RE: Audi tools for the poor...

[Dave Lawson <dlawson@ball.com>]

Hi Steve,

>I'm now well into the suspension upgrade process. I have removed
>all of the struts, control arms and tie rod ends. I will be
>replacing not only all of the above, but the ball joints and
>wheel bearings as well.

Don't forget the upper strut bushing/bearings. I would replace these also.

>    control arm bushing R&R - hourly rate (8 bushings)

This on a 4000 right? The instructions I have for removing them is to use a 
1in(not sure about size) hole saw and cut the center and surrounding rubber 
bushing away. Then take a hack saw and finish cutting through the rubber and 
the metal sleve which is against the control arm, being very careful not to 
touch/harm the control arm sleve. Sounds fun huh? Luckily I didn't get to 
experience this as the 83 TQC bushings pushed right out with a gear puller, 
no metal sleve against control arm. Took about 10 mi for all 8.

On installation, not sure how the 4000 ones go in. On my TQC, I used 
urethane bushings from Sportwheels, which I pressed in with assorted 
sockets, flanged exhaust pipes and a mondo bench vise. Took about 3 hours to 
get all 8 in and centered, including mistakes and a leasurely pace. These 
bushings also work on the 4000 q.

>    wheel bearing R&R - $36 per wheel

I had a mechanic do this. Anyone with a press should be able to handle it. 
Break bearing by pressing on inner race. Press bearing out using outer race. 
Press new bearing in. Don't forget to write down the FAG bearing part 
numbers so the next time you do this, you can get the bearings from a 
bearing house and save some dollars.

>    strut R&R - $28 per strut

I also had a mechanic do this because I was installing Bilstein struts which 
use a special strut retaining nut and he had the Bilstein tool. Its 
basically pretty easy, hold strut in vise and unscrew the retaining nut, 
replace strut and screw nut it back on.

Don't forget to get all new factory bolts and nuts. I also didn't use 
locktite on the axle shaft splines, I was told by an Audi factory trained 
mechanic that it isn't nessecary. I just used a breaker bar with pipe 
extension and applied mucho torque. I then went drove down to a shop and had 
them impact on the axle nuts. Same for the upper strut nuts.

Have fun.
 -
Dave Lawson  dlawson@ball.com