Changing from rear drums to discs.

Birchall

Dick Chown Award 2016
Hi

I need sone help from people who have successfully completed this conversion, please!!!!

I bought an axle from a 1.6 FSI and bought new parts for everything. (And I mean everything.)

My mechanic was about to rebuild the axle but is telling me that most of the parts I bought don't fit !!!

it looks like my assumption has cost me big time again.

That at assumpyion was that I thought a TDI 90 and a 1.6 FSI rear axle would be the same. Why on earth would Audi come up with two different axles with discs??

but it looks like they did?

For example the main rubber mounting bushes don't fit, the brake pipes (the metal ones) don't fit, etc etc.

Can anyone tell me the facts about the differences between the TDI 90 axle and the FSI axle.

Since i didn't have a reg number to quote when ordering the parts (not for the donor axle) I used my wife's car reg since hers is a 90. That seems to be my mistake.

I am now tempted to look for a TDI 90 so that I can use the parts I bought rather than having to buy new replacements suited to the axle.

I guess that it just proves the saying I always use. That is that it is dangerous to ASSUME, because it makes an ASS out of U and ME !!

Steve B
 

Birchall

Dick Chown Award 2016
Hi
thanks for the replies.
It was things like the main rubber mounting bushes?? The metal brake pipes too.
Perhaps I just ordered the wrong part numbers but I used the Audi parts catalogue and so it must be me that looked up the wrong version.
The guy I bought the axle from had just given me the VIN from the car it came out of and it was from a 2003 FSI.
Happy to hear that the TDI 90 and FSI parts are essentially the same.

And thanks for the extra links.

Steve B
 
Last edited:

A2 Cars

Member
Steve, having carried out this upgrade several times, I can confirm that the axle fitted to the FSi & TDi 90 are identical.
If you ordered the parts per the correct vehicle VIN you should have no issue fitting them. Essentially, the hydraulic lines, emergency brake cables, hand brake lever are different between the drum and disc set-up.
If you are replacing the main axle bush, be aware that it must be oriented correctly when fitting or you risk shearing it.

Let me have the part numbers that you ordered and received and I can confirm if they are correct for what you are trying to achieve.

Blue skies
tony
 
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Birchall

Dick Chown Award 2016
The part numbers for the minor parts I ordered are as follows
the most worrying ones are the brake pipes they cost me over £60 from Audi and were special order do no refunds. But I was sure I got the part number right.
The rest are just fasteners etc
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular][/FONT]
I I will get the main part numbers for the other items tonight.

Thanks fir for the help.
[/FONT]

[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]Two main bolts and nuts for theMain bushes [/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]Washers (big) 8Z0505193C x2[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]Bolt N 90710501 x2[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]Small washers [/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]N 01153110 x2[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]Nuts N 90635001 x2[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular][/FONT]
[/FONT]

[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]4 rear calliper carrier [/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]bolts (nuts) [/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]N 90740301 x4[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]Calliper bolts[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]8E0615141 X4[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]Disc screw [/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]N 10648301 x2[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]8 rear stub axle bolts [/FONT][FONT=.SFUIDisplay-Regular]N91006202 x8[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular][/FONT]
[/FONT]

[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]Brake pipes[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]8Z0611763Q left[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]8Z0611764Q right[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular][/FONT]
[/FONT]

[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]plastic clips. [/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]7016117677B (1KD) x2[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]8Z0611797 (1KD) x2[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]1J0611797 (1KD) x5[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]Metal clips[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]191611715[/FONT][FONT=.SFUIDisplay-Regular] (1KD) x2[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular][/FONT]
[/FONT]

[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular][/FONT]
[/FONT]

[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]Rear Spring rubber seats (top and bottom?)[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]1J0512149 top[/FONT][/FONT]
[FONT=.SF UI Display][FONT=.SFUIDisplay-Regular]8Z0511149A[/FONT][/FONT]




 

dan_b

A2OC Donor
Just thinking out of the box here, but if the above parts are correct, perhaps it's the axle that is wrong. Is it actually an A2 rear axle?
 

Birchall

Dick Chown Award 2016
Yes and the seller "Prestige" was good enough to give me the VIN from the car it came from too (which is something they don't do normally, for understandable reasons.)

So I am guessing that when I thought I was looking at the parts explosion for a disc axle it was actually a drum axle ( I am sure it wasn't that but what else could it be)

steve B
 

A2 Cars

Member
The axle is not for an Audi A2 Dan, I've posted this on Steve's "project" thread which has a picture of the axle.

Well done though, Edward De Bono would be proud of you ;).

blue skies
tony
 

Birchall

Dick Chown Award 2016
The dealer gave me the VIN do I know exactly what car it came from and it was a 2003 1.6 FSI.

So unless he is lying (and I have no reason to suspect that he is, he is not going to gain by lying and I have dealt with him before and he seems a decent bloke.)

The picture that Vonnie posted looked the same as mine from that angle. So I don't know what is going on.

Steve B
 

dan_b

A2OC Donor
Shelf-stacking error then in their parts supply. They may well have taken a rear axle out of an A2 1.6FSi, but they picked the wrong one off the shelf in the warehouse?


Yes and the seller "Prestige" was good enough to give me the VIN from the car it came from too (which is something they don't do normally, for understandable reasons.)

So I am guessing that when I thought I was looking at the parts explosion for a disc axle it was actually a drum axle ( I am sure it wasn't that but what else could it be)

steve B
 

A2 Cars

Member
I agree with Dan, I suspect a simple error from the seller - easily done. Prestige is a large breaker specialising in Audi parts. We have dealt with them in the past with good results.
I don't think the seller is lying in this instance Steve, merely made a mistake.

When I suggested that the axle was not from an A2, I was going from memory. If you look closely to the picture Yvonne posted you will immediately see the differences.

The A2 has a bracket for twin hydraulic flexi-hoses on the top left whereas your axle has a single on the top right. If you study the drainage on the spring mounts, you will see further differences in size and shape.
Most evident however are the welds joining the main beam to the trailing arms - these simply do not exist on the A2. The A2 axle beam is of a hollow "U" shape design, I suspect the axle you have is a "C" or "V" section.

Have a chat with the seller, show him the pics and I'm sure he will try to resolve the issue.

blue skies
tony
 

paul_c

A2OC Donor
Let us know how you get on with a refund of the courier costs (can't be cheap to send an axle) and the powdercoating too. I've had 100% failure rate from Prestige, using library pics instead of the actual item, for secondhand items, is a bit of con and is something I'll certainly be checking in subsequent purchases.
 

murdo

Admin Team
What a shame after all that work and anticipating it'd be done soon to potentially end up back to the start. :(
 

Birchall

Dick Chown Award 2016
What a shame after all that work and anticipating it'd be done soon to potentially end up back to the start. :(
Yes, it is now looking like I am going to lose time and money over this and I now have to search for another rear disc axle !!!

I am starting to remember now why I said that this would be my last project.

This will be a real test of the Prestige customer service !!!

I will let you know when I hear from them.

At least it means that I don't have to buy lots of replacement parts and try and sell the others.

Steve B
 

Birchall

Dick Chown Award 2016
Thank you Dan and Tony, I think that I was kidding myself, the last thing I wanted was for it to be the wrong axle, so I convinced myself it was the right one. I should have looked closer before sending it to the coaters / mechanic, I just threw it in the back of his van!!!! No way would I have thought it was the wring axle, from the wrapping and the bits I could see (and the basic shape) it looked like an A2 axle, I guess the seller thought the same!

Steve B
 
J

jp.oog

Guest
I've never had a problem Prestige and have even visited their site a few times. Hope they can sort you out Steve.
 

Birchall

Dick Chown Award 2016
I've never had a problem Prestige and have even visited their site a few times. Hope they can sort you out Steve.
I am sure too, they have ben great with everything else I have bought from them.

The problem is that I am sure they will offer me my money back or credit against another axle and I am not sure what will happen about the powder coating costs. They might correctly claim that this is not their responsibility, but they have contributed to the loss.

We will see.

Strangely enough, they have the right axle advertised (another library photo) but it is £185!!!! and so £100 more than the one they sold me the day before this latest one was advertised. I am intrigued as to why mine was £80 and the (supposedly) same axle is now advertised a day later at £100 more???

We will see what they offer, I have now sent pictures of the one they sent, the one they advertised and the picture that Mike was kind enough to find. That makes it 100% obvious.

As I say, I am glad that this is the last project I will be doing !!! I love the car (obviously) but I HATE the hassle.

Steve B
 

Birchall

Dick Chown Award 2016
I've never had a problem Prestige and have even visited their site a few times. Hope they can sort you out Steve.
I know I have said it before but that Avatar of yours is PERFECT, it would have looked great on the original sales brochures, absolutely stunning!!! (a little off topic, sorry)
 
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