Autotech Mk4 User Manual

AUTOTECH

Installation Instructions

Part Number: 10.425.1526K
Description: ClubSport® Lightweight Front Swaybar for VW A4 Chassis

Notes: The ClubSport® adjustable front swaybar directly replaces the factory unit using

factory mounting points. We include new polyurethane bushings for the inner pivot mounts
of the swaybar. The original outer links are to be re-used. The new 2-position mounting
brackets enable simple and quick roll stiffness adjustment - unique in the market.

Because it is neccessary to support, detach, and then lower the front subframe to gain
access to the swaybar, this installation is best performed on a vehicle hoist/lift, but can also
be performed (with some difficulty) on jackstands.

Procedure:

1) Raise the vehicle. Make sure the the front subframe and its attachment points are not
obstructed by the hoist or jackstands.

2) Position a height adjustable support stand beneath the center of the subframe to the rear
of the engine, around where the steering rack attaches. Later, this will be used to gently
lower the subframe away from the chassis.

Phone [phone] Fax [phone]-E Paseo Adelanto, San Juan Capistrano, CA 92675

3) Removal of the insulation tray:
On gas-engined models, you do not need to remove the tray (that covers the gap between

the front spoiler and the engine). You will need to detach only the two rear-most screws
(Torx® T20) of the left and right side plastic covers where they attach to the subframe.

On TDI models, it is best to remove the center tray entirely.

4) Locate the steering rack. Using a 13mm wrench, remove the four bolts ( 15 ft lb + 90°) that
go up through the subframe and into the steering rack.

5) Using 16mm ( 30 ft lb + 90°) and 13mm ( 15 ft lb + 90°) wrenches, remove the rear support
brace that connects the subframe and the transmission housing.

6) Using a 16mm wrench, remove the nuts ( 22 ft lb ) that hold the swaybar end-links to the
swaybar ends. (note the location on the link on the outside of the swaybar and also the
direction of the bolt)

7) Using a 16mm socket, remove the bolts that hold the end-link to the lower control arm. Set
the end-link aside to be used later in step 5 and 6 of the lower mount instructions.

8) Using a 13mm socket, remove the bolts ( 18 ft lb) that hold the inboard swaybar clips
to the subframe. Remove the swaybar clips and set aside.

9) Lowering the subframe:
There are four bolts retaining the subframe to the chassis that must be removed. With

the support stand in place, use an 18mm socket wrench to remove the four subframe
bolts. All four bolts ( 74 ft lb + 90°) run vertically through the subframe and up into the
car's unibody. The front bolts are accessed through an inboard notch in the lower
control arms, just behind the forward pivot points. The rear bolts run behind the rear
pivot points of the arms and have a large diameter washer.

Once unbolted, slowly lower the subframe away from the unibody using the adjustable

support stand. While doing so, make sure that the steering rack comes free from its
mounts. The rack should stay up while the subframe lowers. Continue to lower the
subframe until it is about 4 inches below its original position.

10) Remove the original swaybar from the car. This is most easily achieved by lifting the bar
upward slightly to get the inboard part of the bar up and over the subframe. With the bar
lifted slightly, rotate the bar in order to "unhook" the ends of the bar from each axle, one
at a time. Then, pull the bar out towards the front of the car, going between the subframe
and the body, passing underneath the engine.

11) After applying a layer of waterproof grease to the inside surfaces of the inboard bushings,
install them on the bar with the flat area facing forward (against the subframe) and the
rounded-off corner at the bottom (near the base of the clip) as shown:

< front

rounded off corner at bottom

12) Installation of the AUTOTECH swaybar is the reversal of the removal process just de­scribed.

After installing the Autotech swaybar you are ready to begin installation of the adjustable

mounting bracket.

Phone [phone] Fax [phone]-E Paseo Adelanto, San Juan Capistrano, CA 92675