GBW

<center><img src="http://pictureposter.audiworld.com/81787/lights.jpg"></center><p>During my H-sport installation last week, I noticed that when the PSK bar was installed in 2005, the plastic arm for the headlight level sensor may have broken. It really hasn't caused any problems, and I wouldn't have known it was damaged if I wasn't doing the H-sports.

So, other than knowing that it's broken....is there any particular reason to replace it? It's the part #2 which I've circled.....

OCDboy

Seriously, if both bits are there you should be able to glue it back together. Maybe a little JB Weld? Just a thought!

4Driver4

Broken or deliberately disconnected?

GBW

I've never noticed any alignment problem, no idiot lights, dealer has never mentioned vagcom errors. Never would have known if I hadn't crawled under the car.

In fact, didn't notice it with any of my tire changes or rotations (about every 3 months)...and I usually look around and check things out...so maybe it didn't happen with the PSK install...

Ritz

On a customer's car when Audi said they couldn't get a replacement for 3 days and the owner needed it back for a vacation roadtrip. Glue alone won't work since that part is constantly being flexed and torqued by the control arm bouncing up and down.

1. Remove the little plastic arm.
2. Epoxy the 2 pieces together.
3. After epoxy sets, drill small hole about 1cm on either side of repair.
4. Find 2 "splints" of thin gauge metal strips for each side of the plastic bar (I used PC card slot blanks to make mine).
5. Drill appropriate holes in "splints."
6. Get tiny #4 machine screws from HD/Lowes/hobby store/etc.
7. Bolt the two splints on either side of the plastic arm (use a lock washer).

I was supposed to order the correct part, but both me and the owner forgot about it. About a year later, I was putting rear brakes on and I noticed it (good as new). I even hit it with a spritz of flat black paint so you couldn't even tell it was there unless you knew to look for it.

Or...you could just order the part from your neighborhood stealer. :-)

Cheers,

GBW

I'll probably take the same route until I can replace the part...thanks for the help!