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help resuscitate an old Audi



Hi everyone,

I'm a new list member.  Sorry to bomb the list with this question,
but the web page search engine is down and there are hundreds of
messages in the archive; I just can't read them all.

I have an '85 5000S (5sp) that I inherited and I need to get it through
Maryland inspection.  It "only" has 112k miles, but there's quite
a laundry list of things I need to fix to get it to pass inspection.
I need some advice on several of them:

- steering rack.  Seems to be leaking inside the boots on the inner
  end of the boot.  (Both sides).  Shop is quoting me $750 for a rebuilt
  rack, not counting labor.  Fair price?  What's the best source for
  these?  I saw the writeup of the replacement procedure and it looks
  doable but more than I want to get into without a garage to work in.
  How many hours labor should I expect?

- other hydraulic items:
   - hydraulic fluid appears to be being pushed out the reservoir cap.
   - there's a possible leak underneath the brake booster/master cylinder
     junction.
   - one shop thought the pump might be overpressurizing the system?
   - what's a reasonable cost to get all this fixed?
   - who designed this thing anyway?

- front wheel bearings
   - what's a good parts price?  How many hours labor?

- drum brake cylinder leaking -
   - I've never worked on drum brakes before.  Can I just replace the
     cylinder, or ...?

- The headlight lever is broken off.  You can still turn the lights on
  and off but of course it doesn't pass inspection.  They're quoting me
  over $300 for the whole switch assembly.  Time to try a salvage yard
  I guess, unless anyone's got an old worn out switch that I can pull
  the lever from?

- The headliner is sagging.  I was going to try tacking it up with those
  corkscrew-shaped upholstery pins, but the insulation seems to be tougher
  than the pins I bought.  In a past (Saab) life, I found that the 3M
  spray-on adhesives don't seem to work that well.  Other ideas?

- Anyone in the Rockville, MD area care to volunteer some garage space
  and Audi expertise if I decide to take any of this on myself?

No, it wasn't meticulously maintained like most of the listmembers' cars.
It's otherwise in very good shape; once I get these problems ironed out,
I should have a real Audi again.

Thanks.  Sorry if these are in an FAQ somewhere; I did look for it first!
Steve