1G 1g Rear AWD subframe work - what to replace?

[dwb]

I'm needing to do some work to the rear subframe/suspension/axles/etc. of my 91 TSI AWD. I've never done any work back there besides brakes and rear diff fluid. Something is causing alignment issues and when I hit a hard bump, I feel the backend slightly skip to the left. I want to rebuild what I can and then have it professionally aligned after.

I don't think I'm dealing with much rust but I know my shocks, wheel bearings, bushings, axle boots, and drive shaft carrier bearings all need replaced. I already have the Energy Suspension Rear End Control Arm Bushing Set and 1 new OEM carrier bearing. I still need to source replacement shocks, wheel bearings, axle boots, and another carrier bearing.

What else should I be looking to replace "while I'm in there?" Subframe bushings? Camber adjustment bolts? Stabilizer links? Can the ball joints be replaced? I'm just aiming to get it back to how it was stock so I can have a successful alignment.

Also looking for any write-ups for 1g rear bushings, struts, wheel bearings, or whatever might be helpful for this project.

 

[pieceofcloth]

I believe if you take the vehicle to the alignment shop, they'll tell you exactly what the recommend to get your alignment done. If you fix things upon yourself now, it may not be enough for them. Then they usually decline until you fix it or have them do it.

The check up shouldn't cost you anything. Ask before though, please don't go saying pieceofcloth said it should be free

 

[dwb]

Alignment isn't my only goal. It's at 280k miles and the OEM rubber bushings are probably dust at this point. New bushings, along with me tearing it apart, will throw off any alignment done prior, so it makes sense to rebuild and then get it aligned.

 

[Christo]

If it were me I would go ahead and do it all while I was in there, new camber bolts, control arm bushings, ball joints, subframe bushings, swaybar links, sway bar mounts, wheel bearings, etc.... Probably go ahead and prep for a repaint or coating as well. Ostar Motorsports has the rear subframe bushings, they look like the old Boostx ones.

That might seem like overkill but that is just me, especially at 280K. I may have some pictures when I did mine, I don't think I did a write up though.

Old picture right before I put mine back in way back when.

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[92AWDHX40]

I did all that except for the sway bar, ostar parts were great moog every thing else with volk upper control arms and toe eliminator kit

 

[dwb]

For ball joints, I'm reading that the rears are the same as the 1g front lower. I know from experience the fronts come in two different sizes, but you cannot tell them apart when ordering. The press-fit measures at roughly 39.89mm vs 40.0mm. The 40mm fit my OEM control arms and the 39.89 fit my aftermarket OEM replacement control arms. I'm speculating the rears are 40mm. Can anyone confirm this? Are rear upper and lower ball joints the same?

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