AUDI A4 1999 B5 / 1.G Suspension Workshop Manual

40-1


Front axle components,
locations

WARNING!

Do not re-use any fasteners that are worn or
deformed in normal use.
Some fasteners are designed to be used only
once, and are unreliable and may fail if used
a second time. This includes, but is not
limited to, nuts, bolts, washers, circlips and
cotter pins. Always follow the
recommendations in this manual-replace
these fasteners with new parts where
indicated, and any other time it is deemed
necessary by inspection.

CAUTION!
Do not attempt to weld or straighten the load-
bearing components or parts of the
suspension.
Do not attempt to move a vehicle from which
the drive axle has been removed. Otherwise
wheel bearing damage will result. If the
vehicle does have to be moved, install an
outer CV joint in place of the drive axle and
tighten to 50 Nm (37 ft lb).
Pa
ge 1 of 14 Front axle com
ponents, locations
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU01.40.1

The bonded rubber bushings can only be
turned to a limited extent. The bolted
connections on the suspension links should
therefore only be tightened when the vehicle
is standing on the ground.
Pa
ge 2 of 14 Front axle com
ponents, locations
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU01.40.1

40-2


1 -
Bolt
75 Nm (55 ft lb)
2 -
Washer
3 -
Bolt Always replace
Note different lengths:With steel mounting bracket: M10 x 60With aluminum mounting bracket: M10 x 62
4 -
Upper link, rear Note different versions: with and without
buffer stop Figs. 1
and 2

Replacing bushing page 40
-75
5 -
Bolt
7 Nm (62 in. lb)Tighten until firm contact is made
6 -
Bolt
7 -
Self-locking nut Always replace50 Nm (37 ft lb)
Pa
ge 3 of 14 Front axle com
ponents, locations
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU01.40.1

40-3


8 -
Bolt M10 x 100
9 -
Self-locking nut
Always replace40 Nm (30 ft lb)
10 -
Upper link, front Remove together with mounting bracketRemoving and installing mounting bracket
page 40
-68

Replacing bushing page 40
-75
11 -
Suspension strut
Note different spring/shock absorber
versions vehicle data label, page 40
-46

Removing and installing page 40
-39
Servicing page 40
-44
12 -
Bolt w/washer M12 x 1.5 x 120
Always replace
Pa
ge 4 of 14 Front axle com
ponents, locations
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU01.40.1

40-4


13 -
Guide link with hydraulic bushing
Removing and installing page 40
-97
Replace hydraulic bushing if leaking
page 40
-99

14 -
Self-locking nut
Always replace100 Nm (74 ft lb)
15 -
Wheel bearing housing Removing and installing on vehicles with
headlight range control page 40
-14

Removing and installing page 40
-54
Servicing page 40
-60
16 -
Splash shield
17 -
Collar bolt
Always replaceWhen tightening, vehicle must be standing
on its wheels
Tightening torques:M14: 115 Nm (85 ft lb) + 1/2-turn (180 )M16: 190 Nm (140 ft lb) + 1/2-turn (180 )
Pa
ge 5 of 14 Front axle com
ponents, locations
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU01.40.1

40-5


18 -
Bolt
10 Nm (7 ft lb)
19 -
Self-locking nut Always replace100 Nm (74 ft lb)
20 -
Bolt M12 x 1.5 x 85
21 -
Self-locking nut Always replace90 Nm (66 ft lb)
22 -
Connecting link Arrow faces direction of travel
23 -
Self-locking nut Always replace40 Nm (52 ft lb) + 1/4-turn (90 )Underside of nut is ribbedReplace only with exact same type of
special nut
24 -
Bolt M12 x 1.5 x 100 Always replace
25 -
Lower track control link
Pa
ge 6 of 14 Front axle com
ponents, locations
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU01.40.1

Removing and installing on vehicles with
headlight range control page 40
-14

Replacing bushing page 40
-94
Pa
ge 7 of 14 Front axle com
ponents, locations
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU01.40.1

40-6


26 -
Bolt M12 x 1.5 x 110
Always replace110 Nm (81 ft lb) + 1/4-turn (90 )
27 -
Bolt M10 x 70
Always replace75 Nm (55 ft lb)
28 -
Self-locking nut Always replace100 Nm (74 ft lb)Replace only with exact same type of
special nut
29 -
Clamp Always replaceAttached onto lower track control link - 25 -
30 -
Subframe Removing and installing on vehicles with
headlight range control page 40
-14

Removing and installing page 40
-77
Replacing bushing page 40
-86
Pa
ge 8 of 14 Front axle com
ponents, locations
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU01.40.1

40-7


31 -
Bolt M8 x 25
Note different tightening torques Fig. 3
:
25 Nm (18 ft lb)75 Nm (55 ft lb)
32 -
Support for subframe
33 -
Self-locking nut Always replace80 Nm (59 ft lb) + 1/4-turn (90 )
34 -
Self-locking nut
Always replace90 Nm (66 ft lb) + 1/4-turn (90 )
35 -
Socket-head bolts
M8 x 48: 40 Nm (30 ft lb)M10 x 48: 80 Nm (59 ft lb)
36 -
Spacer plate
37 -
Drive axle with Constant Velocity (CV)
joint Removing and installing page 40
-17
Servicing page 40
-20
38 -
Drive axle with triple-rotor joint
Pa
ge 9 of 14 Front axle com
ponents, locations
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU01.40.1

Servicing page 40
-29
Pa
ge 10 of 14 Front axle com
ponents, locations
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.SU01.40.1