I need to replace a rear suspension arm on the driver side, its the one that mounts one end at the hub and the other next to the fuel tank in a body/sub frame U mount. The fuel tank end is the one that's going to give me grief, its mounted with a torx head bolt which is too close to the fuel tank to fit a torx head into it and even if i could there's not enough room to remove the bolt fully before it hits the tank. I can only see 3 options.
Drop the fuel tank.
Drop the rear sub frame.
Use a grinder to cut through the arm, bush and bolt in the middle of the mount, refit the new arm with the bolt fed in from the other side leaving a nut between the mount and tank which i can do up with a spanner.
Any advice or suggestions?

Last edited by ricky64 on 29th Mar 2016 10:05 am. Edited 1 time in total

Just had another thought ! If I slacken the fuel tank mounting bolts, would i be able to move the tank forward about 1 inch or so??

If it was me I would disturb as little as possible, like you say cut the arm then through the bush and and bolt and fit new arm and bolt from the other side, if it will go that way of course and its not some stepped bolt with a hole larger one side than the other?
Often happens as they assemble components as a complete unit before fitting it to the car at the factory so bolt direction/access is not an issue then.

Job done!! took about 40 mins.
Good pair of mole grips on the torx head as there's no room for any torxs tool. undo the nut about 10mm to give enough room for the angle grinder to cut the torx head off, pull the nut and remainder of the bolt out. new arm in and new bolt fed in from the bumper side rather than fuel tank side.

Exactly the same way we used to do the N/S/F wishbone bolt on a Mondeo.  Past: FL2 TD4 HSE Auto
Evoque SD4 Dynamic Lux Auto
Present: Audi A3 S Line.

Great thread folks - I crimped bath my arms (RHS + LHS) with the jack - dont ask, about the dumbest move ever....
Anyway used this thread to work out what to do - proximity to the fuel tank at and actually got the job turned around quite efficiently with a couple of new ams off eBay and fasteners from LR. Thx so much - was in despair until I read this thread - got the car aligned and it has driven great since.

photo included (for your amusement) - also parts ordered - in 'the gallery' - might help someone in future.

nice "crimping"

Not seen that before. Jules

flying scot wrote:

photo included (for your amusement) - also parts ordered - in 'the gallery' - might help someone in future.

Opps  Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.

i think we have all been there when i was 15 i gave my first car a 1300 escort an oil change with instant results as i jacked it up by putting a bottle jack under the sump and it punched a hole straight through it , still remember my friends laughter to this day  2009 FL2 S now gone
2011 FL2 HSE AUTO
2012 FL2 XS AUTO
2000 Kawasaki er 5