Front Subframe: Service and Repair

Removing and installing front-axle cross member

Preliminary work

1. Put steering wheel with wheels in straight ahead position and remove ignition key (steering wheel fixed.)
2. Raise the vehicle.
3. Remove front cover and center cover (underbody protection).
4. Remove diagonal braces. Also remove crash support for the Carrera 4.





Diagonal braces

5. Remove front cover.





Cover

Removal

Removing front-axle cross member

1. Pull connector -A- from sensor for HBA and loosen threaded joint -B- on control lever.





HBA sensor

2. Loosen support for coolant pipes (screwed on 4x) and press together the support for coolant pipes in the center -arrows- and unclip.





Support for coolant pipes

3. Loosen anti-roll-bar mount -arrows- and allow anti-roll bar to hang.





Front anti-roll-bar mount

4. Loosen trailing arm on front-axle cross member -arrow - and pull out of the mount.





Trailing arm mount for axle cross member

5. Remove screw -arrow- from universal joint (steering column). Carefully push steering column upward until the universal joint loosens from the steering gear.





Universal joint

6. Remove the steering mount -arrows -.





Fastening points for the steering

Information
Step 7, 8, and 9 are only for Carrera 4.

7. Front-axle final drive with transmission jack.
8. Loosen fastening nuts -B- for front bracket -A- and unscrew the studs -C-.





Final drive mount

9. Unscrewing fastening screws -A- for support.





Fastening screws for support (for the sake of clarity, cardan shaft removed in figure!)

A - Fastening screws for support

B - Support/transmission mount screw. Do not loosen!

10. Remove the front-axle cross member mounts -3 to 10- and carefully lower (2 workers required!). If necessary for the Carrera 4, slightly lower the front-axle final drive and extend the front-axle cross member forward (2 workers required!).





Cross member with diagonal brace to body

Installation

Installing front-axle cross member

Information
Always replace the screw for the universal joint of the steering column.

Observe correct tightening torques.

Installation is in reverse order.

Subsequent work





Cover

Install front cover.

Fit diagonal braces. Also install crash support for the Carrera 4.





Diagonal braces

Fit front cover and center cover (underbody protection).

Fit front wheels.

Information
Check the steering-angle sensor setting.

Adjust toe. Calibrate steering-angle sensor if necessary.