[Vwdiesel] minor tragedies--A4 suspension work

[Doyt W. Echelberger]

I'll raise a draft to Patrick Dolan's "...enjoy the craft."

I own a 1976 VW type 2 Westfalia. The giant rear axle nuts haven't moved in 
25 years.  Just for fun, I have copied the directions for torquing the 46 
mm rear axle nut. (Source is the type2 website, and the tool is reported to 
be the choice of Bob Hoover, a legend in VW bus history.)

"....proper tool is a 46mm 6-point socket welded (at right angles) to one 
end of a 6 foot heavy steel pipe."

Doyt
 >>>>>>>>>>>>>>>>>>>>
At 08:52 AM 2/27/2011, you wrote:
>Ark & Shalyn:  I look at VW stuff just the other way around.  Of course, 
>for me it is (was) a matter of familiarity.  Every time I work on some 
>Yank tank or Jap scrap, things are done differently and I never seem to be 
>able to "settle in" (I won't even bring up Brit BS in this discussion!!!).
>
>The secret of working on VWs (and probably everything else) is 
>preparation, patience and knowing a few trade secrets.  Before you start a 
>new job, read....STUDY....the Bentley for your car, and spend some time 
>looking at the car.  It may not give you the shortcuts, but most of us are 
>not on the clock, so just follow the steps and it will come apart - and go 
>back together.  TAKE YOUR TIME...unless you are indeed in a flat rate shop 
>- and even way back in those days, I would rather get it right and do it 
>only once.  Oh, yeah....CLEAN the bloody thing thoroughly.  Again, not on 
>the clock, and the quality of the job will be much better because you 
>won't be pixxed off and the parts won't be filthy going in.
>
>The right tools are mandatory.  A fastener is a fastener, but a wrench is 
>NOT "just" a wrench.  If you can't get an axle nut off, you are probably 
>using a 1/2" breaker bar.  I use a 3/4" impact, or in the field a 3/4" 
>breaker bar.  If you ever had to get axle nuts off of old, rusty Type II 
>reduction boxes, you would understand why.  Critical fasteners (CV 
>splines, etc.) need decent quality tools - or you will strip 
>stuff.  ALWAYS grab a 6 point socket to break hex nuts loose, not 12.
>
>There are trade secrets in how do do some things as well.  When I hear of 
>people looking for pullers for tie rod ends and other tapers, I kind of 
>chuckle.  Yes, I have a mess of them, but they seldom need to be used.  It 
>takes some practice, but the way it is done on the floor is to loosen the 
>nut a bit, then use a fairly big (3 lb) ball peen as an anvil and strke 
>the opposite side of the steering arm with a smaller (2 lb) ball peen at 
>right angles to the taper centerline.  Usuall in one or two hits, the 
>taper will pop right out.  Not love taps, but pretty agressive stikes are 
>needed.
>
>Don't use mickey mouse press tools (such as spring compressors).  Get 
>something designed for the job (or made if you know how) that is at least 
>twice as good as you think you need.  Not only will the job go easily, but 
>you might live to tell the tales.  There is a LOT of energy stored in a 
>suspension spring, so give it the respect it deserves.
>
>IMHO there are three levels of performing any task:  workmanship, 
>tradesmanship and craftsmanship.  Chill out, think ahead, get the right 
>mindset and enjoy the craft.
>
>Pat
>
>----- Original Message -----
>From: Arkady Mirvis <arkadymirvis at gmail.com>
>Date: Sunday, February 27, 2011 4:39 am
>Subject: [Vwdiesel] minor tragedies--A4 suspension work
>
> > . Familiar opinions!
> > When I was working in Vienna ( Austria ) , even the most
> > experienced
> > mechanics next to me, had decades of experience and best german
> > training,
> > considered VW cars as the nastiest, worst designed, absolutely
> > unfriendly to
> > work on them and maintain. The curses they cried and addressed to
> > " German
> > Engineering " were the worst in German language and could have
> > been heard
> > for kilometers in the hot air. On some day the reputable shop was
> > a real
> > madness and waiting customers could see thru the glass wall red
> > faces full
> > of mad expressions and mouthes profusely salivating. The shop
> > Leiter ( we
> > called him Fuerer ) could enter the work area and was careful
> > avoiding
> > flying wrenches and parts. His attempts to quell the mechanics
> > working on VW
> > were going nowhere.
> > Mechanic next to me in mad expression broke his arm hitting the
> > Transporter
> > wheel, when he couldn't take off the rear drive axle CV joint bolts.
> > In moments of silence people were grateful to VW AG for making bad
> > cars
> > which provided job security.
> > For Shalin: Christ suffered and told us to suffer.    Ark
> >
> > ----- Original Message -----
> > From: "Shalyn Shourds" <sshourds at flash.net>
> > To: <vwdiesel at vwfans.com>
> > Sent: Sunday, February 27, 2011 5:40 AM
> > Subject: [Vwdiesel] minor tragedies--A4 suspension work
> >
> >
> > > Yesterday, I started in on the TDI front end job.  First step
> > was to
> > > remove the aluminum skid plate.  The front of the plate mounts
> > up to
> > > these tubes bolted to the frame.  I was laying under one of those
> > > removing the bolt in the bottom of the tube when I noticed a few
> > drops> of water.  Then the bolt came out and I realized that the
> > whole tube was
> > > full of nasty, brown/grey water.  It all went straight through
> > my nose
> > > into my sinuses.
> > >
> > > I'll just leave it at saying that this is something you want to
> > avoid.>
> > > Sadly, this was not the most flustrated I've been on this
> > project.  I'm
> > > trying to replace the ball joints, struts, complete rack, and
> > control> arm bushings.  I recently did this on my A2, but it
> > didn't take me long
> > > working on my A4 Jetta to realize that I wasn't in Kansas
> > anymore.  I
> > > did break down and order the special "spreader" socket for the clamp
> > > that goes around the strut.  I'll see more about that when it
> > arrives.> Just prying at it and beating the steering knuckle with
> > a hammer wasn't
> > > getting me there.  And, since I'm basically nocturnal, I didn't
> > figure> my neighbors were thrilled about the banging and screamed
> > unintelligible> curses late into the night.
> > >
> > > On my A2, I just pulled the axle shaft from the hub and removed the
> > > whole works.  Am I correct in thinking that this one doesn't
> > just pull
> > > off?  I keep seeing references to a special puller......  I
> > couldn't get
> > > the nut loose anyways.  I had all 135lbs bouncing on my breaker
> > bar and
> > > I didn't even get it to creak.
> > >
> > > I'd actually called a local shop about doing this job for me, I was
> > > dreading it so much.  Oddly, they never called me back.  I guess
> > I know
> > > why--they didn't want to do it either.
> > >
> > >
> > >
> > > -Shalyn
> > > _______________________________________________
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> >
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