Air Suspension Repair/Upgrade
04-10-2013, 05:21 AM
#21
AudiWorld Member
Welcome to all Members! I am completely new here - following 15 years of Audi driving I decided to buy a 2,7T MY 2000 with TT.
We changed a bunch of wearing parts around the engine and also the two front air springs. I chose the Arnott Gen I.
After mounting the springs, my mechanic said that the polyurethan shock absorber inside the spring is (or rather: seems to be - after accomplishment of the mounting) shorter than the original one. Therefore, the 225/55 17 tyres would reach and bend out the mudguards (both aluminium outer skin and the plastic inside) and the chassis would be set on the tyres directly.
Is that true with the Arnott Gen I. airbags?? I do not hope! In that case the simple rolling of the car would be impossible..
Anyway, my winter tyres are 235/55 17 on Audi alloy 7,5x17 ET35 so it is 1 cm inner than the summer wheels which are the originals having 225/55 17 ET25.
Thanks in advance -
We changed a bunch of wearing parts around the engine and also the two front air springs. I chose the Arnott Gen I.
After mounting the springs, my mechanic said that the polyurethan shock absorber inside the spring is (or rather: seems to be - after accomplishment of the mounting) shorter than the original one. Therefore, the 225/55 17 tyres would reach and bend out the mudguards (both aluminium outer skin and the plastic inside) and the chassis would be set on the tyres directly.
Is that true with the Arnott Gen I. airbags?? I do not hope! In that case the simple rolling of the car would be impossible..
Anyway, my winter tyres are 235/55 17 on Audi alloy 7,5x17 ET35 so it is 1 cm inner than the summer wheels which are the originals having 225/55 17 ET25.
Thanks in advance -
04-10-2013, 05:30 AM
#22
AudiWorld Member
Correction: it seems that the tyres would reach the mudguards IN CASE OF deflating front air spring or system failure.
All levels are calibrated 4 hours long and all 4 levels are set really fine..and just 1,6mm height difference between the front and rear wheels.
All levels are calibrated 4 hours long and all 4 levels are set really fine..and just 1,6mm height difference between the front and rear wheels.
05-10-2013, 09:32 AM
#23
Audiworld Junior Member
Thread Starter
<p>been a while, but I thought y'all should have an update.</p>
<p>I've put about 1600 miles on the new Airbagit air shocks, and they seem to be holding up fine. the ride is fine - no perceivable difference from stock.</p>
<p>I got a chance to re-do the top o-ring on the passenger side front shock. it no longer leaks. unfortunately it is still leaking elsewhere - the fitting. I attempted to fix it by putting on a new o-ring (which weirdly, Airbagit supplied two per shock), but the dang thing was still blowing bubbles. teflon tape? same thing. still leaking. too many attempts and I completely FUBAR'd the fitting! yes the hex separated from the thread. good fun :/<br />
<img src="http://freetobelee.earjuice.com/audi/leak.jpg" /><br />
<img src="http://freetobelee.earjuice.com/audi/leak2.jpg" />
</p>
<p>luckily - I found some the right size - 4mm (outside diameter) with 1/8 BSPP (british standard pipe parallel) threads) - at a hydraulic supply store for $3.99 a piece. they are the push on type, not the oem collet kind with a ferrule, but it can handle up to 200 psi. These bags run at about 120psi a piece tops, so it should be fine. oem and om ones are $35+ a piece! You can also find the push on types on amazon for about $1.50.<br />
<img src="http://freetobelee.earjuice.com/audi/fitting.jpg" /><br />
I'm picking up the fitting tomorrow and putting it in. I hope I can get that threading out of there without too much hassle. it's been suggested to use a philips jewelers screw driver, and hope it can bite on something. might need to find an extractor if that doesn't work. and I REALLY don't want to FU the threads and have to re-tap them.</p>
<p>I also discovered the clunking sound on the drivers sound was getting worse, and discovered it is torn control arm bushings. both of the top ones are completely torn though. we put some added stresses on that side trying to remove the shock bolt, and it rides at a different position with the IPP arms on there and no calibration, so that stress tore them. still very drivable, just annoying, and not good long term I'm sure. so I ordered the cheap-o replacements for both sides from fcpeuro. I will put them on soon.</p>
<img src="http://freetobelee.earjuice.com/audi/tornbushing.jpg" /><br />
<img src="http://freetobelee.earjuice.com/audi/Audi4PieceCAKit.jpg" /><br />
<p>I repaired the height sensor fault by fixing the wires, as you saw in the last post. but the light was still on. I figured the code would have to be cleared with a VAG COM, so I met up with AWDjunkies again expecting to do the calibration. NO CIGAR! the code would not clear. at this point I went ahead and ordered a new (used) sensor from audis4parts. got the new sensor in and the light went away! awesome! but then about 10 miles later - light back on!!! double checked my wire fix, and since I did it quick and dirty with electrical tape, it had failed. fixed it properly with crimps and some nice wire wrap to re-enforce it, and used a zip tie to secure the connector to the sensor since the tabs were busted. No light! huzzah!<br />
Now I am thinking my original sensor might actually be fine. I will test it when I get a chance (probably when i do the bushings)</p>
<p>Another day of allroad ownership, but it's pretty easy to remember that it's all worth it when you're climbing fire trails above Tahoe in the lap of luxury...</p><br />
<img src="http://freetobelee.earjuice.com/audi/offroadlakeweb.jpg" /><br />
<p>I've put about 1600 miles on the new Airbagit air shocks, and they seem to be holding up fine. the ride is fine - no perceivable difference from stock.</p>
<p>I got a chance to re-do the top o-ring on the passenger side front shock. it no longer leaks. unfortunately it is still leaking elsewhere - the fitting. I attempted to fix it by putting on a new o-ring (which weirdly, Airbagit supplied two per shock), but the dang thing was still blowing bubbles. teflon tape? same thing. still leaking. too many attempts and I completely FUBAR'd the fitting! yes the hex separated from the thread. good fun :/<br />
<img src="http://freetobelee.earjuice.com/audi/leak.jpg" /><br />
<img src="http://freetobelee.earjuice.com/audi/leak2.jpg" />
</p>
<p>luckily - I found some the right size - 4mm (outside diameter) with 1/8 BSPP (british standard pipe parallel) threads) - at a hydraulic supply store for $3.99 a piece. they are the push on type, not the oem collet kind with a ferrule, but it can handle up to 200 psi. These bags run at about 120psi a piece tops, so it should be fine. oem and om ones are $35+ a piece! You can also find the push on types on amazon for about $1.50.<br />
<img src="http://freetobelee.earjuice.com/audi/fitting.jpg" /><br />
I'm picking up the fitting tomorrow and putting it in. I hope I can get that threading out of there without too much hassle. it's been suggested to use a philips jewelers screw driver, and hope it can bite on something. might need to find an extractor if that doesn't work. and I REALLY don't want to FU the threads and have to re-tap them.</p>
<p>I also discovered the clunking sound on the drivers sound was getting worse, and discovered it is torn control arm bushings. both of the top ones are completely torn though. we put some added stresses on that side trying to remove the shock bolt, and it rides at a different position with the IPP arms on there and no calibration, so that stress tore them. still very drivable, just annoying, and not good long term I'm sure. so I ordered the cheap-o replacements for both sides from fcpeuro. I will put them on soon.</p>
<img src="http://freetobelee.earjuice.com/audi/tornbushing.jpg" /><br />
<img src="http://freetobelee.earjuice.com/audi/Audi4PieceCAKit.jpg" /><br />
<p>I repaired the height sensor fault by fixing the wires, as you saw in the last post. but the light was still on. I figured the code would have to be cleared with a VAG COM, so I met up with AWDjunkies again expecting to do the calibration. NO CIGAR! the code would not clear. at this point I went ahead and ordered a new (used) sensor from audis4parts. got the new sensor in and the light went away! awesome! but then about 10 miles later - light back on!!! double checked my wire fix, and since I did it quick and dirty with electrical tape, it had failed. fixed it properly with crimps and some nice wire wrap to re-enforce it, and used a zip tie to secure the connector to the sensor since the tabs were busted. No light! huzzah!<br />
Now I am thinking my original sensor might actually be fine. I will test it when I get a chance (probably when i do the bushings)</p>
<p>Another day of allroad ownership, but it's pretty easy to remember that it's all worth it when you're climbing fire trails above Tahoe in the lap of luxury...</p><br />
<img src="http://freetobelee.earjuice.com/audi/offroadlakeweb.jpg" /><br />
05-10-2013, 09:36 AM
#24
Audiworld Junior Member
Thread Starter
Pictures of the height sensor repair:
<img src="http://freetobelee.earjuice.com/audi/sensor1.jpg" /><br/>
<img src="http://freetobelee.earjuice.com/audi/sensor2.jpg" />
<img src="http://freetobelee.earjuice.com/audi/sensor1.jpg" /><br/>
<img src="http://freetobelee.earjuice.com/audi/sensor2.jpg" />
05-10-2013, 12:34 PM
#26
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Join Date: May 2011
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I'll be watching this to see how those airbagit units perform.
An idea I've toyed with: replace the leaking/worn-out stock bags with aftermarket bags (like these from airbagit), drilled and tapped for larger air lines, run larger lines with DOT connectors. Using OEM schematics, replace the control block with an aftermarket control block, wired to be controlled by the stock module. Replace the stock (weak) compressor with a high volume aftermarket unit, and replace the small-ish stock tank with a slightly larger aftermarket tank - all wired to operate with the OEM electronics.
Possible, and probably would cost about as much as factory replacement parts.
An idea I've toyed with: replace the leaking/worn-out stock bags with aftermarket bags (like these from airbagit), drilled and tapped for larger air lines, run larger lines with DOT connectors. Using OEM schematics, replace the control block with an aftermarket control block, wired to be controlled by the stock module. Replace the stock (weak) compressor with a high volume aftermarket unit, and replace the small-ish stock tank with a slightly larger aftermarket tank - all wired to operate with the OEM electronics.
Possible, and probably would cost about as much as factory replacement parts.
05-10-2013, 07:06 PM
#27
Audiworld Junior Member
Thread Starter
I'll be watching this to see how those airbagit units perform.
An idea I've toyed with: replace the leaking/worn-out stock bags with aftermarket bags (like these from airbagit), drilled and tapped for larger air lines, run larger lines with DOT connectors. Using OEM schematics, replace the control block with an aftermarket control block, wired to be controlled by the stock module. Replace the stock (weak) compressor with a high volume aftermarket unit, and replace the small-ish stock tank with a slightly larger aftermarket tank - all wired to operate with the OEM electronics.
Possible, and probably would cost about as much as factory replacement parts.
An idea I've toyed with: replace the leaking/worn-out stock bags with aftermarket bags (like these from airbagit), drilled and tapped for larger air lines, run larger lines with DOT connectors. Using OEM schematics, replace the control block with an aftermarket control block, wired to be controlled by the stock module. Replace the stock (weak) compressor with a high volume aftermarket unit, and replace the small-ish stock tank with a slightly larger aftermarket tank - all wired to operate with the OEM electronics.
Possible, and probably would cost about as much as factory replacement parts.
You could add an additional UFO air tank in the spare tire well, and hook it into the system.
Honestly my fantasy for the stock air system would be to flip a switch/press a button and have it drain all the bags, like a kneeling bus, just for use when parked. Not sure if this would be easier done with hacking the control unit or adding physical release valves for each line to the wheels.
05-16-2013, 12:40 PM
#28
Audiworld Junior Member
Thread Starter
The air fittings for these bags has been a bit of a nightmare. I initially identified a slow leak at both the fittings shortly after installing them. With some careful placement of an O-ring (luckily provided by Airbagit) I was able to get the drivers side to be a very slow leak (10-15 hours to deflate), but still not solid.
After struggling with the passenger side, and subsequently breaking it. I had the realization that perhaps the airbagit bags, although listed as OE replacements, might not use the correct threading as specified by Audi (1/8 BSPP)
I wrote an email to airbagit support addressing my concern, and I was very surprised when I was replied to by the owner of the company, in under 20 minutes! He had CC'd someone involved in the design and construction to provide more information. The owners suggestion was to use some blue loctite on the threading to ensure a seal. I appreciated the suggestion, but don't believe it is the proper solution. Granted, it would probably work, but it would gunk up that threading, and introducing a material to the bag that could break down and end up in there, possibly causing damage.
After no response for two days, I inquired again, and finally got an answer. The threads on the airbagit bags that were delivered to me have an upper air fitting that does not follow ANY of the pipe threading standards! It is a regular metric thread (m8x1.0) designed to be sealed by a connector with an O-ring. AHA! Thats the problem!
The OEM brass connectors do not have enough surface area to accommodate an o-ring efficiently enough to withstand the full pressure of the bag. the o-ring would just tear or slip over the hex part at the end of the fitting when tightened down.
So they said they would send me an adapter fitting from their thread to the audi thread. I called and said that a direct fitting from the 4mm (outside diameter) air line to the (m8x1.0) thread on my bags would be a preferred solution, as an adapter is adding another failure point.
He also informed me that they have already ordered the proper threading tap so that all future airbagit audi air bags will be threaded with the proper OE standard!
After some investigation, they couldn't find a fitting for their threads that was acceptable. SO… they are getting the new 1/8 BSPP tap in tomorrow, manufacture two bags for me, and send me replacements!
These should have been made to spec to begin with, and it certainly shouldn't have taken an informed customer complaint to discover their manufacturing error, but I am still very pleased with the build quality of the bags, and the attentive customer service I received.
After struggling with the passenger side, and subsequently breaking it. I had the realization that perhaps the airbagit bags, although listed as OE replacements, might not use the correct threading as specified by Audi (1/8 BSPP)
I wrote an email to airbagit support addressing my concern, and I was very surprised when I was replied to by the owner of the company, in under 20 minutes! He had CC'd someone involved in the design and construction to provide more information. The owners suggestion was to use some blue loctite on the threading to ensure a seal. I appreciated the suggestion, but don't believe it is the proper solution. Granted, it would probably work, but it would gunk up that threading, and introducing a material to the bag that could break down and end up in there, possibly causing damage.
After no response for two days, I inquired again, and finally got an answer. The threads on the airbagit bags that were delivered to me have an upper air fitting that does not follow ANY of the pipe threading standards! It is a regular metric thread (m8x1.0) designed to be sealed by a connector with an O-ring. AHA! Thats the problem!
The OEM brass connectors do not have enough surface area to accommodate an o-ring efficiently enough to withstand the full pressure of the bag. the o-ring would just tear or slip over the hex part at the end of the fitting when tightened down.
So they said they would send me an adapter fitting from their thread to the audi thread. I called and said that a direct fitting from the 4mm (outside diameter) air line to the (m8x1.0) thread on my bags would be a preferred solution, as an adapter is adding another failure point.
He also informed me that they have already ordered the proper threading tap so that all future airbagit audi air bags will be threaded with the proper OE standard!
After some investigation, they couldn't find a fitting for their threads that was acceptable. SO… they are getting the new 1/8 BSPP tap in tomorrow, manufacture two bags for me, and send me replacements!
These should have been made to spec to begin with, and it certainly shouldn't have taken an informed customer complaint to discover their manufacturing error, but I am still very pleased with the build quality of the bags, and the attentive customer service I received.
05-16-2013, 01:20 PM
#29
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Join Date: May 2011
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Well... that's actually pretty impressive! As someone who works in R&D and Production Development, I can fully understand something like that happening - what set's them apart, is their willingness to a) offer a workable solution, b) listen to the customer, and c) quickly fix the problem.
I'm convinced!
I'm convinced!
05-16-2013, 02:55 PM
#30
Audiworld Junior Member
Thread Starter
If you do indeed order, include that you bought on recommendation of Lee, please 
Who knows, it could entice a discount for my efforts if and when I have to replace the rear bags.
Who knows, it could entice a discount for my efforts if and when I have to replace the rear bags.
