A little something else to keep me busy.

[newsh]

Also, I think I might have a spare fan controller left from the RS4 if you need one

[Tractor Dave]

From memory as its been at least 10yrs since I messed with a few of these

As you've found there is that metal clip to hold the sensor in. I know my friend had a lot of issues with finding the right sensor for the temp gauge on his one, could never get the gauge to read well. Same when he had a passat but that was worse and I don't think he ever got the temp gauge on it before another member on here had the car for an engine swap into his project.

At least the heater fan is easy to get to once the glovebox is out the way. Is this a climatronic/digital setup or the dials?

Climatronic.

[Tractor Dave]

Also, I think I might have a spare fan controller left from the RS4 if you need one

Thanks. Will let you know

[Tractor Dave]

Cv joint didn't quite go to plan.


I put the new boot on but whilst the shaft was out I didn't like the feel of the inner cv joint. It was very lumpy and almost locked up. So, off it came.
Looks like water has got inside.


The joint was seized on the shaft.


I have some spare S2 joints. They look the same.


Sent from my iPhone using Tapatalk

[K Simmonds]

I seem to recollect the water temp gauge always read low on Charlies one, or not all, there was certainly some issue with it, I can't remember exactly what though now.

As far as I recall the electronic fan only kicked in when the air-con was switched on.

I like that puller, not seen one quite like that before, very handy.

[B5NUT]

I have some spare S2 joints. They look the same.


Sent from my iPhone using Tapatalk

3B & ABY uses the same inner CV as the B5 A4

[Tractor Dave]

A friend near me is breaking a B5 A4 so I popped over for a few bits. Apparently, fan brushes fail so now I have a spare fan and controller. I also ordered a set of brushes. Also grabbed the thermostat sensor to try a swap with mine. This is a v6 tdi but lots of parts are identical. Stopped at the autofactors while out and picked up a new inner cv boot.

[Tractor Dave]

I cleaned up the cv joint and found the issue.


So I dug out my spare S2 ones and found that they are not the same. They are slightly larger diameter.
Anyway, I found that brand new SKF ones are only £40 from SKF direct so ordered one.
A few other little jobs have arisen. I didn't like the look of the pas fluid. It's very runny and almost clear. I suspect someone has topped up with brake fluid at some point. So that's been drained, bottle cleaned out and fresh fluid in. I swapped the cooler that runs across the rad for the tdi one as the clips weren't broken.
Next, pollen filter and battery tray.


The filter has seen better days.

Whilst hoover out, I found the battery tray is badly corroded. The battery must have leaked at some point.



Luckily the one from the tdi is very good and a perfect fit.

While I'm waiting for the cv joint I have the heater fan to swap and also the injector seals to change. I noticed a weep around injector 2 so bought a full set.


Sent from my iPhone using Tapatalk

[Tractor Dave]

I confirmed the fan was dead using my power probe.


And also checked the replacement one was working before fitting!

It's a bit tight in here. The loom gets in the way.




Flap foam looks iffy but that's a job for another day.

Replacement all fitted but can't test yet.

I need to clean up the rust in the bulkhead and fit the replacement battery tray.


Injectors out and have been sent to a kind forum member who offered to test and clean for me.



Sent from my iPhone using Tapatalk

[K Simmonds]

A cracked inner CV cage, that's a new one on me with VAG cars from this era, they normally go on forever... At least you caught it now, would have been really annoying having to take it all apart again down the the line! Wonder what cause it, other than perhaps a defective part, was the joint dry?

Good you caught that battery tray before it evolved into a serious problem as well.

You'll have it back on the road before long, bring it up one weekend if you feel like it mate, your always welcome to drop in for a cuppa.

[Tractor Dave]

Cheers Kit. Will do.
The grease was quite dry but also someone has been there before me. White paint on the end. I knew something was up, it just didn't feel right. Anyway, just checked my SKF tracking and the new joint is coming from Belgium! They can't have had any left in UK So don't put the kettle on just yet

[Tractor Dave]

The bulkhead got cleaned up and treated with Bilt.

It was quite tricky due to proximity to the air con pipes.


Sent from my iPhone using Tapatalk

[K Simmonds]

Ahh yes, the marvelous Belgian Post Office, still wonder what on earth happened with that simple little package I sent over there???

Looking at the tracking it cleared their customs just fine then had a sticker slapped on it before being put straight in the next container back, no attempt made to contact the buyer to pay the fee, it was only in the country for about five hours.

Hopefully your ball joint doesn't take too long.

[Tractor Dave]

The bulkhead got some epoxy and put back together with new galvanised bolts from my collection.


Bumper and lights replaced.


Had a look at my front discs. Minimum thickness should be 23mm. They are 21 and marked 2004! I had these knocking about but the centre bore was slightly too small. Otherwise they would have been perfect.



So I had a hunt around and found these which seem to be the right ones.
I didn't have pads so they are on order.


The off side outer cv boot also needs doing.


Then I thought what the hell, I will do the inner as well and put some fresh grease in and deal with that rust!


Sent from my iPhone using Tapatalk

[Rikki Kitto]

Love your work, if I come into some extra cash ill drop the S2 off