[s-cars] Two Struts Forward, One Strut Backward

[Brian Pleet]

Six months ago I replaced the strut cartridge and strut mounts on the 
front of my 95.5 S6. I had no specific symptoms, but one of the wheel 
bearings was failing after 205k km and I knew that the entire 
suspension was still original, Three weeks ago I replaced the rear 
stuts. All parts were from Blau Parts. Perhaps coincidentaly, one of 
the bearings they sent me had a bearing popping out so I returned it 
and used another unit.

Last week I had a 4-wheel alignment. When I took it in I was hearing 
a subtle clunk at low speed from the front right so I asked the shop 
to check it as part of the alignment. They returned it (charging an 
additional $75) because they had to adjust the rear but said the 
alignment was now good.

Over the next two days the clunk got louder and audible with any 
braking action or bump. I took it to my local Audi mechanic and he 
initially reported that the driver side tie rod nuts were not 
tightened, likely causing the clunk. In addition, I'd already noted 
that the strut tower covers were not in place after the alignment, 
but sitting on the cowl. Looked like the alignment shop did not 
finish the job! He tightened the tie rod, but the clunk remained. On 
examination from the top while still installed, it appeared that the 
rubber of the right strut mount was torn and they suggested replacement.

I'm confused and concerned. It took me 2 months part-time with 
coaching from this list to remove the front struts, get the new 
cartridge and mount assembled (by the mechanic), then reinstalled. 
I  had to remove and reinstall the stabilizer bar mounts using a crow 
bar. The right side was the toughest, requiring me to turn the 
steering arm 180 degrees from the position it was returned to me from 
the mechanic.

Is a strut mount failure after 6 months unusual? Is this a known 
issue with Blau parts? Could the strut mount have been damaged by 
turning it 180 degree on installation? Would it be damaged by having 
a loose tie rod for 2 days? What could have caused the failure and 
how can I ensure that it won't repeat itself?

Good news. It took me 6 hours to remove the strut assembly the first 
time, but only 2 hours this evening.

Any suggestions welcome.



Brian
95.5 S6
02 TT 225 Roadster
89 90 20VT
90 90 20v
91 90 20v (donor)





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E-mail:bpleet at telusplanet.net
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