joint-of) .
3. Remove noise insulation --> «50 - BODY - FRONT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Remove drive axle - 1 - from flange shaft/transmission.
2. Remove drive axle.

If there is not sufficient room to remove drive axle, the following steps must be performed

1. Disconnect threaded connection - 1 - and pull out both links - 2 - upward.

Slits in wheel bearing housing may not be widened with a chisel or similar tool!

1. Swing away wheel bearing housing toward side while pulling drive axle end out of wheel hub.
2. Remove drive axle.

Installing

Installation is in reverse order of removal. Note the following

1. Insert both linkage stubs of upper links in wheel bearing housing and tension downward as far as possible using pliers T40067.

1. Insert new bolt - 2 - and self-locking nut and tighten.
2. Tightening torque for drive axle to flange shaft/transmission.
3. Install wheel.
4. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Tighten wheel --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Tighten collar bolt for outer joint of drive axle --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__collar-bolt-for-outer-joint-of) .

Collar bolt for outer joint of drive axle, loosening and tightening

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1576

Loosening collar bolt for outer joint of drive axle

1. Remove decorative wheel cover, for light-alloy wheels pull off protective cap (use pulling hook in vehicle tool kit).

1. Loosen collar bolt for outer joint of drive axle a maximum of 90 ° (only loosen when vehicle is standing on its wheels -danger of accident-)
2. Raise vehicle and remove wheel.
3. Install all five wheel bolts again hand-tight.

A second technician is required for the following work step

1. 1. Technician: Sits in vehicle and operates foot brake
2. 2. Technician: Remove collar bolt for drive axle.

Wheel bearings must not be burdened while collar bolt is loose or removed.

If wheel bearing is burdened by weight of vehicle itself, wheel bearing will be pre-damaged. This will diminish wheel bearing service life.

If it should be necessary to move a vehicle whose drive axle has been removed, then before doing so, install an outer joint in place of the drive axle and tighten it to 200 Nm, or else wheel bearing will be damaged.

Tightening collar bolt for outer joint of drive axle

1. Replace collar bolt.

A second technician is required to tighten collar bolt for drive axle

1. 1. Technician: Sits in vehicle and operates foot brake.
2. 2. Technician: Tightens collar bolt for drive axle only to pre-tightening torque --> «Wheel bearing housing, wheel bearing unit, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Install wheel and set vehicle on the wheels.

1. Tighten collar bolt to additional torque angle (only tighten when vehicle is standing on its wheels -danger of accident-) --> «Wheel bearing housing, wheel bearing unit, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 149

1 - Clamp

1. Always replace
2. Tensioning --> «Small and large clamp on triple roller joint and outer joint, tensioning»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__small-and-large-clamp-on-triple)

2 - CV boot for triple roller joint

1. CV boot must make contact in groove and contour of joint piece.
2. Before tightening clamp, briefly raise CV boot to allow pressure to equalize.

3 - Clamp

1. Always replace
2. Tensioning --> «Small and large clamp on triple roller joint and outer joint, tensioning»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__small-and-large-clamp-on-triple)

4 - Circlip

1. Always replace
2. Insert in ring groove of shaft before installation (not visible on installed joint)
3. Before installing CV joint, align sealing ring in center with opening facing upward.

5 - Outer CV joint

1. Replace only as complete unit
2. Removing «Disassembling outer constant velocity joint»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__disassembling-outer-constant-velocity-joint)
3. Checking --> «Outer CV joint, checking»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__outer-cv-joint-checking)
4. Installing «Installing outer constant velocity joint»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__installing-outer-constant-velocity-joint)

1. Grease «Grease quantities and types»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__grease-quantities-and-types)
2. When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.

6 - Collar bolt

1. Always replace after removal
2. Observe work sequence with loosening and tightening collar bolt --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__collar-bolt-for-outer-joint-of)

7 - Clamp

1. Always replace
2. Tensioning --> «Small and large clamp on triple roller joint and outer joint, tensioning»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__small-and-large-clamp-on-triple)

8 - CV boot for outer Constant Velocity (CV) joint

1. Check for tears and scuffing
2. Before tightening clamp, briefly raise CV boot to allow pressure to equalize.

9 - Clamp

1. Always replace
2. Tensioning --> «Small and large clamp on triple roller joint and outer joint, tensioning»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__small-and-large-clamp-on-triple)

10 - Axle shaft

11 - Circlip

1. Allocation Electronic Parts Catalog "ETKA"

12 - Triple roller star

Chamfer - arrow - faces splines of axle shaft

1. When installing triple roller star on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.

13 - Circlip

1. Replace
2. Insert in groove on axle shaft

14 - Bolt

1. Allocation Electronic Parts Catalog "ETKA"

15 - Joint piece

Grease quantities and types

Re-grease joint when replacing CV boot.

Electronic Parts Catalog "ETKA" for grease filling of joints.

Note. Note the different types of grease for outer and inner joints.

Scheme 150

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. Tube VW 416 B
2. Thrust pad VW 447 H

Scheme 151

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

Special tools, testers and auxiliary items required

Scheme 152

1. Slide hammer VW 771

Scheme 153

1. Assembly tool T40018
2. Brass or copper mandrel

Disassembling peened triple roller joint AAR 3300 i

1. Clamp drive axle horizontally into vise.

Note. Use protective jaws. Make sure drive axle is not damaged. Mark position of joint piece to drive axle.

If they are not marked and are not re-installed in their previously installed positions, noises may occur later during driving operation.

A water-proof felt pen is well-suited for marking.

Scheme 154

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

Scheme 155

1. Guide assembly tool T40018 in behind joint piece.

Guide pin - 1 - must make contact with exterior of joint piece.

1. Turn knurled bolts - 2 - at joint piece until assembly tool T40018 makes contact.

Note. Joint piece must be secured in assembly tool T40018 without play. Tighten bolts - 2 - only hand-tight.

Scheme 156

1. Install slide hammer-complete set VW 771 into assembly tool T40018.
2. Pull off joint piece horizontally using knocking tool.

Leave joint piece in assembly tool T40018.

Scheme 157

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

If they are not marked and are not re-installed in their previously installed positions, noises may occur later during driving operation.

A water-proof felt pen is well-suited for marking.

1 - Axle shaft

2 - Triple roller star

1. Remove grease with a lint free rag.

Scheme 158

1. Remove circlip with (commercially available) pliers - 1 -.

Scheme 159

1. Pressing triple roller star off of axle shaft.

Assembly device T10065/4 must not make contact on roller body.

1. Remove CV boot.
2. Remove grease on splines of shaft
3. Check rollers and track for wear.
4. Clean axle shaft and housing.

Assembling tripod joint AAR 3300 i

Scheme 160

1. Before installing triple roller star, splines - A - must be lightly coated with grease used in joint.
2. Slide new CV boot onto axle shaft.

Scheme 161

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

Scheme 162

1. Use special tools shown in illustration.

T10065/3 for drive axles with cylindrical end must be used in place of T10065/2 for drive axles with tapered end This depiction is only valid for drive axles with a cylindrical shape at the end under Peened triple roller joint AAR 3300 i, disassembling and assembling .

Press triple roller star onto axle shaft

Scheme 163

This depiction is only valid for axles shafts with a conical shape at the end - arrow - !

Chamfer on star faces toward axle shaft, it facilitates assembly.

1. Use special tools shown in illustration.

Special tool T10065/2 must not make contact on roller body.

1. Place triple roller star on shaft according to marking and drive on until impact.
2. Circlip must engage audibly, triple roller star must contact circlip gap-free.

Scheme 164

This depiction is only valid for drive axles with a cylindrical shape at the end - arrow - !

Chamfer on star faces toward drive axle, it facilitates assembly.

1. Use special tools shown in illustration.

Special tool T10065/3 must not make contact on roller body.

1. Place triple roller star on shaft according to marking and drive on until impact.
2. Circlip must engage audibly, triple roller star must contact circlip gap-free.

1. Install circlip with (commercially available) pliers - 1 -.
2. Press 70 grams of high temperature grease from repair kit into triple roller joint.
3. Lightly grease rolling body.

Make sure roller bodies do not cant!

Scheme 165

1. Press joint piece over triple roller star using a plastic mallet.
2. Press remaining amount of grease into CV boot.
3. Make sure boot is properly seated on joint piece.
4. Boot must make contact in groove and contour of joint piece

Scheme 166

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

Note. Vent CV boot - arrow - , e.g. using a screwdriver, while positioning joint piece in center position.

1. Mount clamp

Scheme 167

Note. Position crimping tab - 2 - of the clamp between mounting flanges - 1 - of joint piece. This will facilitate threading the socket head bolts during installation of the drive axle

1. Tension clamps on triple roller joint --> «Small and large clamp on triple roller joint and outer joint, tensioning»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__small-and-large-clamp-on-triple)

Disassembling outer constant velocity joint

1. Clamp axle shaft in vise with protective pads.
2. Open both clamps and pull off CV joint boot from outer joint.

Scheme 168

1. Using a hammer hit a copper or brass mandrel - A - onto inner ring of constant velocity joint.
2. Remove joint and joint boot.

Installing outer constant velocity joint

1. Slide on joint boot with small clamp onto axle shaft.

CV boot and axle shaft must be free of grease

Scheme 169

1. Always replace circlip (engaging ring) - 1 -.
2. Position CV boot in outer groove - arrow B -.

Inner groove - arrow A - must remain visible "identification groove" (for correct installation of CV boot).

1. Pack specified quantity of grease into interior of joint piece, see table «Grease quantities and types»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__grease-quantities-and-types) .

1. Before installing joint piece, splines - A - must be lightly coated with grease used in joint.
2. Insert sealing ring in groove on shaft.
3. Slide on CV joint up to sealing ring.

Scheme 170

1. Align sealing ring at center with opening upward - arrows -.

Scheme 171

1. Thread old drive axle bolt into joint piece as depicted in illustration.
2. Drive joint onto axle shaft using plastic hammer, until circlip engages.
3. Pack specified quantity of grease into joint on boot side, see table «Grease quantities and types»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__grease-quantities-and-types) .
4. Slide CV boot onto joint piece.

1. Make sure joint boot is properly seated on joint piece.
2. CV boot must make contact in groove and contour of the joint piece.
3. Tension clamps on outer joint --> «Small and large clamp on triple roller joint and outer joint, tensioning»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__small-and-large-clamp-on-triple) .

Outer CV joint, checking

Joint must be disassembled in order to replace the grease in case of strong soiling, or when the journal surfaces of the balls must be checked for wear and damage.

Disassembling

1. Mark position of ball hub to ball cage and to housing before disassembling, using electro-writer or grindstone.

Scheme 172

1. Swing ball hub and ball cage.
2. Remove balls in sequence.

Scheme 173

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

Scheme 174

1. Swing segment of hub with shortened end into rectangular window of cage.
2. Fold hub out from cage.

Check

The 6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small depressions (pitting build-up) and chafing. Excessive circumferential backlash in joint makes itself noticed via tip-in shock, in such cases the joint must be replaced. Flattening and running marks of balls are no reason to replace joint.

Assembling

1. Insert cage with hub into joint body.

Note. For this, cage must be inserted on the correct side.

1. Press in opposing balls in sequence, during this the previous position of ball hub to ball cage and to joint body must be re-established.
2. Pack quantity of grease into joint body «Grease quantities and types»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__grease-quantities-and-types) .

Small and large clamp on triple roller joint and outer joint, tensioning

Instructions are only valid for stainless steel tensioning clamps!

Zinc-coated clamps for rubber joint boots are tensioned using hose clamp pliers V.A.G 1275.

Scheme 175

1. Use CV joint boot clamp tool V.A.G 1682 as shown in illustration. Be sure that edges of clamping pliers are seated in corners - arrows B - of hose clamp.
2. Tension clamp by turning spindle using a torque wrench (do not tilt clamp tool).

1. Tightening torque: 20 Nm.
2. Use torque wrench with adjustment range 5 to 50 Nm (e.g. Torque Wrench 5-50 Nm V.A.G 1331 ).
3. Be sure thread of spindle of pliers - A - moves freely. Grease with MoS 2 grease if necessary.
4. If it does not move freely, e.g. due to dirt in thread, the required clamp tension will not be achieved at the specified torque.

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

The tightening torques stated apply to non-oiled nuts and bolts.

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

Always prevent the following effects at coil springs: Hammer blows, weld splashes, apply new color markings.

Do not perform welding or cutting operations (separating work) in area of coil springs or suspension struts! If necessary, cover coil springs or suspension struts.

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 200 Nm.

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 in curb weight position or control position.

1. For vehicles with coil springs, lift wheel suspension in curb weight position --> «For vehicles with coil springs, lift wheel suspension in curb weight position»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
2. For vehicles with air spring suspension, lift wheel suspension in control position --> «For vehicles with air springs, lift wheel suspension in control position»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

If the vehicle still needs to be aligned, the bolts and nuts which must be loosened during alignment work must only be tightened with tightening torque. After performing alignment/adjustment the bolts and nuts must be tightened with the prescribed additional torque angle!

Contact corrosion can occur if inappropriate connecting elements (bolts, nuts, washers, ) are used.

For this reason, only connecting elements with a special surface coating are installed (Dachromet). These elements are distinguished by their greenish hue.

Furthermore, all rubber, plastic and adhesive materials used are non-conductive.

If you have doubts about the reusability of parts, it is generally better to install new parts.

Note the following

Use only authorized parts! They have been tested and are aluminum compatible.

Additional equipment must be authorized by Audi AG!

Damage via contact corrosion is not covered by warranty!

Damaged threads in longitudinal member (subframe to body), repairing

Damaged threads can be repaired using wire inserts (heli-coil).

Component overview indicates which threads can be repaired.

Shavings that remain in the chassis must be embedded in wax.

Servicing the thread in the weld nuts in long member 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.

1. Have responsible foreman or next superior check thread repair.
2. Thread insert must have same length as thread in body.
3. Repair any damage to the underbody sealant.

For vehicles with coil springs, lift wheel suspension in 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 at suspension parts with bonded rubber bushings must always be tightened in curb weight position (unloaded condition).

Bonded rubber bushings can only be turned to a limited extent.

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

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

This position can be simulated on the lifting platform by raising the corresponding wheel suspension using engine/transmission jack V.A.G 1383 A and wheel hub support T10149.

1. For example, measure dimension - a - from center of wheel to lower edge of wheel housing using a tape measure before starting work.

Measurement must be performed in curb weight position (unloaded condition).

1. Note measured value. It will be required for tightening bolts/nuts.

Before lifting corresponding wheel suspension, vehicle must be strapped down using tensioning straps T10038 at lift arms of lifting platform.

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

1. Remove wheel.
2. Turn wheel hub far enough until one of the holes for wheel bolts is on top.
3. Install wheel hub support T10149 with wheel bolt to wheel hub.

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 wheel housing, has been attained

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

1. Tighten respective bolts/nuts.
2. Lower wheel bearing housing.
3. Remove engine/transmission jack V.A.G 1383 A from below vehicle.
4. Remove wheel hub support T10149.

For vehicles with air springs, lift wheel suspension in control position

Special tools, testers and auxiliary items required

1. Engine/transmission jack V.A.G 1383 A
2. Torque wrench V.A.G 1783
3. Wheel hub support T10149

Special tools, testers and auxiliary items required

1. Insertion tool 10 mm V.A.G 1783/1

Bonded rubber bushings can only be turned to a limited extent.

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

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

This position can be simulated on the lifting platform by raising the wheel bearing housing using engine/transmission jack V.A.G 1383 A and wheel hub support T10149.

Requirement

1. Engine must be installed.

1. Set vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Perform system bleed using VAS 5051 A --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .

Scheme 176

1. Remove bolt - 1 - and pull wheel house liner aside.

Scheme 177

1. Slowly loosen air line - 1 - for connection - 2 - and let air pressure dissipate. Once air pressure has dissipated, remove air line.
2. Seal both connections. When doing this, make sure that no particles of dirt penetrate into the connections.
3. Turn wheel hub far enough until one of the holes for wheel bolts is on top.

1. Install wheel hub support T10149 with wheel bolt.
2. Insert wheel hub support T10149 into engine/transmission jack V.A.G 1383 A and press wheel bearing housing far enough upward until control position, dimension - a - , is obtained.

Control position

1. Dimension - a - for vehicles with air suspension 384 mm
2. Dimension - a - for allroad vehicles with air spring 380 mm

Work operations after setting control position

1. Tighten respective bolts/nuts.
2. Lower wheel bearing housing.
3. Remove engine/transmission jack from below vehicle.
4. Remove wheel hub support T10149.

1. Install air line - 1 - onto connection - 2 -.

1. Install bolt - 1 -.

Scheme 178

Charging air spring of rear axle

1. Perform system charging using VAS 5051 A --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .
2. Install wheel.
3. Position vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
4. Tighten wheel --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 179

I - Subframe - Front Wheel Drive (FWD), stabilizer bar, coupling rod --> Subframe - Front Wheel Drive (FWD), stabilizer bar, coupling rod

II - Subframe - All Wheel Drive (AWD), stabilizer bar, coupling rod --> Subframe - All Wheel Drive (AWD), stabilizer bar, coupling rod

III - Trapezoidal control arm, upper control arm, tie rod, coil spring, level control system sensor --> Trapezoidal control arm, upper control arm, tie rod, coil spring, level control system sensor

IV - Air spring, shock absorbers for air spring suspension --> Air spring, shock absorbers for air spring suspension

V - Wheel bearing housing, wheel bearing unit, shock absorbers --> Wheel bearing housing, wheel bearing unit, shock absorber for coil spring

VI - Drive axle --> Drive axle

Scheme 180

1 - Upper control arm

2 - Stabilizer bar

1. Stabilizer bar must be removed together with coupling rod.
2. Removing and installing --> «Coupling rod and stabilizer bar, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coupling-rod-and-stabilizer-bar-removing)

Replacing bearings for stabilizer bar --> Bearings for stabilizer bar, replacing

3 - Clamp

4 - Washer

5 - Hex nut, 65 Nm

6 - Hex bolt

7 - Hex bolt, 25 Nm

8 - Hex bolt, 65 Nm

9 - Coupling rod

1. Coupling rod must be removed together with stabilizer bar.
2. Removing and installing --> «Coupling rod and stabilizer bar, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coupling-rod-and-stabilizer-bar-removing)

10 - Hex bolt, 115 Nm plus an additional 90 ° turn

1. Always replace after removal
2. Hex bolts must not be loosened when springs are still installed.
3. Thread in body can be repaired with thread insert made of wire according to DIN 8140 (Helicoil). Thread insert must have same length as thread in body.

11 - Hex bolt, 85 Nm plus an additional 90 ° turn

1. Always replace after removal

12 - Tie rod

13 - Stone impact protection plate

14 - Trapezoidal control arm

15 - Hex bolt, 55 Nm

16 - Hex bolt 115 Nm and turn an additional 90 °

1. Always replace after removal
2. Hex bolts must not be loosened when springs are still installed.
3. Thread in body can be repaired with thread insert made of wire according to DIN 8140 (Helicoil). Thread insert must have same length as thread in body.

17 - Support

18 - Hex nut 95 Nm

1. Always replace after removal

19 - Adjuster plate 36 mm

20 - Subframe

1. Removing and installing --> «Subframe with attachments, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__subframe-with-attachments-removing-and-installing)

21 - Eccentric bolt

22 - Bonded rubber bushing, front

1. Hydraulic support
2. Replace --> «Bonded rubber bushings for subframe, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
3. Note installed position --> «Bonded rubber bushings for subframe, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

23 - Bonded rubber bushing, rear

1. Hydraulic support
2. Replace --> «Bonded rubber bushings for subframe, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
3. Note installed position --> «Bonded rubber bushings for subframe, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

24 - Bolt, 10 Nm

25 - Bolt, 5 Nm

26 - Hex bolt, 85 Nm plus an additional 90 ° turn

1. Always replace after removal

27 - Mounting bracket

28 - Left Rear Level Control System Sensor G76

1. Complete with attachments
2. Sensor lever must point outward
3. Replacing in vehicle --> «Rear Vehicle Level Sensor , removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__rear-vehicle-level-sensor-removing)
4. After loosening, check basic setting of headlamp adjustment --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .

1. After loosening, control position must be adapted again in vehicles with air spring suspension --> «Control position, adapting again»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-position-adapting-again) .

Subframe with attachments, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1332

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

Removing subframe with attachments

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Bleed air spring at rear axle --> «Air spring at rear axle, bleeding/charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to vehicles with coil spring suspension

1. Remove coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .

Applies to all vehicles

1. Remove rear muffler of exhaust system --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281370-S23494820212008031100000) for 3.2 LITER V6 4V GENERIC SCAN TOOL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BAT, BNK 26 EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V GENERIC SCAN TOOL, ENGINE CODE(S): BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .
2. Disconnect electric wires for electronic parking brake and ABS wheel speed sensor, and in vehicles with automatic headlamp range control or air spring shock absorbers, disconnect harness connectors and unclip from upper control arm.

Scheme 181

1. Remove cover - 2 - --> «66 - EXTERIOR EQUIPMENT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove brake caliper --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/s6/c6-2006-2008/remont/anti-locktraction-control/#brake-system) .
3. Secure brake caliper to body so that the weight of the brake caliper does not stress or damage brake hose or brake line.

Scheme 182

1. Disconnect threaded connection - 1 - and disengage shock absorber.

Scheme 183

1. Install engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 and a suitable wooden block at subframe.
2. Pull strap tight around subframe.
3. Remove rear hex bolts for subframe - arrows -.

Scheme 184

1. Remove bolts - 1 - and - 3 -.
2. Remove reinforcement - 2 -.
3. Carefully lower subframe with attachments.

Note. Make sure there is sufficient clearance for shock absorber and electrical wires while lowering.

Install subframe with attachments

Installation is in reverse order of removal. Note the following

Tightening torques: --> Subframe - Front Wheel Drive (FWD), stabilizer bar, coupling rod, assembly overview

1. Drillings of subframe mounts must be aligned centered to bolt-on points on body.

Note. Install coil springs or air springs, respectively, only if threaded connection of subframe has been tightened to specified tightening torque.

1. In vehicles with air spring suspension, install air spring --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing) .
2. Perform vehicle alignment --> «Wheel Alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Suspension setting at front/rear axle must be performed on a VW/Audi approved alignment rack.

Coupling rod and stabilizer bar, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332

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

Removing

Applies to vehicles with coil spring suspension

1. Remove coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Bleed air spring at rear axle --> «Air spring at rear axle, bleeding/charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

1. Remove hex nut - 3 -.
2. Remove hex bolt - 4 -.

Scheme 185

1. Remove hex bolts - 1 -.

1. Pull stabilizer bar toward rear far enough until hex bolt - 2 - can be removed.
2. Remove coupling rod - 5 -.
3. Remove stabilizer.

If there is not sufficient room to remove the stabilizer bar, the following steps must be performed

1. Support exhaust system at both rear mufflers using wooden block and engine/transmission jack V.A.G 1383 A.

Scheme 186

1. Remove hex nuts - 1 - and lower exhaust system.
2. Remove stabilizer bar

Installing

Installation is in reverse order of removal. Note the following

Tightening torques: --> Subframe - Front Wheel Drive (FWD), stabilizer bar, coupling rod, assembly overview

1. In vehicles with air spring suspension, charge air spring at rear axle --> «Air spring at rear axle, bleeding/charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Bearings for stabilizer bar, replacing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

Removing

1. Remove bolts - 1 -.
2. Remove clamp - 2 - and rubber bushing - 3 -.

Installing

1. Rubber bushing must make contact at collar - arrow - of stabilizer bar.
2. Initially tighten bolts - 1 - only hand-tight.
3. Set vehicle onto its wheels and bounce suspension several times.
4. Tighten bolts - 1 -.

Scheme 187

1 - Upper control arm

2 - Stabilizer

1. Stabilizer must be removed together with coupling rod.
2. Removing and installing --> «Coupling rod with stabilizer bar, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coupling-rod-with-stabilizer-bar-removing)
3. Replacing bearings for stabilizer bar --> «Bearings for stabilizer bar, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

3 - Clamp

4 - Washer

5 - Hex nut, 65 Nm

6 - Hex bolt

7 - Hex bolt, 25 Nm

8 - Hex bolt, 65 Nm

9 - Coupling rod

1. Coupling rod must be removed together with stabilizer bar.
2. Removing and installing --> «Coupling rod with stabilizer bar, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coupling-rod-with-stabilizer-bar-removing)

10 - Hex bolt, 115 Nm plus an additional 90 ° turn

1. Always replace after removal
2. Hex bolts must not be loosened when springs are still installed.
3. Thread in body can be repaired with thread insert made of wire according to DIN 8140 (Helicoil). Thread insert must have same length as thread in body.

11 - Hex bolt, 85 Nm plus an additional 90 ° turn

1. Always replace after removal

12 - Tie rod

13 - Stone impact protection plate

14 - Trapezoidal control arm

15 - Hex bolt, 55 Nm

16 - Hex bolt, 115 Nm plus an additional 90 ° turn

1. Always replace after removal
2. Hex bolts must not be loosened when springs are still installed.
3. Thread in body can be repaired with thread insert made of wire according to DIN 8140 (Helicoil). Thread insert must have same length as thread in body.

17 - Support

18 - Bonded rubber bushing, front

1. Hydraulic support
2. Replace --> «Bonded rubber bushings for subframe, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
3. Note installed position --> «Bonded rubber bushings for subframe, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

19 - Hex nut, 95 Nm

1. Always replace after removal

20 - Adjuster plate 36 mm

21 - Hex nut

22 - Washer

23 - Cross member for differential

24 - Bonded rubber bushing

1. For differential cross member
2. Note installation position: Right bonded rubber bushing is marked with yellow colored dot.
3. Replace --> «Bonded rubber bushing for differential cross member, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__bonded-rubber-bushing-for-differential-cross)

25 - Subframe

1. Subframe with attachments, removing and installing --> «Subframe with attachments, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

26 - Bonded rubber bushing, rear

1. Hydraulic support
2. Replace --> «Bonded rubber bushings for subframe, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
3. Note installed position --> «Bonded rubber bushings for subframe, replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

27 - Hex bolt, 55 Nm

28 - Eccentric bolt

29 - Bolt, 10 Nm

30 - Bolt, 5 Nm

31 - Hex bolt, 85 Nm plus an additional 90 ° turn

1. Always replace after removal

32 - Mounting bracket

33 - Left Rear Level Control System Sensor G76

1. Complete with attachments
2. Sensor lever must point outward
3. Replacing in vehicle --> «Rear Vehicle Level Sensor , removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__rear-vehicle-level-sensor-removing)
4. After loosening, check basic setting of headlamp adjustment --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .

1. After loosening, control position must be adapted again in vehicles with air spring suspension --> «Control position, adapting again»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-position-adapting-again) .

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1332

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

Removing subframe with attachments

Note. If the flange bolt securing the drive axle has to be loosened for later operations, remember that this must be done with the vehicle standing on its wheels. Loosening collar bolt for drive axle --> Collar bolt for outer joint of drive axle, loosening and tightening .

Applies to vehicles with coil spring suspension

1. Remove coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Bleed air spring at rear axle --> «Air spring at rear axle, bleeding/charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

1. Remove rear muffler of exhaust system --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281370-S23494820212008031100000) for 3.2 LITER V6 4V GENERIC SCAN TOOL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BAT, BNK 26 EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V GENERIC SCAN TOOL, ENGINE CODE(S): BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .
2. Disconnect electric wires for electronic parking brake and ABS wheel speed sensor, and in vehicles with automatic headlamp range control or air spring shock absorbers, disconnect harness connectors and unclip from upper control arm.

1. Remove cover - 2 - --> «66 - EXTERIOR EQUIPMENT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Loosen driveshaft from rear final drive --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09e-awd) for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE «39 FINAL DRIVE - FRONT DIFFERENTIAL»(ref-281379-S30349739612008031100000) for AUTOMATIC TRANSMISSION 09L, ALL WHEEL DRIVE «39 FINAL DRIVE, DIFFERENTIAL»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING .
3. Remove brake caliper --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/s6/c6-2006-2008/remont/anti-locktraction-control/#brake-system) .
4. Secure brake caliper to body so that the weight of the brake caliper does not stress or damage brake hose or brake line.

1. Disconnect threaded connection - 1 - and disengage shock absorber.

Scheme 188

1. Place engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 under subframe and secure using tension strap.

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

Scheme 189

1. Remove hex bolts - 1 -.

Note. For the sake of illustration, only the left side of the vehicle is depicted.

1. Carefully lower subframe with attachments.

Note. Make sure there is sufficient clearance for shock absorber and electrical wires while lowering.

Install subframe with attachments

Installation is in reverse order of removal. Note the following

Tightening torques: --> Subframe - All Wheel Drive (AWD), stabilizer bar, coupling rod, assembly overview

1. Drillings of subframe mounts must be aligned centered to bolt-on points on body.

Note. Install coil springs or air springs, respectively, only if threaded connection of subframe has been tightened to specified tightening torque.

1. In vehicles with air spring suspension, install air spring --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing) .
2. Perform vehicle alignment --> «Wheel Alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Suspension setting at front/rear axle must be performed on a VW/Audi approved alignment rack.

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1332

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

Scheme 190

1. Hydraulic cylinder VAS 6178

Scheme 191

1. Hollow piston cylinder VAS 6179

Scheme 192

1. Drip tray for workshop crane VAS 6208

1. Assembly tool T10205

Scheme 193

1. Assembly tool T10263

Scheme 194

1. Assembly tool T40033
2. Thrust piece T40141

Note. Before replacing malfunctioning bushing, check other bushings as well. If tears, oil leaks or other damages are visible, these bushings must also be replaced.

Pressing out bonded rubber bushing, front

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

1. Remove wheels.
2. Remove left and right wheel house trim --> «66 - EXTERIOR EQUIPMENT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 195

1. Remove hex bolts - 1 - from left and right shock absorbers.

1. Remove cover - 2 - --> «66 - EXTERIOR EQUIPMENT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove rear exhaust system --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281370-S23494820212008031100000) for 3.2 LITER V6 4V GENERIC SCAN TOOL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BAT, BNK 26 EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V GENERIC SCAN TOOL, ENGINE CODE(S): BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .

Applies to vehicles with air spring suspension

1. Remove air spring --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing) .

Applies to vehicles with coil spring suspension

1. Remove coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .

Applies to all vehicles

Scheme 196

1. Install engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 and a suitable wooden block - 2 - at subframe and support at front.

1. Remove bolts - 1 -.
2. Remove only front bolts - 2 - of subframe.
3. Remove reinforcement - 3 -.
4. Lower subframe only as far as necessary.

Scheme 197

1. Mark position of bearings to subframe - arrow A -.
2. Apply marking - arrow B - of bearing bar - arrow C - to subframe mount - arrow A -.

Note. Marking - arrow B - is needed for installation of new bearing.

Scheme 198

1. Install tools at subframe as shown in illustration.

1. Spindle T10263/4 from nut T10263/5
2. Washer T40033/1. Conical side faces body.
3. Subframe
4. Washer T40033/2. Conical side faces body.
5. Sleeve T40033/3
6. Washer T10205/4
7. Hydraulic cylinder VAS 6178
8. Spindle T10263/4 from nut T10263/5

1. Place drip tray for shop crane VAS 6208 underneath.
2. Press out bonded rubber bushing and collect escaping oil.

Bonded rubber bushing, pressing in

1. Observe installation position of bonded rubber bushing.

1. Observe your marking - arrow B - on subframe - arrow A -.
2. Marking - arrow B - and bar - arrow C - of bearing must align with subframe mount - arrow A -.

Scheme 199

1. Install tools at subframe as shown in illustration.

1. Spindle T10263/4 from nut T10263/5
2. Thrust piece T40141. Conical side faces body.
3. Subframe
4. Bonded rubber bushing
5. Washer T10205/15
6. Washer T10205/4
7. Hydraulic cylinder VAS 6178
8. Spindle T10263/4 from nut T10263/5

1. Press front bearing into subframe until stop.

Rest of installation is in reverse order of removal. Note the following

Note. Install coil springs or air springs, respectively, only if threaded connection of subframe has been tightened to specified tightening torque.

1. Installing coil springs --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) or air springs --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing) , respectively.

Tightening torques: --> Subframe - All Wheel Drive (AWD), stabilizer bar, coupling rod, assembly overview

1. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Tighten wheels --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Pressing out rear bonded rubber bushing

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

1. Remove wheels.
2. Remove left and right wheel house trim --> «66 - EXTERIOR EQUIPMENT»(/audi/s6/c6-2006-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Remove hex bolts - 1 - from left and right shock absorbers.
2. Remove rear exhaust system --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281370-S23494820212008031100000) for 3.2 LITER V6 4V GENERIC SCAN TOOL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BAT, BNK 26 EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V GENERIC SCAN TOOL, ENGINE CODE(S): BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .

Applies to vehicles with air spring suspension

1. Remove air spring --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing) .

Applies to vehicles with coil spring suspension

1. Remove coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .

Applies to all vehicles

1. Remove stabilizer --> «Coupling rod with stabilizer bar, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coupling-rod-with-stabilizer-bar-removing) .

Scheme 200

1. Disengage electrical wiring harness - 1 - left and right from brackets - 2 - at body.

Scheme 201

1. Install engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 and a suitable wooden block - 2 - at rear final drive and support at rear.
2. Remove only rear bolts of subframe.
3. Lower subframe only as far as necessary.

Scheme 202

1. Mark position of bearings to subframe - arrow A -.
2. Apply marking - arrow B - of bearing groove - arrow C - to subframe mount - arrow A -.

Note. Marking - arrow B - is needed for installation of new bearing.

1. Install tools at subframe as shown in illustration.

1. Spindle T10263/4 from nut T10263/5
2. Washer T40033/1. Conical side faces body.
3. Subframe
4. Washer T40033/2. Conical side faces body.
5. Sleeve T40033/3
6. Washer T10205/4
7. Hydraulic cylinder VAS 6178
8. Spindle T10263/4 from nut T10263/5

1. Place drip tray for shop crane VAS 6208 underneath.
2. Press out bonded rubber bushing and collect escaping oil.

Bonded rubber bushing, pressing in

1. Observe installation position of bonded rubber bushing.

1. Observe your marking - arrow B - on subframe - arrow A -.
2. Marking - arrow B - and bar - arrow C - of bearing must align with subframe mount - arrow A -.

1. Install tools at subframe as shown in illustration.

1. Spindle T10263/4 from nut T10263/5
2. Thrust piece T40141. Conical side faces body.
3. Subframe
4. Bonded rubber bushing
5. Washer T10205/15
6. Washer T10205/4
7. Hydraulic cylinder VAS 6178
8. Spindle T10263/4 from nut T10263/5

1. Press front bearing into subframe until stop.

Rest of installation is performed in the reverse order of removal. Note the following

Note. Install coil springs or air springs, respectively, only if threaded connection of subframe has been tightened to specified tightening torque.

1. Installing coil springs --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) or air springs --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing) , respectively.

Tightening torques: --> Subframe - All Wheel Drive (AWD), stabilizer bar, coupling rod, assembly overview

1. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Tighten wheels --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Bonded rubber bushing for differential cross member, replacing

Special tools, testers and auxiliary items required

Scheme 203

1. Tube 3259

Scheme 204

1. Assembly tool 3346

1. Assembly tool 3348

Scheme 205

1. Assembly tool T40032
2. Thrust piece T40144

Removing

1. Subframe with attachments, removing and installing --> «Subframe with attachments, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 206

1. Apply marking - arrow A - above groove - 1 - of bearing - 2 - on subframe.

Scheme 207

1. Install tools at subframe as shown in illustration.

1. Spindle 3346/2
2. Thrust piece 3348/2. Insert in subframe with smooth side toward bearing.
3. Tube 3259
4. Washer T40032/2

1. Pull bearing out of subframe.

Installing

Installation is in reverse order of removal. Note the following

Scheme 208

1. Apply continuous marking - arrow A - at groove - arrow B -.

Note. Marking is needed to align bearing with subframe. When pulling in bearing, groove is masked by tool. Observe different bearing versions.

Bearing - 2 - with yellow dot - arrow B - must be installed on right side.

1. Position bearing - 2 - with groove - 1 - at your marking - arrow A -.

Scheme 209

1. Attach tools and bearing at subframe, as shown in illustration. Marking - arrow A - on bearing and marking - arrow B - on subframe must align.

1. Spindle 3346/2
2. Thrust piece T40144
3. Mount
4. Washer T40032/2

1. Pull bearing into subframe until stop.

Note. If paint damage has occurred during bearing replacement, repair using corrosion protection, primer and black top coat.

Coupling rod with stabilizer bar, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332

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

Removing

Applies to vehicles with coil spring suspension

1. Remove coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Bleed air spring at rear axle --> «Air spring at rear axle, bleeding/charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

1. Remove hex nut - 3 -.
2. Remove hex bolt - 4 -.

1. Remove hex bolts - 1 -.

1. Pull stabilizer bar toward rear far enough until hex bolt - 2 - can be removed.
2. Remove coupling rod - 5 -.
3. Remove stabilizer.

If there is not sufficient room to remove stabilizer bar, the following steps must be performed

1. Support exhaust system at both rear mufflers using wooden block and engine/transmission jack V.A.G 1383 A.

1. Remove hex nuts - 1 - and lower exhaust system.
2. Remove stabilizer.

Installing

Installation is in reverse order of removal. Note the following

Tightening torques: --> Subframe - All Wheel Drive (AWD), stabilizer bar, coupling rod, assembly overview

1. In vehicles with air spring suspension, charge air spring at rear axle --> «Air spring at rear axle, bleeding/charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

Removing

1. Remove bolts - 1 -.
2. Remove clamp - 2 - and rubber bushing - 3 -.

Installing

1. Rubber bushing must make contact at collar - arrow - of stabilizer bar.
2. Initially tighten bolts - 1 - only hand-tight.
3. Set vehicle onto its wheels and bounce suspension several times.
4. Tighten bolts - 1 -.

Scheme 210

1 - Upper control arm

1. Removing and installing --> «Upper control arm, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__upper-control-arm-removing-and-installing)

2 - Eccentric washer

3 - Hex nut, 95 Nm

1. Always replace after removal

4 - Wheel bearing housing

5 - Hex nut

6 - Trapezium control arm

1. Removing and installing --> «Trapezoidal control arm, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__trapezoidal-control-arm-removing-and-installing)

7 - Hex bolt, 85 Nm plus an additional 90 ° turn

1. Always replace after removal

8 - Hex bolt, 25 Nm

9 - Stone deflector for trapezoidal control arm

10 - Bottom spring seat

11 - Coil spring

1. Note different types of suspension versions, see vehicle data plate --> «Explanatory notes for Production Relevant numbers (PR No.)»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__explanatory-notes-for-production-relevant-numbers) .
2. Removing and installing --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing)

12 - Top spring seat

13 - Spacer for top spring seat

1. Only installed in rough terrain suspension

14 - Subframe

15 - Hex nut, 95 Nm

1. Always replace after removal

16 - Adjuster plate 36 mm

17 - Eccentric bolt

18 - Bolt, 10 Nm

19 - Bolt, 5 Nm

20 - Hex bolt 85, Nm plus an additional 90 ° turn

1. Always replace after removal

21 - Mounting bracket

22 - Left Rear Level Control System Sensor G76

1. Complete with attachments
2. Sensor lever must point outward
3. Replacing in vehicle --> «Rear Vehicle Level Sensor , removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__rear-vehicle-level-sensor-removing)
4. After loosening, check Basic Setting of head light adjustment --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment)

1. After loosening, control position must be adapted again --> «Control position, adapting again»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__control-position-adapting-again) in vehicles with air spring suspension

23 - Hex bolt, 85 Nm plus an additional 90 ° turn

1. Always replace after removal

24 - Stone impact protection plate

1. Only installed in rough terrain suspension

25 - Locking clip

26 - Tie rod

1. Removing and installing --> «Tie rod, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__tie-rod-removing-and-installing)

27 - Hex bolt, 85 Nm plus an additional 90 ° turn

1. Always replace after removal

28 - Eccentric bolt

Trapezoidal control arm, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332

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

Removing

Removing coil spring or air spring

1. Remove coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .
2. Remove air spring --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing) .

Scheme 211

1. In vehicles with vehicle level control sensor, remove bolt - 4 -.
2. Remove brake caliper with brake carrier and brake disc --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/s6/c6-2006-2008/remont/anti-locktraction-control/#brake-system) .
3. Secure brake caliper to body so that the weight of brake caliper does not stress or damage brake hose or brake line.

Scheme 212

1. Remove hex bolt - 3 -.
2. Support exhaust system at both rear mufflers using wooden block and engine/transmission jack V.A.G 1383 A.

1. Remove hex nuts - 1 - and lower exhaust system.

1. Remove hex bolt - 1 -.
2. Remove tie rod - 2 -.

1. Remove bolts - arrows - and remove cover plate.

1. Remove hex bolt - 4 -.

1. Remove hex bolt - 1 -.
2. Disconnect threaded connection - 2 -.
3. Remove trapezoidal control arm.

Installing

Installation is in reverse order of removal. Note the following

Note. Bonded rubber bushings can only be turned to a limited extent. The bolted connections on the wheel suspension should only be tightened when the vehicle is in curb weight position or control position. For vehicles with coil springs, lift wheel suspension in curb weight position --> For vehicles with coil springs, lift wheel suspension in curb weight position For vehicles with air spring suspension, lift wheel suspension in control position --> For vehicles with air springs, lift wheel suspension in control position

Tightening torques: --> Trapezoidal control arm, upper control arm, tie rod, coil spring, level control system sensor, assembly overview

1. On vehicles with automatic headlamp range control system, perform basic setting of headlamps --> «94 - LIGHTS, SWITCHES - EXTERIOR»(/audi/s6/c6-2006-2008/remont/cruise-control-systems/#electrical-equipment) .
2. Install coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .
3. In vehicles with air spring suspension, install air spring --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing) .
4. Perform vehicle alignment --> «Wheel Alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Suspension setting at front/rear axle must be performed on a VW/Audi approved alignment rack.

Upper control arm, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1332

Scheme 213

Note. Due to the inaccessibility of the inner threaded connection - 1 - , the upper control arm can only be removed when the subframe has been removed.

Removing

1. Remove subframe on vehicles with front-wheel drive (FWD) --> «Subframe with attachments, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__subframe-with-attachments-removing-and-installing) .
2. Remove subframe on vehicles with all-wheel drive (AWD) --> «Subframe with attachments, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Mark, e.g. using a felt-tip marker, the eccentric washer - 2 - at wheel bearing housing.
2. Disconnect threaded connections - 1 - and - 2 -.
3. Remove upper control arm.

Installing

Note. Replace bolts and self-locking nuts.

Installation position of control arm at subframe

1. Install control arm - 3 - onto threaded connection - 1 - hand-tight.

Scheme 214

1. Lay straightedge or a straight bar - 1 - flat onto subframe - arrows -.
2. Position control arm so that dimension a = 64 mm ± 1 mm is obtained.

1. Tighten control arm in this position to subframe item - 1 -.
2. Install wheel bearing housing on control arm and tighten new nut to 20 Nm. Note installation position of eccentric washer - 2 -.
3. Install subframe on vehicles with front-wheel drive (FWD) --> «Subframe with attachments, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__subframe-with-attachments-removing-and-installing) .
4. Install subframe on vehicles with all-wheel drive (AWD) --> «Subframe with attachments, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 215

1. Loosen threaded connection - 1 -.

Applies to vehicles with coil spring suspension

1. Raise wheel suspension to curb weight position --> «For vehicles with coil springs, lift wheel suspension in curb weight position»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) and tighten threaded connection - 1 -.

Applies to vehicles with air spring suspension

1. Raise wheel suspension to control position --> «For vehicles with air springs, lift wheel suspension in control position»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) and tighten threaded connection - 1 -.

Applies to all vehicles

Tightening torques: --> Trapezoidal control arm, upper control arm, tie rod, coil spring, level control system sensor, assembly overview

1. Perform vehicle alignment --> «Wheel Alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Suspension setting must be performed on a VW/Audi approved wheel alignment stand.

Tie rod, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1332

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

Removing

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Bleed air spring at rear axle --> «Air spring at rear axle, bleeding/charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to vehicles with coil spring suspension

1. Remove coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .

Applies to all vehicles

1. Remove hex bolt - 3 -.
2. Support exhaust system at both rear mufflers using wooden block and engine/transmission jack V.A.G 1383 A.

1. Remove hex nuts - 1 - and lower exhaust system.

1. Remove hex bolt - 1 -.
2. Remove tie rod - 2 -.

Installing

Installation is in reverse order of removal. Note the following

Note. Bonded rubber bushings can only be turned to a limited extent. The bolted connections on the wheel suspension should only be tightened when the vehicle is in curb weight position or control position. For vehicles with coil springs, lift wheel suspension in curb weight position --> For vehicles with coil springs, lift wheel suspension in curb weight position For vehicles with air spring suspension, lift wheel suspension in control position --> For vehicles with air springs, lift wheel suspension in control position

Tightening torques: --> Trapezoidal control arm, upper control arm, tie rod, coil spring, level control system sensor, assembly overview

1. Install coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing)
2. In vehicles with air spring suspension, charge air spring at rear axle --> «Air spring at rear axle, bleeding/charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Install wheel.
4. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Tighten wheel --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Perform vehicle alignment --> «Wheel Alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Suspension setting at front axle must be performed on a VW/Audi approved wheel alignment stand.

Coil spring, removing and installing

Note. To remove and install coil spring, use the procedural description supplied in spring tensioning system VAS 6274.

1. Level control system sensor, removing and installing --> «Rear Vehicle Level Sensor , removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__rear-vehicle-level-sensor-removing) .

Scheme 216

1 - Shock absorber for air spring suspension

1. Removing and installing --> «Shock absorber for air spring suspension, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__shock-absorber-for-air-spring-suspension)

2 - Hex bolt, 150 Nm plus an additional 90 ° turn

1. Always replace after removal

3 - Wheel bearing housing

4 - Hex nut

5 - Washer

6 - Hex nut

7 - Coupling rod

8 - Hex nut

9 - Hex bolt, 85 Nm plus an additional 90 ° turn

1. Always replace after removal

10 - Stone impact protection plate

1. Only installed in rough terrain suspension

11 - Hex bolt, 25 Nm

12 - Multi-point socket head bolt, 20 Nm

13 - Trapezoidal control arm

14 - Rubber sealing ring

15 - Air spring

1. Removing and installing --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing)

16 - Air pipe

17 - Tension clamp

18 - Boot

1. Removing and installing --> «Boot, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__boot-removing-and-installing)

19 - Tension clamp

20 - Hex nut, 25 Nm

21 - Shock absorber mount

22 - Hex bolt, 35 Nm

23 - Buffer stop

24 - Protective sleeve

25 - Hex bolt, 70 Nm

26 - Hex nut 70 Nm

27 - Washer

28 - Stabilizer

29 - Left Rear Dampening Adjustment Valve N338 or Right Rear Dampening Adjustment Valve N339

1. Removing and installing --> «Dampening adjustment valve , replacing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

Air springs, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

Scheme 217

1. Torque wrench V.A.G 1783

1. Insertion tool 10 mm V.A.G 1783/1

1. Vehicle Diagnostic, Testing and Information System VAS 5051 B with corresponding diagnostic cable.
2. Spring tensioning system VAS 6274 from spreader device VAS 6274/8

Removing

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Perform system bleed using VAS 5051 A --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .
3. Remove wheel.

Scheme 218

1. Insert spreader device VAS 6274/8 in correct position between body frame and upper control arm and pre-load lightly.

Note. Beveled surface of upper thrust piece must always point in direction of travel. Brake line may be damaged if this is not done.

1. Loosen bolt - 1 - and pull wheel housing liner aside.

1. Slowly loosen air line - 1 - for connection - 2 - and let air pressure dissipate. Once air pressure has dissipated, remove air line.
2. Unclip air line - 1 - and cut cable tie.
3. Press air spring together by hand.

Scheme 219

1. Loosen bolt - 1 - approx. 5-6 turns.
2. Press air spring out of trapezoidal control arm via socket attachment direction of - arrow -.

1. Remove bolts - 1 - completely.

Note. Air spring can be compressed to remove or insert.

Scheme 220

1. Lift air spring - 1 - upward out of trapezoidal control arm, tilt outward direction of - arrow - and remove.
2. Transfer air line.

Installing

Installation is in reverse order of removal. Note the following

Tightening torques: --> Air spring, shock absorbers for air spring suspension, assembly overview

1. Clean inside of trapezoidal control arm at points where air spring makes contact.

Scheme 221

1. Tab - 1 - on air spring must be positioned into groove - 2 - of trapezoidal control arm.
2. Perform system charging using VAS 5051 A --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .
3. Remove spreader device VAS 6274/8.
4. Install wheel.

1. Position vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Tighten wheel --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Boot, removing and installing

Special tools, testers and auxiliary items required

1. Hose clamp pliers V.A.G 1275

Removing

1. Remove air spring --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing) .

Scheme 222

1. Remove ring - 1 - from boot - 2 -.
2. Remove lower and upper clamps from boot - 2 -.
3. Carefully pull off boot.

Installing

Installation is in reverse order of removal. Note the following

1. Carefully install and align boot.

Scheme 223

1. Attach boot - 4 - at piston - 2 - so that cutout - arrows - is next to connection of air tube.
2. Install clamp - 3 - with ear at center of groove - 1 - and tension using hose clamp pliers V.A.G 1275.

Scheme 224

1. Attach clamp - 2 -.
2. Align clamp - 2 - with ear so that it aligns with connection of air tube - 1 - and pins - 3 - and - 4 -.
3. Tension clamp - 2 - using hose clamp pliers V.A.G 1275.

Shock absorber for air spring suspension, removing and installing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1332

1. Torque wrench V.A.G 1331

Removing

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Remove wheel.
3. Bleed air spring at rear axle --> «Air spring at rear axle, bleeding/charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 225

1. Disconnect harness connector - 2 - and unclip electrical wire.

1. Remove threaded connection - 2 - and pull wheel housing liner aside.
2. Remove hex bolts - 1 -.

1. Disconnect threaded connection - 1 -.
2. Remove shock absorber.

Installing

Installation is in reverse order of removal. Note the following

Tightening torques: --> Air spring, shock absorbers for air spring suspension, assembly overview

1. Perform system charging using VAS 5051 A --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .
2. Install wheel.
3. Position vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
4. Tighten wheel --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Special tools, testers and auxiliary items required

1. Kukko Separating Tool 5-60 mm Kukko 17/0 - 3

Removing

1. Remove wheel.

Scheme 226

1. Mark cable connection position - 1 - of dampening adjustment valve at damper - arrow -.
2. Carefully disconnect connector - 2 - by hand and unclip electrical wire - 3 -.

1. Attach Kukko Separating Tool 5-60 mm Kukko 17/0 - 1 - to damper with smooth surface and pretension by hand. Attach gripping pieces - 3 - and - 4 - between dampening adjustment valve - 2 - and damper tube while doing so.
2. Tap dampening adjustment valve at right angle using plastic hammer. Tap on gripping piece - 4 - as close to valve housing as possible using a plastic hammer. Pull on gripping piece - 3 - in a right angle by hand.

Note. Dampening adjustment valve is destroyed when removed.

1. Remove circlip - 1 -.
2. Remove coil - 2 - and sealing ring - 3 -.

1. Check housing for dampening adjustment valve for deformation all around - arrows -. If necessary, flatten deformations using a small screwdriver.

Installing

Installation is in reverse order of removal. Note the following

1. Clean housing for dampening adjustment valve.

1. Always replace sealing ring - arrow -.

Note. New sealing ring - 1 - is already installed on dampening adjustment valve. Sealing ring and valve are installed together - do not disconnect.

1. Attach new dampening adjustment valve and align cable connection - 1 - with your marking - arrow -.
2. Forcefully press on dampening adjustment valve by hand until sealing ring engages audibly.
3. Connect harness connector - 2 - and clip in electrical wire - 3 -.

Shock absorber for air spring suspension, servicing

Procedure as for servicing shock absorber with coil spring --> Shock absorber for coil spring, removing and installing .

Scheme 227

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331
2. Torque wrench V.A.G 1783
3. Insertion tool 10 mm V.A.G 1783/1

Special tools, testers and auxiliary items required

Scheme 228

1. Vehicle Diagnosis, Testing and Information System VAS 5051 A

Scheme 229

1. Diagnostic cable VAS 5051/5A

Bleeding air spring for repair work

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Perform system bleed using VAS 5051 A --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .
3. Remove wheel.

1. Loosen bolt - 1 - and pull wheel housing liner aside.

1. Slowly loosen air line - 1 - for connection - 2 - and let air pressure dissipate. Once air pressure has dissipated, remove air line.

Charging air spring after repair work

1. Remove air line - 1 - onto connection - 2 -.
2. Perform system charging using VAS 5051 A --> «System bleeding or charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__system-bleeding-or-charging) .

Scheme 230

1 - Eccentric washer

2 - Hex nut, 95 Nm

3 - Wheel bearing housing

1. Removing and installing --> «Wheel bearing housing, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

4 - Ball bearing

1. Items 4 and 5 are installed only in vehicles with All Wheel Drive (AWD)
2. Servicing wheel bearing unit --> «Wheel bearing unit (only possible in vehicles with All Wheel Drive), servicing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

5 - Wheel hub

1. Items 5 and 4 are installed only in vehicles with All Wheel Drive (AWD)
2. Servicing wheel bearing unit --> «Wheel bearing unit (only possible in vehicles with All Wheel Drive), servicing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

6 - Wheel bearing/hub unit

1. Removing and installing --> «Wheel bearing unit, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
2. Complete wheel bearing unit is installed only in vehicles with Front Wheel Drive (FWD)
3. Wheel bearing unit cannot be serviced

7 - Hex bolt, 200 Nm plus an additional 180 ° turn

1. Always replace after removal

8 - Cover plate for brake disc

9 - Hex bolt

10 - Hex bolt, 85 Nm plus an additional 90 ° turn

1. Always replace after removal

11 - Tie rod

12 - Stone impact protection plate

1. Only installed in rough terrain suspension

13 - Locking clip

14 - Hex nut

15 - Hex bolt, 85 Nm plus an additional 90 ° turn

1. Always replace after removal

16 - Trapezoidal control arm with stone deflector

17 - Hex nut

18 - Washer

19 - Shock absorbers

1. Removing and installing --> «Shock absorber for coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

20 - Protective sleeve

21 - Buffer stop

22 - Hex bolt, 35 Nm

23 - Shock absorber mount

24 - Hex nut 25 Nm

25 - Twelve-point socket head bolt, 70 Nm

26 - Drive axle

27 - Upper control arm

28 - Eccentric bolt

29 - Hex bolt 150 Nm and turn an additional 90 °

1. Always replace after removal

30 - Countersunk bolt, 80 Nm plus an additional 90 ° (1/4-turn)

1. Always replace after removal

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

1. Torque wrench V.A.G 1332

Removing

Applies to vehicles with coil spring suspension

Front Wheel Drive (FWD)

1. Remove coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .

All Wheel Drive (AWD)

1. Remove decorative wheel cover, for light-alloy wheels pull off protective cap (use pulling hook in vehicle tool kit).
2. Loosen collar bolt for outer joint of drive axle (only loosen when vehicle is standing on its wheels -danger of accident-) --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Remove coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .

Applies to vehicles with air spring suspension

Front Wheel Drive (FWD)

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Bleed air spring at rear axle --> «Air spring at rear axle, bleeding/charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

All Wheel Drive (AWD)

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Remove decorative wheel cover, for light-alloy wheels remove protective cap (use pulling hook in vehicle tool kit).
3. Loosen collar bolt for outer joint of drive axle (only loosen when vehicle is standing on its wheels -danger of accident-) --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
4. Bleed air spring at rear axle --> «Air spring at rear axle, bleeding/charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

1. Remove brake caliper and brake disc --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/s6/c6-2006-2008/remont/anti-locktraction-control/#brake-system) .
2. Secure brake caliper to body so that the weight of the brake caliper does not stress or damage brake hose or brake line.

1. Remove bolts - arrows - and remove cover plate.

1. Remove wheel speed sensor - 3 - --> «45 - ANTI-LOCK BRAKE SYSTEM»(/audi/s6/c6-2006-2008/remont/anti-locktraction-control/#brake-system) .

1. Remove hex bolt - 6 -.
2. Disconnect threaded connection - 1 -.

1. Remove hex bolt - 1 -.

1. Disconnect threaded connection - 1 -.
2. Remove wheel bearing housing.

Installing

Installation is in reverse order of removal. Note the following

Note. Bonded rubber bushings can only be turned to a limited extent. The bolted connections on the wheel suspension should only be tightened when the vehicle is in curb weight position or control position. For vehicles with coil springs, lift wheel suspension in curb weight position --> For vehicles with coil springs, lift wheel suspension in curb weight position For vehicles with air spring suspension, lift wheel suspension in control position --> For vehicles with air springs, lift wheel suspension in control position

Tightening torques: --> Wheel bearing housing, wheel bearing unit, shock absorber for coil spring, assembly overview

1. Install coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .
2. In vehicles with air spring suspension, charge air spring at rear axle --> «Air spring at rear axle, bleeding/charging»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Install wheel.
4. For vehicles with air spring suspension, set vehicle on its wheels --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Tighten wheel --> «44 - Wheels, Tires, Wheel alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. In vehicles with all-wheel drive (AWD), tighten collar bolt for outer joint of drive axle (only tighten when vehicle is standing on its wheels -danger of accident-) --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Perform vehicle alignment --> «Wheel Alignment»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Suspension setting at front/rear axle must be performed on a VW/Audi approved alignment rack.

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1332

Removing

Applies to vehicles with coil spring suspension

Front Wheel Drive (FWD)

1. Remove wheel.

All Wheel Drive (AWD)

1. Remove decorative wheel cover, for light-alloy wheels remove protective cap (use pulling hook in vehicle tool kit).
2. Loosen collar bolt for outer joint of drive axle (only loosen when vehicle is standing on its wheels -danger of accident-) --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
3. Remove coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .

1. Remove wheel speed sensor - 3 - --> «45 - ANTI-LOCK BRAKE SYSTEM»(/audi/s6/c6-2006-2008/remont/anti-locktraction-control/#brake-system) .
2. Remove drive axle --> «Drive axle, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to vehicles with air spring suspension

Front Wheel Drive (FWD)

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Remove wheel.

All Wheel Drive (AWD)

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Remove decorative wheel cover, for light-alloy wheels remove protective cap (use pulling hook in vehicle tool kit).
3. Loosen collar bolt for outer joint of drive axle (only loosen when vehicle is standing on its wheels -danger of accident-) --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
4. Remove air spring --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing) .

1. Remove wheel speed sensor - 3 - --> «45 - ANTI-LOCK BRAKE SYSTEM»(/audi/s6/c6-2006-2008/remont/anti-locktraction-control/#brake-system) .
2. Remove drive axle --> «Drive axle, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Applies to all vehicles

1. Remove brake caliper and brake disc --> «46 - BRAKES - MECHANICAL COMPONENTS»(/audi/s6/c6-2006-2008/remont/anti-locktraction-control/#brake-system) .
2. Secure brake caliper to body so that the weight of the brake caliper does not stress or damage brake hose or brake line.

Scheme 231

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

Installing

Installation is in reverse order of removal. Note the following

Tightening torques: --> Wheel bearing housing, wheel bearing unit, shock absorber for coil spring, assembly overview

1. Install drive axle --> «Drive axle, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. In vehicles with air spring suspension, install air spring --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing) .
3. In vehicles with all-wheel drive (AWD), tighten collar bolt for outer joint of drive axle (only tighten when vehicle is standing on its wheels -danger of accident-) --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 232

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

Special tools, testers and auxiliary items required

1. Press tube 40-20

1. Thrust piece VW 473

1. Separating tool 3 Kukko 17/2

1. Assembly tool T40089/2
2. Wheel bearing unit removed --> «Wheel bearing unit, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

Pressing wheel hub out of wheel bearing

Pressing bearing inner race off of wheel hub

1. Insert separator between bearing inner race - 1 - and spinning washer - 2 - and pre-load spindle.

Note. Use a commercially available separator, e.g. Kukko 17/2.

This deforms the spinning washer and then must be replaced.

1. Press bearing inner race off wheel bearing of wheel hub.

Replacing spinning washer of wheel bearing

1. Carefully pry off old spinning washer - 1 - using a screwdriver.
2. Position new spinning washer on wheel hub.

1. Attach special tools as shown in figure.

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

1. Press on spinning washer up to radius of wheel bearing hub using assembly tool T40089/2 as shown in the illustration.

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

Press wheel hub into wheel bearing

1. When pressing in, sleeve 40-20 may only lie against bearing inner race.

Note. Machined surface of wheel bearing outer race points upward.

1. Install wheel bearing unit --> «Wheel bearing unit, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 233

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331
2. Torque wrench V.A.G 1332
3. Engine/transmission jack V.A.G 1383 A
4. Wheel hub support T10149

Removing

1. Remove wheel
2. Turn wheel hub far enough upward until one hole for wheel bolt is on top.

Scheme 234

1. Install wheel hub support T10149 with wheel bolt - arrow -.
2. Insert wheel hub support T10149 in engine/transmission jack V.A.G 1383 A and raise wheel housing bearing approx. 5 cm.

1. Disconnect threaded connection - 1 -.

1. Remove threaded connection - 2 - and pull wheel housing liner aside.
2. Remove hex bolts - 1 -.
3. Remove shock absorber.

Installing

Installation is in reverse order of removal. Note the following

Tightening torques: --> Wheel bearing housing, wheel bearing unit, shock absorber for coil spring, assembly overview

Shock absorber for coil spring, servicing

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1331

Scheme 235

1. Special wrench 3017 A

Scheme 236

1 - Self-locking nut

1. Always replace
2. Loosening and tightening «Loosening and tightening threaded connection for shock absorber mount»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

2 - Shock absorber mount

3 - Buffer stop

4 - Protective sleeve

5 - Shock absorbers

1. Removing and installing --> «Shock absorber for coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
2. Note different types of suspension versions, see vehicle data plate --> «Explanatory notes for Production Relevant numbers (PR No.)»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__explanatory-notes-for-production-relevant-numbers) .
3. Always release gas and drain malfunctioning shock absorbers before disposal --> «Shock absorbers, checking»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
4. Checking removed shock absorbers --> «Shock absorbers, checking»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

Scheme 237

Removing

Applies to vehicles with coil spring suspension

1. Loosen collar bolt for outer joint of drive axle --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Remove coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .

1. Remove wheel speed sensor - 3 - --> «45 - ANTI-LOCK BRAKE SYSTEM»(/audi/s6/c6-2006-2008/remont/anti-locktraction-control/#brake-system) .

Applies to vehicles with air spring suspension

1. Position vehicle on lifting platform --> «Placing vehicle onto lifting platform and onto wheels»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
2. Remove decorative wheel cover, for light-alloy wheels remove protective cap (use pulling hook in vehicle tool kit).
3. Loosen collar bolt for outer joint of drive axle (only loosen when vehicle is standing on its wheels -danger of accident-) --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
4. Remove air spring --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing) .

1. Remove wheel speed sensor - 3 - --> «45 - ANTI-LOCK BRAKE SYSTEM»(/audi/s6/c6-2006-2008/remont/anti-locktraction-control/#brake-system) .

Applies to all vehicles

1. Remove rear muffler of exhaust system --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281370-S23494820212008031100000) for 3.2 LITER V6 4V GENERIC SCAN TOOL, ENGINE CODE(S): BKH 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BAT, BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-281367-S05556147682008031100000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ 26 - EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V FUEL INJECTION AND IGNITION, ENGINE CODE(S): BAT, BNK 26 EXHAUST SYSTEM, EMISSION CONTROLS for 4.2 LITER V8 5V GENERIC SCAN TOOL, ENGINE CODE(S): BNK «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(/audi/s6/c6-2006-2008/remont/cooling-fan/#52l-10-cyl-4v-engine-mechanical-engine-codes-bxa) for 5.2 LITER 10-CYL. 4V ENGINE MECHANICAL ENGINE CODE(S): BXA .
2. Remove rear final drive --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09e-awd) for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE «39 FINAL DRIVE - FRONT DIFFERENTIAL»(ref-281379-S30349739612008031100000) for AUTOMATIC TRANSMISSION 09L, ALL WHEEL DRIVE «39 FINAL DRIVE, DIFFERENTIAL»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING .
3. Remove drive axle inward.

Installing

Installation is performed in the reverse order of removal. Note the following

Tightening torque for drive axle --> Wheel bearing housing, wheel bearing unit, shock absorber for coil spring, assembly overview

1. Install rear final drive --> «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#6-speed-automatic-transmission-09e-awd) for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE «39 FINAL DRIVE - FRONT DIFFERENTIAL»(ref-281379-S30349739612008031100000) for AUTOMATIC TRANSMISSION 09L, ALL WHEEL DRIVE «39 FINAL DRIVE, DIFFERENTIAL»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J «39 - FINAL DRIVE, DIFFERENTIAL»(/audi/s6/c6-2006-2008/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING .
2. Install coil spring --> «Coil spring, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__coil-spring-removing-and-installing) .
3. Install air spring --> «Air springs, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__air-springs-removing-and-installing) .
4. Tighten collar bolt for outer joint of drive axle (only tighten when vehicle is standing on its wheels -danger of accident-) --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Special tools, testers and auxiliary items required

1. Torque wrench V.A.G 1576

Loosening collar bolt for outer joint of drive axle

1. Remove decorative wheel cover, for light-alloy wheels remove protective cap (use pulling hook in vehicle tool kit).

1. Loosen collar bolt for outer joint of drive axle a maximum of 90 ° (only loosen when vehicle is standing on its wheels -danger of accident-)
2. Raise vehicle and remove wheel.
3. Install all five wheel bolts again hand-tight.

A second technician is required for the following work step

1. 1. Technician: Sits in vehicle and operates foot brake
2. 2. Technician: Removes collar bolt for drive axle.

Wheel bearings must not be burdened while collar bolt is loose or removed.

If wheel bearing is burdened by weight of vehicle itself, wheel bearing will be pre-damaged. This will diminish wheel bearing service life.

If it should be necessary to move a vehicle whose drive axle has been removed, then before doing so install an outer joint in place of drive axle and tighten it to 200 Nm, or else wheel bearing will be damaged.

Tightening collar bolt for outer joint of drive axle

1. Replace collar bolt.

A second technician is required to tighten the collar bolt for drive axle

1. 1. Technician: Sits in vehicle and operates foot brake.
2. 2. Technician: Tightens collar bolt for drive axle only to pre-tightening torque --> «Wheel bearing housing, wheel bearing unit, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
3. Install wheel and set vehicle on the wheels.

1. Tighten collar bolt to additional torque angle (only tighten when vehicle is standing on its wheels -danger of accident-) --> «Wheel bearing housing, wheel bearing unit, assembly overview»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

Scheme 238

1 - Cover

1. Always replace

2 - Circlip

1. Remove and install with standard securing pliers
2. Always replace

3 - Inner Constant Velocity (CV) joint

1. Outside diameter: 108 mm
2. Replace only as complete unit
3. Checking --> «Inner constant velocity joint, checking»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__inner-constant-velocity-joint-checking)
4. Pressing off «Removing inner CV joint of 108 mm diameter»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__removing-inner-cv-joint-of-108)

1. Pressing on «Installing inner CV joint of 108 mm diameter»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__installing-inner-cv-joint-of-108)
2. Grease quantities and types «Grease quantities and types»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
3. Bonding surfaces must be free of grease and oil
4. When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.

4 - Clamp

1. Always replace
2. Tensioning «Install clamp on inner joint and tension»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

5 - CV boot for inner Constant Velocity (CV) joint

1. Without ventilation bore
2. Check inner CV joint for damage --> «Inner constant velocity joint, checking»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__inner-constant-velocity-joint-checking)
3. Sealing surfaces of joint boot/drive axle must be free of grease when installing.

6 - Clamp

1. Always replace
2. Tensioning «Install clamp on inner joint and tension»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

7 - Drive axle

1. Removing and installing --> «Drive axle, removing and installing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

8 - Backing plate

9 - Bolt

10 - CV boot for outer Constant Velocity (CV) joint

1. Without ventilation bore
2. Check for tears and chafe marks; replace if necessary
3. Check outer CV joint for damage --> «Outer CV joint, checking»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
4. Sealing surfaces of joint boot/joint must be free of grease when installing

11 - Clamp

1. Always replace
2. Tensioning «Install clamp on outer joint and tension»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__install-clamp-on-outer-joint-and)

12 - Circlip

1. Always replace
2. Insert in ring groove of shaft before installation (not visible on installed joint)
3. Before installing CV joint, align sealing ring in center with opening facing upward.

13 - Outer CV joint

1. Outside diameter: 88 mm or 100 mm
2. Replace only as complete unit
3. Checking --> «Outer CV joint, checking»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
4. Driving off --> «Outer CV joint of 88 mm or 100 mm diameter, servicing»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering__outer-cv-joint-of-88-mm)

1. Installing: Drive onto shaft using plastic hammer, until expanded circlip contracts.
2. When threading, circlip must lie in joint chamfer using pliers if necessary.
3. Grease quantities and types «Grease quantities and types»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)
4. When installing joint on axle shaft, splines on axle shaft must be lightly coated with grease used in joint.

14 - Collar bolt

1. Always replace
2. Observe assembly instructions when loosening and tightening --> «Collar bolt for outer joint of drive axle, loosening and tightening»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering)

Re-grease joint when replacing CV boot.

Electronic Parts Catalog "ETKA" for grease filling of joints.

Note. Note the different types of grease for outer and inner joints.

Outer CV joint of 88 mm or 100 mm diameter, servicing

Special tools, testers and auxiliary items required

Scheme 239

1. Pliers 3340

1. Hose clamp pliers V.A.G 1275

Removing outer CV joint of 88 mm or 100 mm diameter

1. Clamp drive axle in vise with protective pads.
2. Open clamp and pull off CV joint boot from outer joint.

1. Using a hammer hit a copper or brass mandrel - A - onto inner ring of constant velocity joint.
2. Remove joint and joint boot.

Installing outer CV joint of 88 mm or 100 mm diameter

1. Slide CV boot onto drive axle.

Scheme 240

1. Position CV boot between - arrows -.

1. Before installing joint piece, splines - A - must be lightly coated with grease used in joint.
2. Insert sealing ring in groove on shaft.
3. Slide on CV joint up to sealing ring.

1. Align sealing ring at center with opening upward - arrows -.

1. Thread old drive axle bolt into joint piece as depicted in illustration.
2. Drive joint onto drive axle using plastic hammer, until circlip engages.
3. Pack specified quantity of grease into interior of joint piece, see table «Grease quantities and types»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .
4. Pack specified quantity of grease into joint on boot side, see table «Grease quantities and types»(/audi/s6/c6-2006-2008/remont/axle-shafts/#suspension-wheels-steering) .

1. Install CV joint boot on outer joint.

Install clamp on outer joint and tension

Tension clamp on outer joint with 88 mm diameter.

Scheme 241

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

Tension clamp on outer joint with 100 mm diameter.

1. Engage clamp on first tab by hand.

Scheme 242

1. Close clamp using pliers 3340.

Pliers 3340 must be inserted at front of clamp, as depicted in illustration.

Scheme 243

Special tools, testers and auxiliary items required

1. Thrust plate VW 401
2. Thrust plate VW 402
3. Punch VW 409
4. Sleeve press tool VW 522

1. Press block 40 - 204 A

Removing inner CV joint of 108 mm diameter

1. Clamp drive axle in vise with protective pads.

Scheme 244

1. Strike down on cover using a copper or brass mandrel
2. Remove circlip.

Scheme 245

1. Open both clamps and pull off CV joint boot from inner joint.

Scheme 246

1. Press off inner constant velocity joint from drive axle using special tools shown in illustration.
2. Pull off CV boot from drive axle.

Installing inner CV joint of 108 mm diameter

1. Slide on joint boot with small clamp onto drive axle.

1. Before installing joint or triple roller star, splines - A - must be lightly coated with grease used in joint.
2. Press on joint until it stops.

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

Scheme 247

Use special tools shown in illustration.

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

Always replace circlip.

1. Install circlip.
2. Check prescribed seating of circlip.
3. Before installing CV joint boot, pack 60 grams of drive axle grease into joint on boot side.
4. Install CV joint boot on inner joint.

1. Pack 60 grams of drive axle grease through ball tracks into constant velocity joint.
2. De-grease contact surface for cover.

Scheme 248

1. Align new cap with bolts - arrows - to bolt holes.

A very exact alignment must be performed because an alignment is no longer possible after driving on.

1. Drive on cap using plastic mallet
2. Immediately remove excess sealant.

Scheme 249

1. Position CV boot in outer groove - arrow 2 -.

Inner groove - arrow 1 - must remain visible "identification groove" (for correct installation of CV boot).

Scheme 250

1. Use CV joint boot clamp tool V.A.G 1682 as shown in illustration. Be sure that edges of clamping pliers are seated in corners - arrows B - of hose clamp.
2. Tension clamp by turning spindle using a torque wrench - C - (do not tilt clamp tool).

1. A stainless steel clamp must be used due to hardness of CV boot material (compared to rubber). This clamp can only be tensioned using CV joint boot clamp tool V.A.G 1682.
2. Tightening torque: 20 Nm.
3. Use torque wrench with adjustment range 5 to 50 Nm (e.g. V.A.G 1331 ).
4. Be sure thread of spindle of pliers - A - moves freely. Grease with MoS 2 grease if necessary.

1. If it does not move freely, e.g. due to dirt in thread, the required clamp tension will not be achieved at specified torque.

Joint must be disassembled in order to replace the grease in case of strong soiling, or when the journal surfaces of the balls must be checked for wear and damage.

Disassembling

1. Mark position of ball hub to ball cage and to housing before disassembling, using electro-writer or grindstone.

1. Swing ball hub and ball cage.
2. Remove balls in sequence.

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

1. Swing segment of hub with shortened end into rectangular window of cage.
2. Fold hub out from cage.

Check

The 6 balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small depressions (pitting build-up) and chafing. Excessive circumferential backlash in joint makes itself noticed via tip-in shock, in such cases the joint must be replaced. Flattening and running marks of balls are no reason to replace joint.

Assembling

1. Insert cage with hub into joint body.

Note. For this, cage must be inserted on the correct side.

1. Press in opposing balls in sequence, during this the previous position of ball hub to ball cage and to joint body must be re-established.
2. Pack quantity of grease into joint body.

Grease quantities and types for drive axle with outer CV joint 88 mm or 100 mm diameter Grease quantities and types .

Inner constant velocity joint, checking

Joint must be disassembled in order to replace the grease in case of strong soiling, or when journal surfaces and balls must be checked for wear and damage.

Disassembling

Note. Ball hub and joint piece are paired for identification before removing. Do not interchange the track allocation.

1. Swing ball hub and ball cage.

Scheme 251

1. Press joint piece out in direction of - arrow -.
2. Press balls out from cage.

Scheme 252

1. Flip out ball hub from ball cage via running path of ball - arrows -.
2. Check joint piece, ball hub, ball cage and balls for small broken off depressions (pitting build-up) and chafing.

Note. Excessive circumferential backlash in joint makes itself noticed via tip-in shock. Joint must be replaced in such cases. Flattening and running marks of the balls are no reason to replace the joint.

Assembling

Scheme 253

1. Insert ball hub into ball cage via two chamfers. The installation position is at random. Press balls into cage.
2. Insert hub with cage and balls upright into joint piece.

Scheme 254

1. When inserting, make sure that in each case the wide gap - a - at joint piece contacts narrow gap - b - at hub after swinging in.
2. Chamfer on inner diameter of ball hub (splines) must face drive axle.

Scheme 255

1. Swing in ball hub, to do so swing out hub far enough from cage - arrows - so that the balls have the distance of the running paths.

Scheme 256

1. Swing in hub with balls by pressing forcefully onto cage - arrow -.

Checking constant velocity joint for function

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

1. Pack quantity of grease into joint body.

Grease quantities and types for drive axle with inner CV joint 108 mm diameter Grease quantities and types .

Settings for air spring suspension, and connecting VAS 5051 and selecting functions

Possible level control settings --> Possible level control settings .

Adjusting vehicle level --> Vehicle level, adjusting .

Vehicle jack mode --> Vehicle jack mode .

Operating with something in tow --> Operating with something in tow .

Shipping mode --> Shipping mode .

VAS 5051 , connecting and selecting functions --> VAS 5051 , connecting and selecting functions

Possible level control settings

Driver can set four different level settings

1. Automatic
2. Dynamic
3. Comfort
4. Lift