Jretal

Here was the list of things I was going to tackle last weekend:

-P/S Rack replacement
-P/S High pressure pump to rack Pipe repacement
-Fuel Filter
-Rear Diff Fluid change
-Tranny Fluid Change
-Allroad Tranny Mounts
-Engine Oil Change
-ECT Replacement
-OEM Jack Mounts

I started off with this pile of parts:
<img src="http://pictureposter.audiworld.com/21175/dscf0009.jpg">

I started with the installation of the OEM Jack Points, since I needed to lift the car off the ground to get it up on jack stands:

Here's the mount:
<img src="http://pictureposter.audiworld.com/21175/oem_jack_point.jpg">

Here's where it goes on the front and rear respectively:
<img src="http://pictureposter.audiworld.com/21175/plug_removed_front.jpg">
<img src="http://pictureposter.audiworld.com/21175/plug_removed_rear.jpg">

I then used some 3m underbody coating to cover the bare metal... just as a precaution thing, nothing more. Need to do some treating to the rest of the underbody later on, but one thing at a time
<img src="http://pictureposter.audiworld.com/21175/front_coated.jpg">
<img src="http://pictureposter.audiworld.com/21175/rear_coated.jpg">

And the installation and installed pix:
<img src="http://pictureposter.audiworld.com/21175/installation.jpg">
<img src="http://pictureposter.audiworld.com/21175/installed.jpg">
I actually didn't install the rear pads because I can lift the entire side of the car from the front pad alone, so didn't find in necessary to install the rears. Soooo, I got 2 extra jack points if someone wants them. Email me. I'll sell 'em to you at my cost (was list less 15%... love quattro club discount ) Just don't want them sitting around.


Once this was done, I lifted the car off the ground and took off the front wheels to start the process for the p/s rack:
<img src="http://pictureposter.audiworld.com/21175/dscf0013.jpg">
<img src="http://pictureposter.audiworld.com/21175/dscf0014.jpg">

I then took off the lower knee bolster for the driver's side:
<img src="http://pictureposter.audiworld.com/21175/dscf0015.jpg">

Then took off the joint from the steering colum off the rack (iirc it was a 16mm open end wrench):
<img src="http://pictureposter.audiworld.com/21175/dscf0016.jpg">

And then wired it up so it was out of the way and couldn't fall down:
<img src="http://pictureposter.audiworld.com/21175/dscf0017.jpg">

I then took off the mounting bolts that were accessible from the top. THis one was visible from the brake booster, the other one is under the battery (didn't get a pic of that one) Socket needed was a 10mm 12 point:
<img src="http://pictureposter.audiworld.com/21175/dscf0019.jpg">

I then took off the tierod ends. Came off with a lil PB blaster and a lil persuasion from mr. hammer
<img src="http://pictureposter.audiworld.com/21175/dscf0021.jpg">

Then I took off teh cover and exposed the 2 lines on the driver's side:
<img src="http://pictureposter.audiworld.com/21175/dscf0022.jpg">

This was friday. Here's where I started off saturday:

Took off the 22mm bolt with the 22mm universal socket. This along with a 2' extension made it a cakewalk to get THIS bolt off... 19mm one wasn't as easy. I had to slide the rack towards the front of the car and pushed it to the passenger side. This is how my mechanic said his buddy did it... worked out pretty well, but was still a royal PITA
here's the 22mm bolt removed as well as the 3rd and final mounting bolt:
<img src="http://pictureposter.audiworld.com/21175/dscf0023.jpg">

I then took off the connection to the P/S hose that was leaking... it's the one with the curly cue on it. Here's a pic of it removed and out:
<img src="http://pictureposter.audiworld.com/21175/dscf0027.jpg">
<img src="http://pictureposter.audiworld.com/21175/dscf0029.jpg">

Here's the rack out of the car (don't worry... grass has been mowed since this pic =P you can also see the p/s hose behind it buried in the grass):
<img src="http://pictureposter.audiworld.com/21175/dscf0030.jpg">

The boots on both ends were completely soaked in P/S fluid... so needless to say, it was shot and did need to be replaced:
<img src="http://pictureposter.audiworld.com/21175/dscf0031.jpg">

Here's a pic of the new rack going in:
<img src="http://pictureposter.audiworld.com/21175/dscf0034.jpg">

Here are the tools we used to get 'em out. I owe a lot to my mechanic for loaning them to me! Made my life way way easier:
<img src="http://pictureposter.audiworld.com/21175/dscf0055.jpg">

Once this was buttoned up I primed the system. The tech article I followed said to turn the car on and do it. What I did was turn the wheel back and forth with the car off. This enabled me to get about 99% of the air out of the system without running the pump dry. Went lock to lock full left to full right about 50+ times. Worked out very well, and when I started the car on Sunday I got no dry pump noise.

At this point, we called it a day and went out to relax after showering w/ lava soap =P

Sunday is when even more fun began. I started at about 10 with full expectations to be done and on the beach by 2... didn't happen. Everything fought me every step of the way.

Fuel filter was a royal b!tch. that bolt holding it in was so rusted that I couldn't get it out and ended up stripping it. I followed the tech article pretty much the entire way. I didn't need to put the 2x4 under the tank to get enough clearance though.
<img src="http://pictureposter.audiworld.com/21175/dscf0036.jpg">
here's what happens when mr bolt meets mr hacksaw:
<img src="http://pictureposter.audiworld.com/21175/dscf0038.2.jpg">
And here is the new filter installed and ready to go:
<img src="http://pictureposter.audiworld.com/21175/dscf0040.jpg">

I used a zip tie to hold it in place. It's as secure as it was with the other mount, and now 10x easier to change out. I did run into an issue with the bottom banjo bolt. When I finished and started the car, it was leaking fuel from the banjo bolt. After alot of fighting today (monday) I finally got it right... but that's after I managed to hose myself with fuel. not a happy camper, lemme tell ya... but it stopped leaking, so that's a plus. Ran the car for 40 min or so on jackstands and it didn't leak a drop, so I'm pretty confident I'm good.

I then attempted to do my rear tranny fluid. Went to remove the fill plug and found that it was stripped. Not good. So now I need to source a new fill plug before I even attempt to change the fluid... anyone got a p/n for that by chance?

I then went to the tranny fluid. This went real easy. Ended up picking up a 17mm allen socket at autozone in a kit of 12mm, 14mm, and 17mm for $7.99... Can't beat the price, that's for sure! Sears wanted $18.99 for just the 17mm... riiight.

SO I managed to get my harbor freight pump to work, and ran into little issue. Took 2 of us to get it in cuz the hose kept kinking that I used.
<img src="http://pictureposter.audiworld.com/21175/dscf0041.1.jpg">

Again, followed the tech article in the archives. Not hard at all.

Next was the allroad tranny mounts. I used the tech article Mr D had written. Went down without a hitch... here's the mounts ready to go in:
<img src="http://pictureposter.audiworld.com/21175/dscf0044.jpg">
and the old one (found the turtle in the backyard and figured it'd be a funny addition to the pic... it was later released w/o harm to PETA don't worry =P):
<img src="http://pictureposter.audiworld.com/21175/dscf0046.jpg">

I then changed my oil w/ mobil 1 oil filter and Castrol syntec 5w-50. Was pretty standard... no issues what so ever. Then installed the ECT. I removed all my intake hosing to give myself enough room to R&amp;R the sensor. Here it is as I'm installing it:
<img src="http://pictureposter.audiworld.com/21175/dscf0049.jpg">

Was pretty easy install as I said. I then buttoned everything else up and fired the car up while it was the stand. No P/S leaks, no tranyn leaks, but as I said above, the fuel filter was the biggest source of a headache for me.

So now after several bloody knuckles and multiple curses I am finished. All said and done this was not a cheap repair, but I at least saved a few hundred bucks by sourcing the parts myself and doing all the work myself. Very self fulfilling

So there it was... pretty busy lil weekend. Unfortunately I did not make it to the beach, but there will be plenty more weekends for that .

I ahve an alignment setup for tomorrow at the local firestone tire and alignment center. $140 for lifetime alignment. Wish I woulda known about this last year so this time woulda been free :-P Oh well, live and learn, live and learn.

Just want to say thank you to the guys who wrote those tech articles... they made my life real easy. The P/S rack was nothing compared to my evap core/heater core replacement (like 1/16th the parts!).

Hope you enjoyed the story. As for me, I'm gonna go have a beer... I think I've earned it

j31izzle

Dude you rock!~ About to have a pretty busy weekend myself and can't wait for it!&gt;

MikTip

<center><img src="http://pictureposter.audiworld.com/6607/open.jpg"></center><p>A/C compressor died, so I removed the entire a/c system. Grrr!

Maybe one day I might re-install...

JG18TAVANT(FXK04)

YGM

Jretal

somehow I think that was a mixed blessing for you Mike lol. I'm sorry for your loss? =P

djordan

Are you sure you didn't accidentally install the turtle?

JAFO

do you have a part # on the jack points?

Jretal

figured my car makes enough noises on it's own, i don't need to install things that add to that

quattro90S6

1. Swivles are AMAZING 2.Same b/s with the filter, behold the power of the Zip - Tie

Jretal

from modifieda4's sig... has all the info you need.<ul><li><a href="http://www.passatworld.com/forums/showthread.php?t=151261">oem jackpoint post</a></li></ul>