I fitted new Front shocks today, got them from FK in Germany Part number FKZZVW22 they are incredibly cheap at just over 6 euro each, the delivery actually cost more than the parts, but even with delivery they came in at just over £23 for the pair, which must be the bargain of the year.
I was going to get the adjustable ones at 9 euro each, but they only have one in stock and advise that they will not be getting any more in stock. I get the feeling that they are so cheap because they are end of line, so if anyone else is interested buy them why you can.
They have gone onto my 280,000 mile TDI, to say that the original shocks where well worn would be a big understatement, they had no 'push' left in them. Once the spring was removed and you could pull and push on them you could see how worn they where, very little resistance. The new ones felt much stiffer and had a notable push outwards.
The top mounts where the original Audi ones and went through the MOT fine a week ago, I asked the MOT tester to give them a good looking at, but he couldn't find any play in them. I stripped them down, clean out the race ways and all the balls, re greased with molly greased and put them back together, no play and really smooth, very good for 280K miles.
The near side was easy to get to the strut mounting bolts, I did this one first and all was completed in about 2 hours. The drop link bolt came undo OK, and a good inspection of the drop links revealed no play, so I will leave the new ones in the jiffy back
The Bottom mounting pinch bolt was well and truly stuck, the nut came undone OK, then lots of hammer blows / penetrating oil latter and it started to rock a little, rocking and more oil and few more hammers blows and it came out. Tapped an old flat blase screwdriver into the gap and the old shock was released.
You need a 7mm allen key which is a none std size, but I had one that I made from an 8mm allen key and a surface grinder some 30 years ago
Spring compressors fitted and spring compressed, top nut removed, top mount removed.
Rebuild is 'as the manual says' a reversal of the strip down steps, new nuts and bolts fitted of course.
The off side was a bitch, firstly you have to remove the MAF and then push all the pipes out of the way, undo the bolts attaching the Aux heater and the brake fluid reservoir, easier said then done as some of the bolts spun the inserts. An hours or so latter and I could see the strut mounting bolts, great I thought nearly there. The back two undid fine, the front one spun the nut out of the top mount. At this point there was a LOT of swearing done
and a fair amount of head scratching. Out came the 4" angle grinder and the head of the bolt was ground away, this released the strut from the car, finally !!!
Same procedure as the other strut, except the stuck bolt was removed, this mount is now attached to the car with the original two back bolts and an 8mm allen bolt, head under the car and a washer and nut in the engine bay. All went well when reassembling as I had also replaced the spun inserts with new ones (I new that insert tool I bought on ebay a few weeks ago would come in handy)
So all in all it didn't all go to plan, but it is all back together some 8 hours after I started, the MAF was also stripped and cleaned with Isoproponal alcohol, It should run better now I have removed all the crap out of the MAF. I also checked and topped up the gear box oil, 1 litre added (I don't think the previous owner ever checked it, no leaks, but I guess at 288K miles some of the oil will have escaped through the seals), new air filter fitted (the previous one had been in there for FAR too long, it was black and rotting away)
I checked the rear shocks last week when I changed a broken spring and they felt good, much better than the front did, maybe the rears have been changed at some point, or they don't get the same hammer as the fronts do. I couldn't find any labels on the rears, but the fronts said AUDI on them so I am sure they are originals.
The good news is the ride as been transformed, it rides pot holes and road imperfection like a goodun.
I am placing an order for another pair of shocks for my Petrol A2, but I may leave it a couple of weeks before fitting them
Loving getting me hands oily again
Cheers,
Paul (Depronman)