Another Rear subframe refurb...

[scottmgibb]

Apologies for the very long post…

Progress

I am well underway with a rear subframe overhaul, and though I would post with some pictures of the progress and a few questions…

It was looking quite rough:





The process of stripping down has been generally been quite pleasant. The only real issues were some stubborn prop shaft bolts, a diff crossmember bolt seized in the bush (which had to be cut), a seized anti-roll bar drop link end (seized into the hub) and a very stiff n/s hand brake bracket bolt (the one done once the subframe has been lowered slightly).

I refurbished an A4 B5 (2.5 TDI quattro – what a lovely car that was) rear subframe a few years ago, and I seem to remember it being a real pain to dismantle!

I used some pictures from one of MikkiJayne’s old threads as a guide on what to strip off the subframe before lowering, and that worked very well, so thanks for that.




The subframe looked very crusty, as expected, but after spending a couple of hours with a needle gun it was looking not bad, and actually seems very solid. The eccentric bolts guides (? – the raised bits that hold them in place) were all in great nick, unlike the ones it the A4 one I did (which had mostly rusted away!). Maybe this car hasn’t spent all it life in Scotland!





I will give it a bit more of a clean, and then probably paint it (I have ordered some Rust-Oleum as per MikkiJayne’s recommendations that I have seen). I might look into getting it blasted and powder coated, but am not sure if this will be worth the extra cost? This may also depend on the subframe bushes…

Other stripped parts:










Parts

Which leads me onto the then next bit, getting the replacement parts. The previous posts on this forum have been a great help, and I (think I) have got far more of the bits than I though I would through Auto-Doc, but would be happy for anybody to point out anything I have got wrong (or could get better elsewhere – the order has been placed, but I can always send back)!

Wheel Bearing Housings
4x FEBEST VWAB-039 (bonded rubber bush 4D0 505 171 L)

Trapezium Link / Axle Guide (lower)
4x Febi Bilstein 32226 (mounting 4D0 505 171 H) – I understand these are steel rather than aluminium
2x MEYLE 100 511 0007 (mounting 4D0 511 523 C)

Transverse Link / Wishbone (upper)
4x FEBEST ADAB-022 (bonded rubber bush 4D0 505 203 E)

Anti-Roll Bar
2x FEBEST ADSB-4FHR (mounting 4D0 511 327 C)
2x MEYLE 116 060 8240/HD (coupling rod 4D0 505 465 D)

Miscellaneous
2x MEYLE 116 050 0164 (Track Rods 4D0 501 529 H )
2x FEBEST 2329-006 (Eccentric Bolt 4D0 501 387 A - these were probably fine, but for the cost I thought just get new)
2x FEBEST 2329-007 (Eccentric Bolt 4D0 501 387 B - these were a bit rusty though might have cleaned up okay, but again for the cost I thought just get new)
1x FEBI BILSTEIN 25282 (Coupling Rod (left) 4D0 505 547 C)
1x FEBI BILSTEIN 25280 (Coupling Rod (right) 4D0 505 548 C)


Missing Bits:

The items that I have not been able to get (so far) are:
4x subframe bushes, which I understand can be the D3 bushes - Lemforder 27312 01; these are out of stock everywhere (though I have not tried the local Audi dealer yet)

2x bonded rubber bush 4D0 505 203 G - from the middle of the upper links/wishbones; this does not seem to be available anywhere (I was actually surprised to see the other 4 bushes on the links were available, as I though I read none of these were available)

2x lower spring support 4D0 512 297 E - these are really rusty so it would be good to replace, but – as expected - this does not seem to be available anywhere; I might just look out for some reasonable second-hand ones, if such things exist!

2x upper spring support 4D0 512 297 G – again I did not expect these to be available, and they actually look fine so I do not think this will matter.

1x gearbox support bonded rubber bush 4D0 599 381 E, which I understand can be replaced with the D3 version - 8E0 599 381 B; these are out of stock everywhere (though again, I have not tried the local Audi dealer yet)

I also need to replace the diff crossmember support rubber bushes (especially as there is still part of a bolt in one of them!), and have sent a pm to MikkiJayne to see if she can do the refurb (as she mentioned she might be able to start doing in a previous post).

Shocks & Springs

So what does that leave? Well, shocks and springs…

The springs seem pretty good, though quite rusty at the very bottom. I think the shocks might be done though, however to be honest I don’t really have enough experience of testing them to be sure, as I am not sure how stiff they should be.



I have attached a video of me pushing and pulling them, which is easy enough with a couple of fingers – I would have assumed it would be harder than this?

If they do need replaced then the question is with what. The one thing I do not want to do is lower the car, and I don’t want it to be particularly stiffer – mainly because I live a long a track. I guess I could get some decent 2nd hand ones from the forum sponsors, or go for something like the Bilstein B6s (if these work with the standard springs; or even the full B12 kit if not, or if this would be a good thing to do anyway), as long as these don’t lower it etc. Or is there any other recommendation?

Subframe

As noted above, I have not been able to get the subframe bushes yet, but like the shocks, I am not to sure to tell how worn out these are. I have attached another video showing how much (what is probably) the worst one moves. Does this look bad good? If they do need replaced then hopefully I can get them somewhere, and I might look more seriously at blasting/powder coating too.

Tools

And the last thing for now, with regard to installing all the new bushes. I have access to a 10ton press, but I have seen some comments about using the right tools (assuming big sockets sets won’t do the job!). Would anybody be able to rent these out for a reasonable fee and postage costs?


Thanks for reading this far and I look forward to any comments and feedback, good or bad!

Scott