Front Sway Bar Bushings
 

What is the proper procedure to replace the front sway bar bushings (The two inner ones)?

First thing is to determine whether you have the factory sports suspension or not. If you have a 1992 UrS4 you do. If you have a 1993 UrS4 built in August 1992, you might. You need to find the build tag (in the trunk under the carpet or in the warranty book).

This example build tag shows the NON-sport suspension code in the lower right corner "1BA". The Sport Suspension code is "1BE".

http://12v.org/urs/93Euro100BuildTag.JPG

Once you know which suspension, or you measure the diameter of the front anti-sway bar, you can then order the correct bushing. The 1BE sport suspension will have a 28 mm thick anti-sway bar. The 1BA non-sport suspension is 26 mm. The bushing PNs are 4A0 411 327 G for the 26 mm bar and 4A0 411 327 J for the 28 mm bar. Confirm this by looking at Item 21 in this useful website output:

Click Here: suspension; wishbone; wheel hub; anti-roll bar Audi 100 quattro (A10Q) 1992 year Audi USA 407010

As for doing the work, this is what you are up against, removing Item 22 "clamp", via removing nut 24 from bolt 23 on both sides (more under diagram)

http://12v.org/urs/Front%20Suspension2.jpg

Here is a better look at the front subframe, in this case, upside down, showing the Items 22 and 24 as you would see them from underneath the car.

http://12v.org/urs/FrontSubframeWith...yBar_Clean.jpg

You're going to need to get the front of the car up on jack stands with the front wheels off. (I will leave you to do that safely).

Getting at the Item 24 nut while holding the top of the Item 23 bolt is an exercise in frustration unless you drop the front of the front subframe (can be done without dropping the subframe down a bit but dropping the front subframe down a bit would help). Just be aware that in theory, the subframe bolts are single use. Item 17 here:

http://12v.org/urs/Front%20Subframe.jpg

While I think of it here are some torque values that you will need (2 page pdf): http://12v.org/urs/FrontSuspensionTorqueValues.PDF

Once you have the Item 22 "clamp"s are off, the anti-sway bar bushing might still be still jambed up against the bottom of the subframe. This is because the suspension is hanging down. The solution will then be to use a jack on the bottom of the lower control arm where the antisway bar end goes through it and jacking up (on both sides, i.e. two jacks), just enough to pivot the antisway bar away from the subframe enough so you can slip the old bushings out (they are split) and slip the new ones in. I would consider spraying a rubber-safe silicone spray on the inside of the bushing and on the sway bar to make their lives friction free.

Once the bushings are in place, remove the jacks from the bottom of the two lower control arms and reinstall the Items 22, 23 and 24 (have fun with those bolts and nuts). Note the torque as spec'd in the pdf. If you did drop the subframe down, replace the Item 17 N90583401 bolts and torque and stretch them (the 1/4 turn after you hit the torque value = the stretch).

I think that should be it.

:)