My car recently failed its NCT (MOT) on corrosion to the rear sub frame. Has anybody removed theirs on here. Im not afraid of hard work and have a well stocked garage. I cant find much information about it apart from removing arms and airbags. Ideally Id like to lower the whole lot in one go as most bolts are rusted solid and rounded off.

Any advice appreciated. Thanks. 2002 TD6 Epsom Green

where abouts on the subframe is it rusty, they're made of pretty thick steel?

It has rust all over which looks terrible but Im confident a session with the wire wheel will clean this up nicely before painting. Its very weak around where the height sensors mount and where the toe arm mounts. The height sensor bracket turned to dust in my hand when I poked it. Obviously its very confined area around the subframe so I figured to to it all properly it would be best to removed it in one piece. There is zero chance of opening the bolts on the suspension arms. The nuts and bolts are rounded off with rust.

Theres only 4 bolts holding on the subframe. How hard can it be.😁 2002 TD6 Epsom Green

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Theres only 4 bolts holding on the subframe. How hard can it be.😁

EAS deflated and off
Battery disconnect
Exhaust off
Propshaft off
Shock Absorbers off
Brakes off (pipework)
FBH pump released or disconnected
EAS pipework unclipped from body/disconnected from valveblock
Electrics disconnected - height sensors/FBH/Diff?
Anything else I have missed

Undo four bolts holding subframe to body

Then a couple of seriously good jacks to lower the thing down.

You should have it out in an hour

It is all in RAVE (see the wiki) .
Experience is the only genuine knowledge, but as time passes, I have forgotten more than I can remember
Volvo V70 P2 2006 2.4 Petrol 170bhp Estate SE
MG Midget Mk1 1962

Previous: L322 Range Rover TDV8 3.6 2008; L322 Range Rover TD6 3.0 2002; P38A Range Rover V8 1999

OK I'll bite. 1hour? Kidding right.

On a side note I had a 63 midget as a kid and no mechanical knowledge. I'd still be driving it if Al Gore got the internet up and running sooner. I miss that piece of crap.

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OK I'll bite. 1hour? Kidding right.

Nah, Gas Axe can work wonders!!

Already, the exhaust is not designed to be removed, and following the procedure needs to be "cut off" at a certain point.
Just more 'daftness' on a Friday afternoon in the design dep't.

All brake lines would be replaced anyhow, so no real bother.

Me thinks "wire brush" and "black paint" is a most commendable idea.

Best Rich

I really like this picture from the 2010-12 workshop Manual., but it looks like a good days work to me.

Click image to enlarge

Yeah it looks simple when you see it like that alright. I spent all day under neath it today grinding/wire brushing/air hammering/swearing and it looks much better than I first thought. It is a tad ropey around the toe arm mounts as I said. I also made new height sensor brackets which turned out quite well. Tomorrow I will be removing the heatshields, arch liners and possibly the fuel tank covers to see how things look under there and make my painting look a bit tidier. I will be using Dinitrol products. I figured Id have a go at sorting it out on the car as its a daily driver (school runs etc) so I cant have it on jack stands for too long.

Just to put it in context the car is a 2002 TD6 and has 4 previous owners. it has covered 157,000 miles. The service history mentions 1 rear lower control being replaced and I did the hub bushes and drop links when I bought, other than that it would appear every thing else back there is original. No fails on any rear bush during its recent NCT so make of that what you will.

I will try to put up pictures when Im done if anyones interested. Thanks for all the replies thus far. 2002 TD6 Epsom Green

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the exhaust is not designed to be removed

Off course it is. On a TD6 this is straight forward (if a little tight for space by the manifold, and don't do it when hot )
Had mine on and off a few times when doing stuff at the rear end (ooer! ) .
Experience is the only genuine knowledge, but as time passes, I have forgotten more than I can remember
Volvo V70 P2 2006 2.4 Petrol 170bhp Estate SE
MG Midget Mk1 1962

Previous: L322 Range Rover TDV8 3.6 2008; L322 Range Rover TD6 3.0 2002; P38A Range Rover V8 1999

You will need plenty of height to get the tank covers out, a good 2 1/2 ft

One of my toe control mountings was like an eight year olds wobbly front tooth, had to get that proper welded .
Experience is the only genuine knowledge, but as time passes, I have forgotten more than I can remember
Volvo V70 P2 2006 2.4 Petrol 170bhp Estate SE
MG Midget Mk1 1962

Previous: L322 Range Rover TDV8 3.6 2008; L322 Range Rover TD6 3.0 2002; P38A Range Rover V8 1999

Thanks Joe90. I built my own pit when I bought the house. Garage was there already. Previous owner used to hire and work on mini diggers in the garage so floors were reinforced and over 6 inches thick. It was hard work digging it out but it was well worth the effort. 2002 TD6 Epsom Green

So a little update on this. Turns out after a bit of stripping my subframe isnt as bad as first thought. However after removing my arch liners I was greeted with this beautiful sight.










Its totally rotton on both lower arch corners. It just crumbles when touched. Not sure what to do now. Car isnt worth much so no point spending huge money on professional work. Are there repair panels available for this area.? 2002 TD6 Epsom Green

Owch !

Massive dose of Frameto or some such and then a couple of coats of direct rust paint before fighting to replace the arch liner.

Although I can't believe that your 'hard' brake lines are not badly corroded with this amount of rust.

Best, Rihc

You'd be best to get the side steps off and plastic will covers off too and see how bad it is under there and decide then. There aren't any repair panels I believe so it's cut back to good and then weld in new metal. If you can diy it may be ok but a pro job could be uneconomical Current 2007 TDV8 Vogue Buckingham Blue

I did read somewhere that someone was going to start making repair panels but I can't remember who so not very helpful... 2010 4.4 TDV8 Vogue SE