Wastegate Diaphragm R&R--stuck nut!

[superba]

Hi,

I'm a btdt on this one. I went to replace the one I made of innertube that
lasted several years with a genuine Audi one and a local wrench couldn't
budge the nut from the top because he had no way to stop the shaft.  I made
an appointment with a real Audi shop to take the wastegate off and replace
the diaphragm at a cost of about $150, I think.  So being the el cheapo that
I am, a few days before the appointment, I took off the top cover, about 6
small nuts and washers, exposing the diaphragm. I worked a large 1/2" blade,
heavy screwdriver under the diaphragm between it and the bottom half of the
housing.  I put a few drops of Liquid Wrench on the nut at the shaft and
effectively "worried" the nut off the shaft.  The screwdriver had little or
no purchase on the shaft but the pressure was just enough that eventually
the nut came loose.  Score 1 for the good guys.  You must use care not to
scratch the flange on the lower half.

The alternative, and I've done this also,  is to remove the waste gate from
the vehicle and put it on a bench where you can get at the hot valve on the
bottom.  In mine there was a large hex socket, and I had to fabricate a hex
tool to fit it.  The hex tool used to remove the differential filler plug on
an automatic might do it.  And, I believe I saw some with slots on the hot
valve in wrecking yards.  Taking off the waste gate is a pita because a one
man gang has to work alternatively from the top and the bottom.  Maybe you
could enlist your wife to crawl under and do the lower nuts to the exhaust
header....

Not much advice, just narrative.

HTH.

Cheers!

Jim Jordan

>  Date: Sun, 09 Dec 2001 09:11:11 -0800
>  From: Motor Sport Visions Photography <msvphoto at pacbell.net>
>  Subject: Wastegate Diaphragm R&R--stuck nut!
>  To: quattro at audifans.com
>  Reply-to: msvphoto at pacbell.net
>
>  I tried and tried, but couldn't get that wastegate diaphragm upper nut
>  removed yesterday afternoon. I have started to remove the wastegate, but
>  put off finishing 'till this afternoon since darkness was setting in
>  last night.
>
>  I have already searched the archives, visited Scott's site, and tried
>  the screwdriver trick. Anyway, I thought I would bounce this off the
>  list to be sure I am heading in the right direction.
>
>  I assume that once I get the WG off I can access something on the bottom
>  of that shaft (hex? slotted?) to lock and turn against to remove that
>  top nut? It has all soaked in PB Blaster and Kroil overnight--which may
>  help. Anyway, I have managed to remove the four nuts that hold the WG to
>  the EM already. I can see the three bolts that secure the WG to the
>  downpipe and think I can get to them (and I can also see that I will
>  need help holding/turning from the top while I'm underneath--my wife has
>  already been warned ;-)...). Once I get those three bolts removed, will
>  the WG come out? (Looks so...but I wanted to be sure having no BTDT in
>  this area of the car yet).
>
>  Any and all BTDT advice will be greatly appreciated. TIA!
>
>  Mike Veglia
>  Motor Sport Visions Photography
>  http://www.motorsportvisions.com