View Full Version : Bora Bora Bora ! , not Tora Tora Tora ! the 1970 war film
I thought this would make a refreshing change on here and before I start, any comments, humorous observations, critisism and general banter is more than welcomed.
This is a story about a year 2000 or X reg VW Bora 1.6 16v with an AUS engine called Derek !
The car was named Derek by an old friend, I've no idea why. The old friend is actually a school friend who lives very close to me, we are both in our mid 40's and have our respective families He had owned the car since it was nearly new so had it a long long time. It has only got a touch over 76,000 on the clock and apart from a few dinks is in great condition.
The car was having a few problems and my friend threw quite a lot of cash at it including a new throttle body, cambelts etc in an effort to resolve some running issues. He was in the process of changing the fuel filter and buggered up one of the connectors to the filter and then gave up. He went out and bought a newish Audi A6 Avant and Derek sat on his drive for a few months untouched.
We quite often take our dogs for a walk over the fields and farm tracks near to us and obviously Derek was the topic of some conversations. He was talking about scrapping it, breaking it and doing all sorts. In the end and after several months the talk got serious and I we did a "deal", I got Derek for a very good price.
As Derek was a non runner we towed it back to my house, all 1/4 of a mile away, what great fun, hadn't done that for a long long time, just a tow rope, me towing in my Passat and friend in the Bora.
My intention was to quickly get it running, give it a good clean and polish and then sell it on for a small profit.
So I set to work, got a new fuel pipe from VW, about £16, partly dropped the fuel tank, fitted it and job done. There was a coolant leak which friend said was probably radiator fan switch which he had been messing with.
After the fuel pipe was installed it started and ran perfectly.
I them spent a fateful day washing and cleaning the car. Wheels off arches jet washed wheels cleaned back and front, paint work t-cutted (yes I do still use t-cut as it is cheap, works very well but sadly doesn't have an exotic name which seems to be the trend these day and besides I remember the TV adverts back in the 80's where Mr T advertised T-cut), a going over with some autoglym resin polish and then all the black bits blackened up. The car was looking good.
On the same day, the fateful day as the clean and polish after I had finished I thought I'd nip up the sensor on the rad and top up the coolant. The sensor was fine but topped up anyway, the coolant ran through and leaked out straight away. Dodgy radiator I thought. So instead of just pulling the lock carrier forward, taking the fans off and then examining the rad I thought it would be a good idea to take the whole front end off.
Still on that fateful day, I got the front end off got the rad out which was rotten and then pushed the car into the garage. The intention was to get a rad on the Monday and have the car ready by midweek.
At about 11pm I was just about to sit down on the sofa when bang, I collapsed.
I've got, have and continue to have heart issues brought on by complications to a viral infection. The year before I had a really really fateful day which I was lucky to survive. I spent a few weeks in hospital the year before on the cardio ward and came home with an ICD (Implanted cardioverter defibrillator) in my chest. The ICD is like a pacemaker but can and will shock you back to life if thing turn bad. My ICD box sits just under the skin and has two cables that go from the box via a main vein into the heart itself where the ends of the cables are bored into the heart chamber wall. Having gone through a 6 month medical driving ban from the summer of 2013 to Feb 14 I'd only had my licence back about four months when it happened again. This time the ICD shocked me back to life. Another week in hospital some minor yet unsuccessful heart surgery and home, another six month ban. The day was the 22nd of June.
All good, slowly recovering then in mid August, BANG! it happened again, I dropped dead, the ICD did its trick and saved my life again. More hospital time but came home having been started on some fairly powerful and toxic drugs. This one was on the 10th of Aug.
The Bora was still sat in the garage in bits and quite obviously I had no interest in it. I slowly recovered and gained my confidence back. After going through the dropping dead and being brought back to life thing a few times, an experience like that has an effect on you and can make even the most mundane and simple of everyday tasks difficult. I spent a lot of time sat in the 'chair' in dread and fear.
Eventually a switch went off in my head and I thought I'd better get the Bora sorted. By this time a few months had passed and we had sold our other car with the Wife driving my Passat and I'd made the decision to keep it!
Pictures say a thousand words and all that so from here on at least until I've caught up with where I am now with it, a picture commentry...
AND I DO POST A LOT OF PICTURES !
76k
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF3749_zpsdd636bd9.jpg
This is how it sat for months in the garage, I pulled it out of the garage and pushed it under the car port to re-assemble the front.
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF3750_zps6b1e39f9.jpg
The car and my car port
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF3751_zps4a1f37b0.jpg
My Pasty
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF3752_zps47a3efae.jpg
I'm a big fan
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF3753_zpsa8707236.jpg
The other side of the fans
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF3754_zpsfb2b0638.jpg
Signs of where the coolant had been leaking
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF3755_zps7c381f65.jpg
One corner of the rotted radiator
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF3756_zpsc10a852e.jpg
Another corner
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF3757_zps1db1dcf8.jpg
Cleaned front end bits ready to be refitted
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF3770_zps8683c645.jpg
The power house 1600 as was
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF3774_zps2a9773fd.jpg
The powerhouse as is, tarted up a little bit and obviously cleaned. That silver bit of crinkly hose is out of place but staying as VW want you to buy the whole air intake for about £160 to replace it! Has anyone got some they wouldn't mind donating to Derek ?
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF4156_zps03b1260d.jpg
So to recap;
The fateful day was the 22nd of June 2014, then another one on the 10th of Aug 2014. The above work getting the front back on was in mid Sep 2014. The car then sat in the garage and was SORN'd as the tax was running out at the end of Sep14.
Early October, it happened again, my heart played up again. This time though the ICD probably in combination with the drugs managed to do some ATP (Anti tachycardic pacing) which is like over drive pacing above and beyond the bad arrhythmia heart fluctuations. However that meant another few days in hospital for observation. I came home with the drug doses doubled but properly down in the doldrums!
As you may expect there has been a lot of time for thinking whilst sat in the 'chair' feeling sorry for yourself. One thing that has kept me going though is walking the dog and cycling, yes cycling. Bonkers I know but it makes me feel good and is currently my primary mode of transport.
Cycling wise, I have three bikes, those that know cycling will be aware of the equation n+1 where n equals the number of bikes you want and the +1 is what you want, it also works well with cars.
My lineup is as follows;
The 1984 Pug classic 10 speed racer, very fast but not user friendly by todays standards
http://img.photobucket.com/albums/v602/colin__/DSCF3786_zpsf38c59a2.jpg
The all singing and dancing modern "roady"
http://img.photobucket.com/albums/v602/colin__/DSCF3831_zpsaa605927.jpg
The workhorse, I do most miles on this one!
http://img.photobucket.com/albums/v602/colin__/DSCF3861_zpsdda68a7f.jpg
I even made myself a wheel truing stand and taught myself how to true bike wheels up. Something that is vital for me as I give the bikes a hard time!
http://img.photobucket.com/albums/v602/colin__/DSCF3777_zps7ccf3383.jpg
I'm currently doing between 40 and 60 miles a week on the bikes. Not a massive amount of miles but for someone like me with my condition I think it is quite a good effort.
Back to the car.
It sat from mid Sep14 until early December (this month).
At that point, having had the nagging thought in my mind of some advisories on the last MOT about suspension bushes I thought it'd be good to get things sorted.
What happens and is posted in the posts that follow should be viewed as either (bullet point list coming up)....
A technical exercise
A pointless exercise
But I love messing about with cars and with both me and the car being off the road (me, apart from the bikes) I thought, why not indulge. It is way over the top on such a car but who cares, I thoroughly enjoy pottering about in the garage / man cave. My methods and thinking may not be orthodox but who cares!
zollaf
22-12-2014, 03:55 PM
love that old pug. i had one from about the same time, 1986 iirc, from halfords, when they sold mainly bikes. it was orange mainly, a team anc bike. really good . now own a giant road bike which is all modern but i prefered the pug. wish i still had it. also have an orange mountain bike, just never get enough time to ride either enough as i should.
hope your ticker fixes itself.
...... the Pug is for sale.
It is a 62cm or 25" frame though, a large bike.
2nd of Dec 2014
So, onto the rear suspension refresh.
Plans are to...
1, Change the rear beam bushes
2, Clean up, adjust and paint the beam and attached bits and bobs.
3, Check and rustproof the rear end.
So this evening I thought I'd make a start. I'm very lucky to have a very well lit garage with an inspection pit in it which means I'm not effected by the elements. the only thing I cannot do at this time of year is painting body panels as the garage isn't heated.
So I jacked it up, took the wheels off and removed the mudflaps and wheel arch liners to inspect things! I actually did this last night.
Grotty flaky beam, drivers side
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3882_zps3c6ea65a.jpg
The garage that had looked after the car liked to use copper grease!
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3883_zps56ed2e40.jpg
Original factory wax / rust proofing still clearly visible
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3884_zps5aac9b02.jpg
No a spot of rust anywhere important. Just dirt.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3885_zps04472473.jpg
Dirty but all ok
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3888_zps21029a25.jpg
Dirty. The plastic coating has gone in a few places on the springs. How much are Eibachs going for these days.... NO! no mods!
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3889_zps781e6c31.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3890_zps26043d8b.jpg
Fuel tank strap is a bit rusty
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3891_zpsbf63219a.jpg
Bit of crush damage on the rear end of the sill where it has been jacked up over the years. Easily sorted
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3892_zps14fa92e1.jpg
And this is the only rust I could find, probably caused by a tie down strap where it may have been on a low loader at some point in its life
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3893_zps6f8b2400.jpg
The exhaust has seen better days and it will be a touch and go thing if it gets through its next MOT.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3894_zpsd1e9e90b.jpg
Grotty exhaust
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3895_zps052a9741.jpg
3rd of December
So all the above was last night.
Tonight I cleaned up the arches and started dismantling
Cleaned arch, I left the factory wax / rustproofing in place. I'll add to it when I eventually put the arch liners back in.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3896_zps2b6ac230.jpg
Caliper already off, cleaning out the allen bolt recesses before undoing and removing the caliper brackets. These are 8mm allen key bolts whereas on the Passet they are triple square or spline bolts.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3897_zpsdca54bed.jpg
Calipers off, caliper bracket off and disc off. All nice and easy as the garage that had worked on the car had copper greased things.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3898_zps49cedb39.jpg
Hub dust cap time. Some people destroy these. I prefer the gently gently catchy monkey method. An old wood chisel and tappy tap.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3899_zpsdfd8b01d.jpg
Success, dust cap off totally undamaged and ready to live another day.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3900_zpse3022336.jpg
Hub nut time. 30mm socket ad long breaker bar. These were not as tight as I thought they would be and came undone very easily.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3901_zpsd1e37bf4.jpg
Hub puller mechano set set time
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3902_zps647f60e5.jpg
Puller on and pulling !
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3903_zpsb050594e.jpg
The drivers side came off only leaving the dust / water seal on the stub axle, the passenger side, pic below left the inner bearing race and ABS reluctor ring on the stub axle. A bit of gentle levering got them off.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3904_zpsf5bbae75.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3906_zps592b5cea.jpg
Stub axle off. ABS sensor disconnected before hand. Everything looks good, just a bit grotty.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3907_zps6574f725.jpg
3rd of Dec contd.
And carrying on...
I don't know how many of you have changed a rear ABS sensor on a MK4 ?
I have and it is a nightmare of a job. It is one of the things I knew would be a bit tricky to contend with in this process but I'd rather service the sensors with the stub axle on the bench rather than struggling at a later date doing it on the car.
What happens with them is they get rusted into the stub axle. In extreme cases the rust expands and cracks the sensor casing making it fail. Once that has happened they are very tricky to get out.
This is one of those jobs that either goes right or horribly wrong. There is a lot of luck involved with regards to how bad the rust hold of the sensor.
I started off with the trusty old wood chisel around the edge of the sensor. No joy so sprayed with some plusgas onto it moved onto the other one.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3908_zpsffa2a4d2.jpg
Wiggly-age
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3911_zpsc5bfaa6f.jpg
A 13mm socket over the inboard side and some gentle hammer action got it going in the end.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3910_zps8c34b167.jpg
Success
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3912_zps227c4b89.jpg
I then went back to the other side and the plusgas had done its thing. It popped out quite easily.
4th of Dec
I've decided to write off the wheel bearings and replace with new ones, same for the brake discs. So less to do there. For the rest of things, a bit of prep work getting the rust off things.
Grotty stub axle
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3914_zps1cdee8a6.jpg
Grotty stub axle, back side
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3915_zps6ec623ea.jpg
Cleaned. Angle grinder with wire brush. I've got three types of brush, a cup brush, a flat brush, both of these are steel wire and another cup brush with brass wire for more delicate work
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3916_zps817f8a5e.jpg
Front side cleaned. I used one of the mounting bolts to hold it in the vice. I whizzed the rust off the bolt and in answer to my previous question, the stub axle bolts are 10.9 grade high tensile.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3917_zps0a48bd11.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3918_zps85be7143.jpg
Cleaned vs grotty
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3919_zps9c1de12c.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3920_zps3d06b0e7.jpg
Brake discs are about 50% worn. I'll probably change these.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3921_zps5dd3b1cd.jpg
Calpiper carrier bracket el grotto
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3923_zps23d0cc26.jpg
One cleaned one grotto
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3924_zpsbcd5688f.jpg
Half cleaned
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3925_zps8b7b8ed5.jpg
Caliper carrier bolt heads cleaning in progress
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3926_zpsb3be2e45.jpg
Shockers. They are fine functionally. So stripped them down and whizzed off the surface rust.
Top mount coming off
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3927_zps70890be9.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3928_zpsc102ef7e.jpg
One cleaned up, one grotty. I've sprayed them wiith some satin black and they are drying. The camera memory was full!
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3929_zpsa7bf4fa4.jpg
5th of Dec
Another session. More cleaning and prepping and a bit of painting done.
Left off with one cleaned and one grotty shock. I whizzed the surface rust off and gave them a few coats of satin black. They came up well but there again they are only shocks that will never been seen other than by me and the MOT tester!
Before
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3929_zpsa7bf4fa4.jpg
After, like new
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3930_zpsc80e66e1.jpg
Same for the springs, scuffed off as much rust and where the plastic coating had split. Also gave a quick coat of satin black to one of the springs only at this time. Only a temp measure but it should give them a few more years of service.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3931_zps493762c8.jpg
Disc backplates, one cleaned off and de-rusted, the other grotty.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3932_zps26e9d8c8.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3933_zps5add2772.jpg
Building the shocks back up.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3934_zps555c5711.jpg
Cleaned the flaps and yes I like them!
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3935_zps38676545.jpg
Undercovers, dirty
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3936_zps11a205b6.jpg
Bag of VAG clips for the undershields, the old ones were rusted to dust almost
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3937_zps16860f93.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3938_zps67940656.jpg
New clip on cleaned under cover
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3939_zps7a78409e.jpg
Stub axles in 1st coat paint.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3940_zps9313b58f.jpg
This is what I use and have been for years. It is really good paint and even brushed on gives a surprisingly smooth finish. Although shiny in the pics it dries a nice OE satin.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3941_zpsab4bc3da.jpg
Caliper brackets in 1st coat. "Entrance to the bloody tower" sign in the background, yes it is genuine and from the tower of London.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3942_zps63d7f433.jpg
Disc shields 1st coat on one side only. This was sprayed satin black not brush painted.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3943_zps400c4682.jpg
Three out of four pads anti rattle brackets cleaned up.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3944_zps3dd24931.jpg
I thought I'd try the VERY expensive 303 stuff to clean up the slider pin boots. It didn't work very well http://uk-mkivs.net/public/style_emoticons/default/sad.png at all so ended up using some thinners on a rag.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3945_zpsa983c0b7.jpg
6th of Dec
A bit more done despite it being a busy Saturday.
Anyone ever sanded / de-rusted a spring? No neither had I until today, tricky to say the least. In the past I would have simply scrapped them and bought new. The point of this project is to spend as little as possible and keep it OE. So I sanded and sanded and sanded the rusty bits off as much as I could, a real labour of love. I might yet whack some eibachs on but that means new shocks and this and that and costs spiraling. Not worth it on a car that cost £250.
Also whilst in the mudane-ness of the sanding by hand and with the dremel I got thinking, a dangerous thing. I've come to the conclusion that this car does in fact make perfect sense. Small reasonably simple petrol engines are likely to live alonside the TDI's, 1.8T's and V6 in terms of being able to keep them on the road for reasonable cost. The more powerful engines either petrol or diesel are likely to get hammered with VED, especially the TDI's as they are now public enemy Nr.1 with emissions. I love the 1.9 TDI, I've had four of them and the current Passat is powered by one. But I think they are going to get increasingly expensive to run.
Whilst sanding I also thought I should really be out on the bike with it being such a nice sunny day all be it freezing. Also the dog needs a good run so I'll combine the two after I've posted this. I'll leave the road bike at home and go off road with the dog running along side.
Anyway.
Springs,one prepped and one ready for prep.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3946_zps449a6a7e.jpg
Prepped, looking at this photo, what I'm doing should give them at least another five years life, the car is 14 years old.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3947_zps7f7b181a.jpg
1st coat dried nicely on the caliper brackets, lovely satin'y OE look.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3948_zps0f391519.jpg
The 10.9 grade M10 x 30mm high tensile bolts and washers arrived in the post today. These are the stub axle to beam fixings. I know they are not 'green' VW bolts but I got ten of them for probably the price of one from VW.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3949_zps415386a9.jpg
10.9 !
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3950_zps00433480.jpg
Third coat on one side of the disc shields, I'll flip them and give the backs three coats. These are sprayed but still satin black. Springs also drying in the background. Have you ever tried spraying a spring, it is mind bogglingly dizzying! The springs will get three coats that side then will get flipped for the same on the other side.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3951_zps003fbeaf.jpg
Stub axles also 2nd coated. You need to be careful to keep the paint film thickness even on the mating surface that bears onto anything else so you don't get a wonky fit, particularly important on anything that rotates. Any paint runs here and those runs would act like cambers adjusters (actually probably not http://uk-mkivs.net/public/style_emoticons/default/paperbag.gif ).
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3952_zps2c4ff562.jpg
7th of Dec
So, some more done this evening, what else is there to do, watch songs of praise ? Don't think so.
I've things as far as I can without actually dropping the beam now, almost all the fiddly time consuming stuff is now done and is ready to re-fit.
This evenings progress;
Rear spring cups, one cleaned one dirty
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3954_zpsf2d73517.jpg
And again
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3955_zps67535292.jpg
Caliper bracket built back up and ready to fit, very pleased with these.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3957_zpsf647a09d.jpg
And again
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3958_zps64eb767d.jpg
And again
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3959_zpsd6a9b27b.jpg
Touched up the ends of the springs with some thicker brush on paint, the ends were impossible to spray when spraying
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3960_zps1d103f88.jpg
Onto the beam. I removed the three (each side) brake pipe clips
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3961_zpsf8d0f26d.jpg
These little monkeys
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3962_zpsf27d697e.jpg
The brake pipes that mount on the beam are in good condition but wouldn't be for much longer, the paint / coating is going in a few places. I'd like to save them as they are £15 each to replace afterall.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3963_zps527ab4e0.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3964_zps1945d887.jpg
Back to the little monkey pipe clips. There are three each side, two cracked but are re-usable. Does anyone know if these are available or are they made of un-obtainium?
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3965_zpsf13235f2.jpg
One of the last jobs was to release the handbrake cables. Spring hanger, the cable simply levers out of them.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3966_zpsd1174532.jpg
They are a bit of a fiddle. I thought there must be a sensible way to undo these. If there is I couldn't find it and levered them off with brute force.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3967_zpse643a0bd.jpg
They should be re-usable though
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3968_zpsbdd3a217.jpg
Axle beam bolts, 18mm both ends. The pre-soaking in plusgas paid off, they came off easily.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3970_zpsdacb99bb.jpg
Plus gas, everyone should have a tin of this if you are working on an older car, it make life much easier taking things apart and lasts for ever, I must have had that tin over 10 years and I'd say it is still half full!
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3974_zps5b4ed4c2.jpg
Another job was to sort out the rusty fuel tank hanger straps. There are two so I took one off and worked on it. You may think I'm going over the top but years ago I had a car fail its MOT on these. Easy to sort now but in years to come they will be tricky to get hold of and second hand doubtful as they all rust!
Two mounting bolts, 13mm heads
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3971_zps505ead09.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3972_zpse2df1a96.jpg
Rusty fuel tank strap
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3973_zpsf70f6520.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3975_zpsa49027cb.jpg
For clarification, this is what I use to de-rust. Note the softer bristled cup brush for more delicate work. what is not seen are the safety goggles and ear defenders. This is really really noisy work. WHAT? And wires from the brushes flick off at hundreds of miles an hour. You do not want one in your eye!
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3976_zpsf08481c8.jpg
Part cleaned
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3977_zps221b41c3.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3978_zps5b5b1f0e.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3979_zpsb5928229.jpg
A little helper although he makes himself scarce when the grinder is making its horrible noise.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3981_zps0389b5a9.jpg
Helper wants to play
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3982_zpscc36d2b2.jpg
Good old hammerite. I like this stuff and have used it for years and years and years. This is the smooth satin balck and looks very OE when dried.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3983_zpsde24a224.jpg
Tank strap is 1st coat hammerite hanging up drying.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3984_zps406c612a.jpg
That really is just about as far as I can go without dropping the beam which I will not do until the brake hose clamps turn up. If they ever do.
8th of Dec
The shopping fairy brought things today.
Hose clamps, I've been waiting and waiting for these.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3985_zpsddebe413.jpg
Hubs
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3986_zps3d8d5f2f.jpg
So I got to work this evening, beats sitting indoors despite it being freezing cold.
Hose clamps on, bloody useless, the fluid dripped and dripped and dripped...
Passenger side first
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3987_zps77d95bb9.jpg
Bit of flaking on the main brake pipe, will need to sort this.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3988_zps1d5d586e.jpg
Clip coming off
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3989_zps1c3830cc.jpg
Undoing brake pipe union. No drama, not rusted in as others have warned of.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3990_zpsad8a6348.jpg
Drivers side, again no bother.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3991_zps1db1480c.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3992_zps90755888.jpg
Calipers off. I'm not touching the banjo bolts, there is no point.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3993_zps913fe8a0.jpg
Flakey. The plastic coating is going in places
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3994_zps46a400e2.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3995_zpsb379017e.jpg
Manky
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3996_zps4edda2f1.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3997_zps0c922757.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3998_zpsd17aabcf.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3999_zps450f3345.jpg
Bolts are good and re-usable, they are not stretch bolts.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4001_zpsc4881717.jpg
8th of Dec
And at long last.
The beam is off the car!
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4002_zpsac012cd7.jpg
Manky
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4004_zpsa1b17f74.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4005_zps29fda325.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4006_zpsa0fe4aa3.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4007_zps5bd0013c.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4008_zps500b7e94.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4009_zpsd0704570.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4010_zpsdf6a7857.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4012_zps6e0e6d40.jpg
8th Dec contd.
So got to work again after dinner.
I decided to remove the plastic covers off the beam. Below is a very bright Cree T6 bike torch shining into a hole on the beam. Put a big screwdriver in there and whack it. It took me ages to work that out!
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4012_zps6e0e6d40.jpg
Pic of the cover clip for reference
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4014_zpse197317f.jpg
Caliper cleaning, one done.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4015_zpsf499de75.jpg
This how clean this bit should be (piston head)
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4016_zps69974f2f.jpg
Not like this.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4017_zps0d6dd854.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4018_zpsbd943de7.jpg
One thing any rear disc calipers can suffer from is lack of efficiency come MOT time. This is mainly due to a sticky adjuster mechanism inside the caliper. Nine times out of ten you can remedy this by winding the pistons back, pulling the handbrake on and off about times times (careful not to pop the piston out) wind back in and repeat. Do this five or six times and you should feel things free up.
Windback tool in place
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4019_zps5319ce97.jpg
Caliper painting. I'd freed off both bleed nipples to make sure everything was ok before I put any more work into these. Prepped brake pipe, corrosion removed. The good thing about the engine enamel paint is that it has a corrosion inhibitor in it.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4020_zps8278469d.jpg
I'll paint the calipers in two halves just to keep it managable.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4021_zpsa80d1803.jpg
Quite chuffed, I got a lot done tonight. Things are moving along nicely.
There is no easy way to change the bushes. It has been a job I've been dreading doing for a long time. It was something I was just about to do on my old MK4 just before I sold it in Jan 2007.
I had a bit of a session on the beam today to say the least.
Scabby beam and state of the bushes.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4022_zps8312b9e7.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4023_zpsbbc8aa83.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4024_zpsc7969085.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4025_zps1afb3250.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4026_zps06b75594.jpg
Pretty grotty. The bushes were an advisory on the last MOT so would have probably failed this time round. The bushes are the main reason I'm doing the rear suspension refresh and tidy up. The car is SORN'd and off the road so there is no hurry.
I cleaned the beam up with the wire brushes in the grinder. What a job that was. I didn't and couldn't get everywhere due to the shape of certain parts but am happy with the level of preparation I've put in. It was all surface rust, all be it quite bad in places but it is all very heavy gauge steel so will be ok. It is going to be covered in a few coats of paint far better than from the factory so should last for years and years.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4027_zps1f86e538.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4028_zpsfd49e314.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4029_zps36c59936.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4030_zps33c497a7.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4031_zps9187433b.jpg
9th of Dec
The removal of the bushes. This is not an easy job and if you are planning to do this, bargain for at least an hour each side if you are doing them on the car with restricted access.
There are two part to the exercise;
1, Remove the inner rubber and bolt holder.
2, Remove the outer shell
I started drilling through the rubber and tried to join the holes. Then it was a case of pulling the rubber apart and out bit by bit using a screwdriver and pliers. This bit took ages and is by far the hardest part of the bush removal process. It is a brute force job.
Drilled rubber although it is hardly noticeable
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4032_zpsfb3b0e47.jpg
Had a go with a flat woof bit. It didn't end well.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4035_zps460b5844.jpg
Part way through getting the rubber out, bit by bit.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4036_zps35268a1c.jpg
Drilling
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4037_zps76b863b3.jpg
Bits of the rubber bush and the bolt guide that is encased by the rubber.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4038_zps9210cfae.jpg
This is what I was left with after removing the rubber, the outer shell.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4039_zpsa086fe0c.jpg
My method was to cut some slots in the shell and then hammer the crap out of it using a chisel to drift the shell out.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4040_zps2857d32d.jpg
Hammertime
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4041_zpsaeb68908.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4042_zpsb0ecdfcf.jpg
And then all of a sudden it popped out
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4043_zps35d72403.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4044_zps39d9a445.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4045_zps5935e0d0.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4046_zps55625d62.jpg
And then it all started over again on the other side
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4046_zps55625d62.jpg
This time the shell popped out in two bits
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4048_zps3922ab1f.jpg
Not a nice job and I doff my hat to those that have gone before and done this with the beam on the car. But for those that have not done it and are contemplating doing it, it is possible. All I used was a drill, a large screwdriver, some slipjoint pliers, a chisel and a lump hammer.
Bushes out, final prep done on the beam and then 1st coat Hammerite smooth satin black. I intend to give it three coats in all.
Things are moving along nicely now.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4049_zps0416ae63.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4050_zpsb9b5db61.jpg
10th of Dec
Not much progress tonight despite being out there for hours and hours. Saying that I had a really good tidy up which took a while. I don't know if anyone else is the same but I go for it and leave a trail of devastation behind. It gets to a point where I cannot find anything and then decide that I HAVE to have a tidy up and sort out. Well that happened tonight.
Another coat of paint on the beam
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4051_zpsedc273d8.jpg
Whizzed the rust off the beam bolt heads. These are not stretch bolts and are good to go again once tidyied up. I bet these would cost about £10 new from VW so I'll make do and mend.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4052_zps05d753eb.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4053_zps8f9dcf31.jpg
Splitting hairs here. The undershield screws, you all know the ones. Well they get scabby so, you guessed it, a quick whizz.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4054_zps9df17ac6.jpg
Forgot to paint them (just remembered)
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4055_zps1fd15e24.jpg
I'd be happy to get a box like this for xmas, easily pleased I am. £31 delivered, bargain!
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4056_zps7a1176dc.jpg
Painted the backs of the new hubs so they don't rust and get manky
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4057_zps4df36cfe.jpg
And the beam bolts
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4058_zps057008a8.jpg
That is it, looks like nothing happened.
I was going to paint the disc edges as well but am loathed too clean the protectant off them as they (the faces) will rust. As the car is going to be off the road until Feb 15 at the earliest I know they will get surface rust on them even if the car is sat in the garage.
12th Dec
And so it continues.
I'm getting dragged further and further into doing more things than I set out too do but that is how things go when you are doing any kind of restoration project on a car. Whatever your budget and time set aside is, double it and add some more!
Spoken to Old Nr7 (Neil) who is kindly sorting me out the proper beam bush installation tool.
This evening I have mostly been gaining access for brake pipes. I've got the gear on order to make my own and am going to use copper nickel pipe rather than copper as having researched it, pure copper pipe for brakes can be dangerous as is work hardens, becomes brittle and gives way. Not something you want to happen with your brakes.
The main issue (at the moment) was the drivers side brake line which passes over the top of the fuel tank. There is NO information I could find about MK4 brakes so I had to partly drop the tank to investigate. I was expecting the brake pipe to have been clipped, but no, no clips above the tank. This is good news for those of you who need to change this pipe for an MOT fail as it means that you could simply feed a replacement from one side, and above, of the tank to the other.
Fuel filler flap off. There is one torx screw then it wiggles out.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4063_zpsb69da5a4.jpg
Tank partly dropped and being supported on blocks of wood, I am lucky I have the pit.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4064_zps52548d38.jpg
View above tank showing brake line (one of a few pics of this for reference)
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4065_zps5b365726.jpg
Me holding the drivers side bracket where the hose join the pipe. I unbolted the bracket as it was quite rusty so guess what, I whizzed the rust off and painted it, it is drying as we speak!
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4066_zps98d3283f.jpg
another bit blurry view
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4068_zps45134600.jpg
and another
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4069_zpsfe79d9da.jpg
This is how much the tank is dropped, for reference
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4070_zps8654b324.jpg
and as seen from the filler neck which you need to unbolt, 2x 10mm bolts
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4072_zps93f849ad.jpg
Fuel flap release mechanism if you were ever wondering what it looks like !
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4073_zps31e18c67.jpg
the bracket, the one I have since whizzed and painted
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4074_zps018e4d58.jpg
undershields, I cannot believe I managed to get them off without destroying them.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4075_zpsc08cc64e.jpg
new brake hoses, they are the same, thankfully
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4076_zps1dc1ee3e.jpg
I cut the brake pipes at the unions as they would not come off. The brake pipes were a bit grotty but gave no indication that they would be this bad. My advice to anyone if they are ever doing any work similar to this is to consider changing them whilst you have access. I think they are made of aluminium due to the white powdery residue and they were seized solid in the unions. They would not undo without twisting the pipe.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4078_zps1d6e642a.jpg
I did get the union out in the vice but even hammering a screwdriver in, wouldn't budge them.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4079_zps2db4be35.jpg
dirty
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4080_zps4003f39f.jpg
And to finish, a few more of the brake over the tank as viewed from the rear drivers side wheelarch
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4081_zps9cb985b3.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4082_zpsfd3228d4.jpg
15th Dec
Not much happening at the moment, I am waiting for some parts.
But I thought I'd take the existing front to rear brake line out, a job I have not been looking forward to.
I cut the pipes about 300mm under the front. I did this so as to preserve the factory bends which would have got ruined otherwise. I marked the left and right hand sides on the ABS unit and then went for it. Once cut I just about managed to wriggle the longer back sections of pipe out from under the car.
Labelled pipe port unions on the ABS unit (don't rely on this, yours may be different).
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4083_zps49f8bc37.jpg
One pipe removed but the other in place disappearing down and under.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4084_zpsfc12ad6d.jpg
On the bench, you can just about see the passenger side pipe (joined back together with tape for reference)
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4085_zps43aeac22.jpg
Drivers side on the floor in two bits. In the background you can see the section that turns over the top of tank.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4087_zpsaec44272.jpg
Drivers side pipe, section over the tank, quite badly corroded. These need changing and and is a job well worth doing if you ever drop your beam.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4089_zps45963733.jpg
These spacer clips (remainder of pics below) are on the pipe, about five of them, where it goes over the top of the tank. Four of them have fallen apart and I need to replace them. Problem is there is no part number on them, any ideas Gents? Anyone got ETKA or whatever it is called these days?
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4090_zps7ba059a3.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4091_zpsf7a5476e.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4092_zpse34a92c0.jpg
16th dec
At long last. I actually built something back onto the car today even if if was only a really minor job.
I fitted the rear brake hoses that go from the body to the beam, only did so so I have a reference point for when I run the new brake pipes. I felt good to put something back together instead of taking it apart for a change!
Driver side, and yes I did paint the beam brackets on the car, I didn't want to take them off so as to avoid any alignment issues. On the drivers side there is also a sub bracket which was rusty, so guess what, I took it off cleaned it up and painted it. Also cleaned up and painted the hose clips! Quite annoyed I didn't clean and paint the bracket bolt though.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4093_zpsbd5a8c69.jpg
Passenger side.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4094_zps90233231.jpg
I also had a go at making some flares on the copper nickel brake pipe as well. The flaring kit I've got is old and I've only got an SAE die for 3/16th pipe so it wouldn't work with the VW metric / DIN fittings but I thought I'd have a practice. I'm waiting for a DIN flare tool, one which obviously does the correct DIN flares but more importantly will enable me to make the flares on the car. I plan to run the pipes then make up the ends.
I've made up copper SAE pipes before with this flare tool I've got but this time I'm going over to Copper Nickel. This Copper Nickel pipe is a long harder than copper and the flare tool struggled a bit, I wouldn't be happy and would fit these practice flares to any car. The new tool that will hopefully arrive tomorrow will make things a breeze to do, it is designed to flare steel pipes which are even harder.
Dodgy flares
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4095_zpsbeaa9999.jpg
Getting cheesed off having to wait and wait and wait for bits to be delivered. That goes with not being able to drive. Never mind, I can see it all coming together quite quickly once the brake pipes are done.
Plans for the front suspension are nothing more than a clean and paint up and the following;
TT solid flat bushes in the wishbones
New top mount rubbers
New top mount bearings
New pads and discs if they are shot.
And of course lots of time spent cleaning and painting.
Small update.
Got the bushes in the beam and ran the new brake lines under the car. Hopefully two things will happen tomorrow, the flaring tool will arrive and the VW dealer will have the pipe spacers in ready to pick up.
Bush being drawn in.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4096_zps81bce19a.jpg
Done.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4098_zps6ced83b2.jpg
New brake lines in. I'll tidy up the alignment once the fittings are on and they are connected up
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4099_zpsfdd8df75.jpg
Driver side line which simply sits above the fuel tank, in fact get wedged between the tank and the floor. This is the section that the spacers need to be fitted to. Again end not flared / connected so it is just roughly in place.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4100_zps04dac6e1.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4102_zps8b539f8b.jpg
Passenger side not even near but ready to put the fitting on.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4099_zpsfdd8df75.jpg
If everything arrives tomorrow then the plan is;
Flare the pipe ends and connect up
Get the exhaust heat shields back on
Get the fuel tank bolted back up
18th of Dec
Quite a bit done tonight although it hardly shows. Spent a good few hours out in the garage.
Got the brake lines flared and plumbed in from the rear flexi's to the ABS unit.
Got the heatshields back on
Got the tank bolted back up and the fuel flap door back on
That is it, all that time. Despite taking all these photos, I wasted loads and loads of time getting the heat shields back on as I forgot how they came off and it is like the krypton factor getting them back. Top tip; the passenger side fuel tank strap goes on after the heatshield http://uk-mkivs.net/public/style_emoticons/default/wink.png
With regard to the brake lines, I posted up a how-to on how I've done the flares for the pipe ends, here;
http://www.vwaudiforum.co.uk/forum/showthread.php?163300-Brake-pipe-FAQ-and-how-to
So, the work tonight...
Flaring tool in position
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4121_zpsf20c92eb.jpg
Blurry photo of the flare
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4122_zps901ff94e.jpg
They new brake line spacer clips in position
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4123_zpsfbce4341.jpg
At the ABS pump end. I did have a brown trouser moment on one of the pipes, made the flare up complete with new backnut and went to fit it into the ABS unit, too small. VW in their wisdom fitted a larger nut on that one so you cannot get them mixed up. So I had to cut it off and re-make the flare with the old nut. Luckily there was enough pipe to so.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4125_zps115afc56.jpg
Job jobbed at the ABS pump end
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4126_zps4b614e9b.jpg
Shields. A huge timewaster for me tonight, these were!
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4127_zps8176f985.jpg
Fuel tank straps de-rusted and painted ready to fit.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4128_zps836a8682.jpg
Spot the deliberate mistake ...... the heat shield should have gone on first, took me a while to figure that out http://uk-mkivs.net/public/style_emoticons/default/rolleyes.gif
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4129_zpsd13e27ae.jpg
Sorted. ready for the beam to go back on tomorrow, AT LAST !
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4130_zps1a4fa0ae.jpg
19th of Dec
Busy tonight.
Got the beam on and everything built back up. All to do now is grease caps on the hubs, wheelarch liners, wheels on and let it down off the jack. I'm not going to bleed the brakes yet as I am going to do the front end next.
Discs, been leaving these until the last minute as I don't want any surface rust on them. Cleaned the protective coating off them.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4131_zpse57ad9f8.jpg
And then painted the bits that go rusty
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4132_zps4cc388c8.jpg
Both sides two coats
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4133_zpsd3083c5d.jpg
What that? That is the nearest the beam has been to the car for a week or so.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4134_zpscb7e7783.jpg
Beam on
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4136_zpse22a349c.jpg
Nice
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4138_zps50337e7b.jpg
Stub axle, brake shield and ABS sensor on
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4139_zps37712762.jpg
Hubs on
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4140_zps845addda.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4141_zpsd0be9443.jpg
Note how close the ABS sensor sits to the reluctor ring. This is why it is critical that everything is clean. Also why to NEVER use copper grease on your wheel bolts as they poke through into the area where the reluctor ring and sensor is, that metallic grease can flick off the wheel bolts and mess things up. Use ceratec brake assembly grease instead
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4142_zps74c687cf.jpg
Discs on
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4143_zps7e448f8f.jpg
Caliper carrier on
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4144_zps2baa3e8d.jpg
What a difference
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4146_zpsd73e78b0.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4147_zpsf5472fd0.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4148_zps1e5259ca.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4150_zps546a0516.jpg
As a comparison from this.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF3882_zps3c6ea65a.jpg
To this. Everything cleaned, painted, adjusted, renewed and now known to be all good for a long time.
http://img.photobucket.com/albums/v602/colin__/Bora/Bora%20rear%20beam/DSCF4148_zps1e5259ca.jpg
Well chuffed. A lot of effort but worth it for the peace of mind.
21st of Dec
I got the arch liners on, the wheels on, the car down onto the ground and the beam bush bolts tightened. All good and went on to remove the rear bumper to check for nasties, there were none. The car really is as clean as a whistle, amazing for its 14 years.
Dusty, the car is covered from all the crap from cleaning off and de-rusting the suspension components. I'll have to look up the actual colour, I don't know it!
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF4151_zps69f10b33.jpg
Arch liners on, nice and clean. Also waxoiled under them in the contact areas especially the arch lip.
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF4152_zps32eac61c.jpg
Bumper off. I hate taking the lights out, those pesky little difficult to get to nuts!
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF4153_zpse45d79db.jpg
A quick wipe over
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF4154_zpsbf57fa07.jpg
These were the bits I wanted to look at, clean and no rust, waxoiled the clips where the bumper fixes to to keep it that way.
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF4155_zpsf4c0bbc9.jpg
I'll hopefully get the running issue sorted tomorrow and then might start on the front suspension.
I started on the front end this afternoon after a lazy morning. I jacked up all four corners and took all the wheels off in readyness for a full system bleed. That will be a long way off, see below!
Wishbone bush, surprised this was only an advisory!
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4162_zpsa4c3ad4f.jpg
ARB clamps, will the bolts undo?
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4163_zpscdf9792a.jpg
General grottyness, the discs and pads are quite new and will go back on, that is an expense saved, thankfully.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4164_zps749fd104.jpg
Rusty
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4165_zps0b25458d.jpg
Grotty
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4166_zpsde37cdda.jpg
Grotsville
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4167_zps078883db.jpg
So, calipers off, discs off. I was working on both sides at the same time.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4168_zpse5bee7a1.jpg
Bit blurry but one of the disc shield bolts, in fact the same one on each side rounded off with rust so I had to use one of my Urwin bolt grip sockets. These are brilliant and have saved me many times.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4169_zpsb4d5af0e.jpg
Shields off
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4170_zps0a4200c3.jpg
Then disaster struck. Splitting the trackrod end balljoint on the drivers side, the taper broke when undoing the nut, the allen key recess rounded as well. I hack sawed through the joint spiggot and freed it from the hub, no problem. Then as the track rod end is scrap I though I'd wind it off the track rod. NOPE, seized solid. I had to hacksaw through the backnut to get it started. Got the backnut moving, yes! Then went on to try and get the main body off the rod end, NOPE. I've got some 2' (600mm) stilsons which are a very heavy weapon for this sort of work and I'm a big strong bloke. I couldn't shift it. The problem is you cannot get any force on it due to the location. I may be dropping the subframe afterall. I will of course try a cunning spiral cut with the hacksaw first though. This is a very time consuming job so it may be quicker to simply drop the subframe and get rack on the bench where I can give it some welly!
Split cut on back nut. This is taken after I got the nut to move.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4171_zps107a88ac.jpg
Strut removal, top tip, use an a spark plug socket, much easier than messing about with a ring spanner which never fits and slips off. That is unless you have VW special tool 666 !
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4172_zpsa9cc5113.jpg
Strut and hub assembly on the bench, i'll split the the strut from the hub up on the bench, much easier than trying to do it on the car.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4173_zps0556a83c.jpg
Also got to attempt the passenger side track rod end which I'm not looking forward to. Some good news though, the wishbone bolts came undo easily!
That is it and brings things up to date.
I cannot believe I neglected to post this up on here.
Cavanmick
22-12-2014, 10:23 PM
Well done buddy, really really thorough work there and looks the business going back together.
Mick
Some more done this evening.
I got the passenger side dismantled. The track rod end balljoint needed to be hacksawed off again on this side.
The pics..
Puller pulling and pushing the same time !
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4174_zps3bfc6ae8.jpg
Dangle-age, these are holding the drive shafts level or is it a repelling line and am going to have the SAS abseil down it and blow everything up?
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4175_zps6cfda242.jpg
These are the 24" Stilsons, they are older than me and kindly handed down by my Dad. I couldn't shift the track rod ends with them though.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4176_zpscceff496.jpg
A random shot of the back end
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4177_zps92ccf9de.jpg
Flakey
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4179_zpsc182d887.jpg
Strut to kuckle pinch bolt, rusty.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4180_zps883fa584.jpg
Both sides played the game and easily came out, struts out of knuckles and I also got to use some big hammers
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4181_zpsc13bc75d.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4182_zps7b380658.jpg
Hammertime again to whack the hub out of the knuckle. I really enjoyed this bit
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4183_zps11b02f20.jpg
11mm socket used to gentle tap the ABS sensor out, tap tap tapedy tap
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4184_zps5267d2e1.jpg
Balljoints out, the nuts came off easily and the pickle fork broke the tapers, more hammer-idge
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4185_zpsa7f1c047.jpg
I had to cut the track rod end balljoint spiggot again as I miss cut it last night (drivers side), knob, passenger side was ok.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4186_zps303adc14.jpg
Wedged in the vice for more hammer time, note the block of wood spacing it up so as to prevent the reluctor ring getting damaged.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4188_zpsca449b0f.jpg
Wood chisel and hammertime tried but didn't work. It did on the rear races though, they wacked off the stub axles without too much hassle.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4189_zpsd9f1285a.jpg
Some head scratching on how to proceed and I settled on the Dremmel like tool with a cut off disc. I didn't know if this would work but I was all out of ideas and tools to do this. I've had a dremel type tool for years and never really found it that useful but this time it got me out of a hole, I like it!
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4190_zps61c2d627.jpg
I carefully cut the bearing race bit by bit wacking the cut with the chisel, eventually the race split and came off the hub. Nice
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4192_zpsd033ab04.jpg
I also dismantled both struts.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4193_zps68de8f0d.jpg
The shopping fairy came today, quite surprised as I didn't expect anything I'd ordered to arrive before Christmas.
I now have two front wheel bearing kits and a pair of Audi TT lower arm flat bushes.
I've got a lot of preparation, cleaning, painting and fettling to do though before I even begin to think about fitting new parts.
I'm going to drop the front subframe but am a little worried about the alignment. I've done this before on Fords and had a set of subframe alignment pins. Not sure about the Bora and all I know is that the subframe can float about on its fixings before they are finally tightened so as to allow equalisation of the camber. What I intend to do is mark the position on the underbody of the car and then put it back the same. Does anyone know if there are any special tools for Golf4/Bora subframe alignment?
More done, one of those evening spent ages and seemed to achieve nothing.
Mainly had the grinder and wire brushes going preping everything I'd previously dismantled. I also took the front calipers off.
Knuckles, one cleaned off, one dirty. They were clean of road dirt as I jet washed under the arches back in the summer and the car hasn't been driven since. Still rusty as a rusty thing though.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4194_zpsd873b2c2.jpg
There are some bits you cannot reach with the grinder so it is as good as it is going to get.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4195_zps4f6c6fc7.jpg
Hubs / drive flanges done as well
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4196_zpsb467da66.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4197_zps23743260.jpg
Done and ready for paint.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4198_zps473a7fe6.jpg
The springs were quite good and only needed some minor cleaning off. I'll just touch up the ends on these.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4199_zpsb7a0c451.jpg
Also got the calipers, struts, the strut end cups which were quite rusty, the disc shields and a few bolts cleaned off and ready for paint. I'm glad I got all that done, it is a filthy job and you get little bits of wire flying off the grinder at 200+ mph and embedding themselves into your clothes.
New wishbones also arrived so I can swap over and fit the TT bushes in them.
Right then freaks.
I know the title says on car but I did this on the bench only because I'm doing a bit of a restoration. There is however no reason why you couldn't do this with the steering knuckle on the car.
First of all, this post, all the pictures and comments are for information only and I and this forum take no responsibility if you decide to do this yourself and damage either your car or more importantly yourself. This is a quite advanced bit of work and if you do not have the confidence or ability or are unsure in any way, take your car to a garage.
As such, this guide misses out the preliminary stages of this process and assumes you will be able to get yourself, I will however list them directly below (these preliminary stages will vary car to car and front to rear);
Loosen hub nut, do this before anything else
Loosen wheel bolts
Jack the car up, as high as you can get it so you will have a decent swing and leverage on your breaker bar(s)
Wheel off
Brake disc and caliper off
Split lower balljoint(s) or remove balljoint from wishbone if FWD,
Use a puller either to the driveshaft CV joint back and clear of the steering knuckle or if on the rear to pull the hub off
If front, tuck the drive shaft to one side and tie it up.
So now you should either have clear access front and rear to the front wheel bearing or if on the rear of a FWD the hub on the bench.
The following I carried out on my year 2000 Bora.
This is the kit I used, it cost me about £40 (2014). I've read a lot of "woof woof woof blah blah, it won't work, you need a ten tonne press woof woof woof, blah blah" but they would make these kits if they didn't work, would they? Besides, if you are in a spot and need it done it'll save you having to take the knucke off and down to the local garage who'll obviously need £20 for the favour.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4218_zps9ebf1040.jpg
It is all very duty stuff as you would expect and you will need some big sockets to wind the tool up, make sure you have sockets that will fit both ends before you start any work on a Sunday afternoon when every car shop is shut and you need the car for work on Monday! I'm not sure how long the threaded bar would last if you were using this tool day in day out but for a DIY'er it is perfect.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4219_zpsc2915c9c.jpg
There are various thrust plate, receiver cups and end caps in the kit, you will have to find the best fit for your bearing.
Below tool in place at the commencement of me drawing the first bearing out.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4219_zpsc2915c9c.jpg
Totally useless picture which was to show the thrust plate, except you can't see it but hopefully get the idea.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4201_zps99444afe.jpg
Bearing partly drawn out, I had to turn the bolt round at this point on the threaded bar to continue but thought I'd take a photo.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4203_zpse91880f5.jpg
Old bearing on the bench. Was it difficult? No, not at all, these bearing had been in that steering knuckle for 14 years and came out with ease. The hardest part is working out what plates and cups you are going to use.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4204_zps421c1e3e.jpg
Bare knuckle!
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4205_zps6cc68e89.jpg
I started by starting the new bearing into the knuckle by using the correct sized thrust plate and gently tapping it into the knuckle with the handle of a lump hammer. Be very careful and make sure it is square.
Tool in and drawing the new bearing in.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4206_zpsaecca88d.jpg
And again
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4207_zps13fae00b.jpg
Circlip, this is the new one that came with the bearing kit, you obviously need to take the old one out first
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4208_zps1d85ae63.jpg
New bearing in
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4209_zps7f1e1b4f.jpg
Fitting new circlip
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4210_zpsf90b82e2.jpg
So there we have it.
I know if I'd left it there some might say something like "woof woof woof, you were lucky, that was an easy one, woof woof blah blah" but below is the other front bearing.
Removal
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4212_zps576bc9b5.jpg
I didn't take a photo of it on the first bearing but make sure you carefully clean out the circlip recess and in the case of this knuckle the recess at the back. This is the crap before I blew it away.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4213_zps60c9779b.jpg
Make sure all the crap is cleaned out and then I smeared some oil onto the recess to help things in (Ooo-errr Mrs) As above start the bearing into the knuckle using a thrust plate and some gentle tappage.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4214_zpsb88ed74e.jpg
Second bearing in and new circlip
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4215_zpsabc14ca8.jpg
Job done, twice, both front bearing replaced
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4216_zps4e6cc7a5.jpg
Scrap bearings
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20wheel%20bearings/DSCF4217_zps2d95ff13.jpg
For any woofing that may kick off, down Shep and have a scooby snack. I'd recommend one of these tool kits to extract and install wheel bearings. I've just done two with ease and it would have only been marginally more difficult doing it on the car. In fact doing the prep and getting the driveshaft out will take longer than the bearing in/out process.
zollaf
24-12-2014, 02:53 PM
nice job. well done.
2 things. some vags don't use a circlip, so all thats holding the bearing in place and thus the wheel on is friction. my s4 is one. scary stuff.
also, these bearing will come out usually with a big hammer. some bearing won't and will register 15 tons on the press before they start to move, but they are usually french. i don't think this kit would do one of those. but then you don't own a french car so who cares. merry xmas.
Some more but limited progress. Things are at a stage where they are going slowly. But soon, soon it will all come together.
Hubs painted and re-assembled
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4233_zps1b5e7dd0.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4234_zpsbb179857.jpg
Although the wishbones were brand new, I whacked out the flat bushes and whacked in some TT solid bushes. I did this years ago on my old Golf, that time I used used the vice to draw the new bushes in. This time they were whacked in, no bother.
Whacking out socket sitting on the old bush
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4236_zps5cb403aa.jpg
TT bush in with the old bush sitting next to it, also starring in this photo are the whacking in and out sockets and special guest star and introducing "Lump Hammer"
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4237_zps1b03b50e.jpg
Time for the front discs. These are almost new and despite looking a bit grotty were no where near ready for the bin.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4238_zps5db8b3f3.jpg
Partly cleaned
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4239_zps44b6175b.jpg
A top tip from someone http://uk-mkivs.net/public/style_emoticons/default/wink.png
Sprayed the faces
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4240_zps38888b96.jpg
And everything painted. I'll wipe the overspray off the disc faces with some thinners when the time comes.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4241_zps2f37f8e4.jpg
Hammerited wishbones, one side, they will get another coat them get flipped and the same for the other side
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4242_zps6cfca842.jpg
New trackrods and ends 1st coated
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4243_zps7983d025.jpg
Calipers, balljoints and strut cups painted.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4244_zpsc5b023d6.jpg
More painting tomorrow.
I had to hammer and chisel the dogbone mount off of the subframe. The reason being I think is that the gearbox side engine mount has partly collapsed and the dogbone was acting as an engine mount. When I undid the dogbone bolts off the gearbox the engine dropped about 10mm. Not good.
So the snapped bolt, I sprayed it with plusgas and went in for dinner. Went back out about an hour later and it came out by hand! Amazing stuff.
Subframe on the bench
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4245_zps42c8ffa3.jpg
You can see the right hand bolt remains
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4246_zpsc1b3cf1e.jpg
First job was to swap the track rods, the old ones were a bit floppy but had to be changed due to me having to cut the ends off!
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4247_zpsfc129d6d.jpg
Broken bolt, this came out hand in the end, a stroke of luck !
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4248_zpsf04f38ab.jpg
You could grow potatoes in there!
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4249_zpsea88090a.jpg
Bit of mud up there. Unlike the back of the car there are also a few areas of surface rust. These will need treating and seam sealing as part of the resto process.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4250_zpsc0e4a7e2.jpg
The subframe was made on the 14th of June 2000 !
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4251_zpsf5b9404a.jpg
Cleaned arch
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4253_zpsc55306b5.jpg
Plans tomorrow are to whizz the surface rust off the subframe and get a 1st coat of paint on it. Whiz the ARB down where it is rusty and paint it. I've already given the rack a quick wipe and that is all it is going to get. I might build up the front struts.
I need to order a few parts so after that things will be on hold for a day or two.
As I type this, I am actually watching Tora, Tora, Tora on Film 4 and what a good film it is too.
Freezing cold!
Jobs done in the last day;
I've got the struts fully built up and ready to fit, bulljoints, abs sensors back on etc
Got a new dogbone and a gearbox side engine mount ready to fit.
Got some new steering hose banjo crush washers and some bolts from VW
Wishbones have had two coats of paint both sides now so are finished.
Subframe has had its 2nd coat on one side only (top), needs flipping and a couple of coats to the bottom.
My only real concern is the anti roll bar. Where the inner bushes are there was quite bad corrosion which I buzzed off but am now worried that any new bushes won't be snug enough over the bar. I've obviously painted it but that will wear away very quickly once it is back on the road. I'm going to live with it and see how it goes.
So the plan is to get the front suspension finished by the end of the weekend and then move on to what I'm not looking forward to and that is bleeding the brakes.
Struts built up and a messy bench!
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4254_zpsaff3337d.jpg
ARB, strut and subframe either finished or with paint drying
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4255_zps98fc4110.jpg
Wet (blurry) subframe
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4256_zps6ef51fab.jpg
The paint has dried and some good progress made this evening.
I got the subframe built back up on the bench, fitted the wishbones and steering rack to it and then it was ready to go back onto the car. I was going to use the jack but two things stopped me, it doesn't balance on the jack head and it is not that heavy. What I did was simply pack it up bit by bit on blocks of wood until it was near enough to start the bolts. Once it was up to height, being on the blocks of wood meant that I could accurately position it to where it came off, the clean bits showed where it needed to go.
Once the subframe was back up, I bolted the gear selector mechanism onto the steering rack, I don't know if this is peculiar to the 1.6 but have not seen it meantioned elsewhere. There are two 13mm bolts and a 13mm nut for the selector mechanism, all difficult to get on.
Then it was the struts back on, lower balljoints are always a fiddle especially when painted, trackrod balljoints on and then I wound the driveshaft hub nuts up as tight as I dared up on the axle stands to fully draw the drive flanges in. For that I used the old nuts.
I wasted an hour having snapped a new bolt off in one of the disc shield holes on the drivers side knuckle. I thought it would be a good idea to clean the threads out but went a bit too far. Took me an hour to drill that little bugger out.
A comedy timed shot of my little helper
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4260_zpsf913e9c4.jpg
One area of rust just starting on the seam and spot welds, buzzed it off and then painted it. This was the same both sides so if you ever have your arch liners off, check these seams and deal with any rust.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4261_zps384e4146.jpg
Packing the subframe up. I was able to get the bolts in and position from here. Although the jack is in the background, I didn't use it for the subframe, not that I could get the subframe to balance on it anyway.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4263_zps7d1a42b5.jpg
What I did use the jack for was to change the gearbox side engine mounting. This mount was knackered and the dogbone was doing a lot of support work which it isn't designed for.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4265_zpsf908b044.jpg
Engine mount position clean and rust free
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4266_zpsf3d36035.jpg
Waxoyl to make it stay that way
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4267_zps2330768e.jpg
I thought I'd have to move the whole loom but cunningly VW put a hole in the trunking you can get an extension bar though, nice. A point to note on this mount is that you have to drop the engine a fair way down to be able to get the mounting in and out. Easily done with a trolley jack. If you are doing it in isolation make sure you undo the dogbone first so as to allow the engine and gearbox to come down enough.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4268_zps06daf4f2.jpg
New dogbone
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4269_zps686830dd.jpg
Random shot of the passenger side being built up. Note there is no small inner cv boot clip
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4270_zps9ff80816.jpg
I hope to get everything fully built up tomorrow ready for the brake bleeding.
Got the suspension fully built up, all that is left to do is torque up the front wishbone bush bolts and the hubs nuts!
Top tip if you ever have to do this is to get the power steering fluid lines connected as you are raising the subframe when there is room to get on them from below. With the subframe in position they are a bit tricky. I couldn't get a torque wrench on either of them so guessed the torque and got it right as there are no leaks. A perilous exercise as I have read of an instance where someone snapped a banjo bolt. Upon starting the car up the power steering make a right row until the fluid got round.
What has taken the most time though was messing about getting the splash shields and engine side shields cleaned and fitted. Even got the front mudflaps back on.
Shock horror new bolts! I did have to cut them down but they are 8.8 grade, should hold the disc dust shields on nice. These have 10mm heads rather than the poxy VW ones that are 8mm and easily rounded off.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4271_zps5e7c7bbb.jpg
Dust shield on
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4272_zpsc021246f.jpg
And then the new bolts touched in with paint so they don't rust
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4273_zps21daa7fb.jpg
Previously prepared disc but with overspray and other paint on the face
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4274_zps6e5031df.jpg
Cleaned off with thinners
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4275_zps6e7e783b.jpg
Brake caliper on, new front hoses as well.
http://img.photobucket.com/albums/v602/colin__/Bora/Front%20suspension/DSCF4279_zps9fad71d5.jpg
I had a lovely evening doing all the above.
Brake bleeding tomorrow, something tells me doing a full (dry) system bleed is going to be a nightmare!
Doctle Odd
03-01-2015, 01:09 AM
Don't forget the little bugger under the master cylinder!
Don't forget the little bugger under the master cylinder!
There were two of the little buggers on the master cyl.
Good call by the way.
Well.... touch wood, fingers crossed, kiss the blarney stone and all that old b*ll*cks.... it looks like things have gone well with the bleeding.
What I did;
Gravity bled the system, fluid in res and then went round each corner opening the nip until fluid came out, this was simply to get fluid in the pipes. Used maybe 1 ltr.
Connected the Eazi-bleed up, then bled the master cylinder, two nips on that, upon opening each up a little pfft of air then fluid. Used very little fluid.
Then went round and bled each corner, nice and slow, letting the dog see the rabbit. Used maybe a 1 ltr.
Then did the VCDS thing, very un-intuitive that is. Basic settings 1 press and hold pedal, abs pump activiates, release pedal open both front nips, pedal 10 times and so on. First time round did two cycles of that. Maybe 1.5 ltrs of fluid used.
Topped up the Easibleed bottle a few times in all the above.
Went round and bled all corners again, with the EB obviously still pushing the fluid round.
Did the VCDS thing again, to make sure!
Re-bled all four corners again.
Then bled the clutch which is horrible, took the battery out for access as I wanted to get properly on the nip for initial cracking as it looked a bit rusty.
All good so far, rock hard brake pedal with engine off, doesn't sink. Engine on, the pedal dipped a bit exactly as you would expect.
I'm not being complacent so am posting this up then will take the dog out and then go back up to the garage and re-check. Hopefully it is job done but I'll probably re-bled again, especially the rears.
A very simple setup and I'm lucky to have the compressor, of which I regulated the air pressure right down on.
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF4285_zps37f5aa7a.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF4286_zpsdaf4b7cb.jpg
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF4287_zps396699ae.jpg
And battery and battery holder out for acces to the clutch nip, nice and clean under there but the clamp is rusty! And I thought all the painting had been done for now!
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF4288_zps9ab47764.jpg
Right off now to take Captain Woof for a run, i'll report back later if there is a soggy / spongy pedal or NOT !
I'm parallel posting this on here and another forum and missed the update below. I've found out the part number for the oil pressure switch plug...
What a pleb.
I blame myself but I don't really think it was me.
Two problems have developed;
First; The oil pressure sender wiring connector fell off. Literally. I've bodged it up but need a new connector. Does anyone have a spare bit of loom with such a connector on it? Are they available from Kufatec or the like ?
Connector that fell off
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF4290_zpsb99db24e.jpg
My bodge
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF4291_zpsfc564013.jpg
If it is going to cost more than a couple of quid, I'll go out and get a Mk2/3 sender that will take a spade connector. Any help much appreciated on this.
Secondly; The boot decided not open from the handle. Central locking works fine off the remote so probably not a fuse. So I dived straight in, whipped the boot inner panel offand started stripping down for some testing. Whilst stripping down I inadvertently sheared of the actuator rod balljoint from the boot badge lock assembly. I wasn't going mad and reckon it was just fragile. Bit cheesed.
So am looking for a boot lock assembly.
Ironically once stripped and tested on the bench, both the handle and actuator solenoid are fine and so is the wiring between them. Looks like the problem lies elsewhere.
A random photo of the boot lock gubbins
http://img.photobucket.com/albums/v602/colin__/Bora/DSCF4292_zps7e0710dd.jpg
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