Durrsaku Posted January 23, 2007 Report Share Posted January 23, 2007 Car failed the MOT today because this was split. Need to do it tomorrow as i need the car on Thursday. I am sure someone has done it in here before, can anyone point out a quick "how to" guide? And what is this plastic cone tool i need to get and where from? cheers Link to comment Share on other sites More sharing options...
meriafel Posted January 23, 2007 Report Share Posted January 23, 2007 I did mine recently. Difficult to remove the top suspension bolt if it has never been removed before, you will need to replace so get one as it isn't in the kit. VW use a special tool to remove. I had to soak in WD-40 and apply gentle heat with a micro torch as it was rusted in. Absolute pig to get out. Put Waxoyl on new pin on assembly. You will also need to remove the drive shaft centre bolt needing the correct sized Allen tool which needs a long lever to undo and tighten. Don't know of any 'dodges' although used to be able to do Golfs and earlier Passats (Macpherson strut) leaving the CV joint in the hub. Probably not possible with this complicated multi link suspension. Sure someone on here will tell you? Snapon do an excellent drive shaft bolt tool. Certainly easier to rebuild driveshaft CV/replace boot when on the bench. (Think that the new grease supplied with kit is not compatible with the old? Must have seen that somewhere?) Presume plastic cone tool is to get new boot over splines? Never seen one and with care I have had no problems. Best of luck and avoid driving over branches on the road which I think caused mine to rip as the other side is still ok. Link to comment Share on other sites More sharing options...
Durrsaku Posted January 24, 2007 Author Report Share Posted January 24, 2007 Thank you for the reply. I am wondering to leave this till weekend to do now but was puzzled if i would need to change the joint at all? I had the car serviced 3 months ago and the boot was fine then. I have no click sounds from it so i am hoping it will be ok. Do i need to get the shaft out completely? Link to comment Share on other sites More sharing options...
pingpongpo Posted January 24, 2007 Report Share Posted January 24, 2007 You can still get those split cv boot kits where you glue the rubber around the shaft. If its done properly the glue joint is stronger than the rubber material itself although it can be tricky. It depends on how tricky you see stripping everything done to put a complete one on? Link to comment Share on other sites More sharing options...
gazthecab Posted January 25, 2007 Report Share Posted January 25, 2007 Someone has done it before without removing the upper arms, can't find the post I'm afraid but I'm sure one of the VW techs will be along soon to help out. Link to comment Share on other sites More sharing options...
Durrsaku Posted January 27, 2007 Author Report Share Posted January 27, 2007 Snaped the pinchin bolt of the upper arm (ball joints) not sure how to get the rest out. got to do it tomorrow now. Link to comment Share on other sites More sharing options...
meriafel Posted January 28, 2007 Report Share Posted January 28, 2007 Easy to dismantle CV joint to remove all old grease and to rebuild. Just mark all parts and replace the six balls in their respective positions. Think is covered in Haynes, basically the two cages need to be replaced in their original positions in the outer case and the balls also. The other point to mention is to ensure the driveshaft spline is locked into the hub so that the new 'C' washer locates into the hidden groove in the hub when all is finished. The pinch bolt will need WD-40 and gentle heat to the surrounding casting, shieldind the arm ball joint rubbers from heat. Loosen the pinch bolt nut and add another so you can lock these nuts to the pinch bolt. I've found it best to turn the whole pinch bolt clockwise/anti-clockwise alternately with spanners at both ends rather than just trying to undo the head of the bolt which if siezed solid will eventually snap off. (Is this what you have done?) By knocking the second nut you have locked onto the pinchbolt thread it will protect the thread and should 'eventually' loosen the pinchbolt from the rust holding it. Clean out the two pinching cuts in the casting first to get the WD-40 in and be patient as it can be very frustrating! I spent an hour getting mine out. If the bolt head has sheared off you may have to resort to a Vise-Grip on the exposed thread and if that fails to drill out and drift out what is left! Best of luck. Link to comment Share on other sites More sharing options...
Durrsaku Posted January 28, 2007 Author Report Share Posted January 28, 2007 thanks for that, i will have to persevere with it. The nut end has sheared off and the head bit is still there. I tried to knock it out but no luck. I have drilled half of it out but still no joy with the remaining bit(head side which is on the inside). Link to comment Share on other sites More sharing options...
Durrsaku Posted January 28, 2007 Author Report Share Posted January 28, 2007 I am removing the hub carrier now and hopefully drill the bolt out properly. Does anyone know how to get the ABS sensor out of the hub? doesn't look like it is going to fit through the hole if i just pull it? Link to comment Share on other sites More sharing options...
xaddiction Posted January 30, 2007 Report Share Posted January 30, 2007 I think you may find you'll need more than a little gentle heat from a heat gun or blow torch. I replaced all the suspesion arms on both sidea of my 1999 a6........ which uses the same set up as the passat, and i had to use gas welding tackle to heat it enough to make removal easy. Link to comment Share on other sites More sharing options...
Durrsaku Posted January 30, 2007 Author Report Share Posted January 30, 2007 Yes, i am finding that too. I will have to replace the upper arms now because the ball joints are bust. £30 each. Still cant get the ABS Sensor out of the hub carrier though. Anyone has a diagram of where this wire goes to? i need to disconect without damaging it as i can't afford to buy a new one. Help. Link to comment Share on other sites More sharing options...
Durrsaku Posted January 30, 2007 Author Report Share Posted January 30, 2007 Right this is the wiring i am talking about. Any idea where it goes? Link to comment Share on other sites More sharing options...
xaddiction Posted January 30, 2007 Report Share Posted January 30, 2007 The ABS sensor just pulls out, its held in by an odd looking copper sleeve. I know this because mine actually came out by accident when i was replacing the arms. I was driving around for weeks afterwards with my abs warning coming on occasionally. Solved the problem when my mate noticed it looked a bit dodgy, and pushed it back in with his finger. It is actually possible to do the work without taking the abs sensor off. when you bolt the top arms back to the shocker..... make sure you put them back in relation to the angle they would be in while under load. If you fail to do this they will wear the bushes out rather quick. Link to comment Share on other sites More sharing options...
Durrsaku Posted January 30, 2007 Author Report Share Posted January 30, 2007 I have got to remove the hub now that's why. I have removed the sensor from its socket but i need to get it out of the hub arm so i have to find where it connects to on the upper side. Cheers Link to comment Share on other sites More sharing options...
Durrsaku Posted January 30, 2007 Author Report Share Posted January 30, 2007 I have sorted it finally and it was easy really. doh!! Link to comment Share on other sites More sharing options...
meriafel Posted February 1, 2007 Report Share Posted February 1, 2007 It's as well you are replacing the top arms too since if you used too much heat with a 'gas welding torch' you will probably have knackered the plastic/nylon ball seating within the ball joint, apart from ruining the rubber cover which doesn't look too good in the above pic. Suggest wire brushing pinch bolt assembly on the other side, spray with WD 40 and then cover with Waxoyl. Hopefully when you have to do that side it will be less of a problem. Have seen a tool made by Klann Tools to remove the pinch bolt but no idea what it costs? Link to comment Share on other sites More sharing options...
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