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  • Project unsieze

    I've been lucky enough to have had almost 3 years without having to do anything significant on the car but this year I have decided to finally sort out the underside as there is so much slack from a combination or worn bushes and I am expecting cv joints on the propshaft that are well past their prime after 200k miles.

    She's up on 4 axle stands and I'll be doing the following to ger her ship-shape for the now very late MOT unfortunately work is meaning a distinct lack of time...

    Renew diff mounts (done)
    Renew gearbox mounts
    Attempt to source and change propshaft centre bearing (done)
    New cv joints and covers on the propshaft (Sourced)
    Rebalance the prop prior to reinstallation
    change oil seals on the rear differential and fluid
    New pad retainers and pins for the brembo monoblock to hope to stop annoying brake squeal and resonating disc hum once hot (done)
    New rear drop links (done)
    Brake fluid flush
    Goo flush for the steering
    New voltage regulator for the alternator as seems not to be firing correctly under 2000rpm
    Likely another set of front top mounts
    Boost hose refresh as some of the samco's have started to sweat oil (done - thanks Newsh!)
    no doubt a load of stuff i shall uncover on the way!

    Last edited by s2driveruk; 9th October 2017, 20:40.
    sigpic

    1992 3b S2 Coupe

  • #2
    Good list but don't look for peeling underseal...

    If you find some like i did, rust will be underneath it and there is no end in sight from that point on!

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    • #3
      Managed to change the rear drop links without incident with new ones from Pete at Quattro Corner, the previous set were creaking all the time and was annoying the hell out of me. Then I made a start on the diff mounts as the rear is a powerflex one so no need to do anything with that...

      After running the car as a daily driver for the last 2.5 years, things are getting a little crusty underneath which ensured a fantastic wrestling match trying to remove the 17mm nylocs from the long bolts through the diff mounts. One finally gave up and let me have it, however the nearside one was less interested in giving into me and after much swearing it was clear this was going knowhere fast. gave it some plusgas and cleaned the threads that were still exposed but it was stuck fast. Eventually after a couple of hours soaking in penetrating oil, it finally gave up and i was able to wrestle the mounts out, ready to slot in the new Meyle ones I had sourced (eventually...these are getting hard to find!)

      As the bolt is not exactly easy to find, i cleaned up and attempted to reuse the original...which was a mistake. Started tightening up the new nyloc and then it decided it was going no further. bit of brute force and suddenly felt like it was going again....actually it was spinning on stripped threads....

      I decided as i couldn't get the angle grinder even close to it that i was attempt to burn the nyloc out and then hope it would actually come off which thankfully it did...this was the offending item

      sigpic

      1992 3b S2 Coupe

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      • #4
        today i decided to try and get the prop off the car so I could begin the process of refurbishing it.

        All going well until i tried to undo the 3 bolts at the base of the 3b downpipe...in typical fashion having not being touched in a very long time thanks to the local MOT place continuing to pass the car for several years.

        Managed to get two off then the top-most and least accessible decided to round the caphead out, leaving me with zero room to do anything about creative removal. Bought a hacksaw to attempt to try and cut it off but couldnt get it in close enough. Losing the will with yet another simple task on this car i was getting close to just walking away then realised i could split the exhaust and turn it around enough to get one of those irwin extractor sockets on it....1/2hr later and the exhaust was off and the swear box was full however, i was not able to start on prop removal.

        Thankfully getting the prop off was a breeze, not something you can say often with the S2!!!!

        Before i removed it, i spent a while trying to work up where the slop was from front to back. just rotating it fwds and backwards it was clear the front cv was toast. it was actually clunking and making a metallic twang which would account for the noise and vibration i could feel and hear.

        Front cv grease is just so waxy and thick it is little wonder it is knackered...



        To be honest the rear wasn't much better either



        The centre bearing rubber is cracked and the weight of the prop had sunken it too, looking very tired but actually oddly still pretty smooth on rotation



        sigpic

        1992 3b S2 Coupe

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        • #5
          figured as this was a genuine OEM bearing I would take a few pics and measurements to help with sourcing a decent replacement...















          sigpic

          1992 3b S2 Coupe

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          • #6
            new cv boots from Demon Tweaks and new UJ from IMS with centre lube







            going to run out of space at this rate

            sigpic

            1992 3b S2 Coupe

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            • #7
              Nice work, it looks like space is a bit of a premium already. Is it straight forward to change the centre bearing now that the propshaft is off?
              Greg

              S2Forum.com Administrator & Webmaster

              '93 Coupe with a few tweeks

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              • #8
                I did it before on another prop that i have and wasnt too bad from memory...just need to crack the 17mm bolt on the yoke side from memory. Key thing is to find the right centre bearing to replace it with.

                this one is looking promising for mine..will order it and do a side by side

                http://www.driveshaftparts.co.uk/ind...&product_id=90

                seems to be two availble, this being the other but first looks like the main bracket is like mine...

                http://www.driveshaftparts.co.uk/ind...&product_id=98
                sigpic

                1992 3b S2 Coupe

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                • #9
                  New diff mount bolts if you need them, one side is 110mm, the other 95mm

                  http://www.ebay.co.uk/itm/M10-10mm-P...zfFovbb94SQ25Q

                  sigpic
                  1991 Audi S2 3B - 2.5 Stroker engine
                  1997 A6 2.5TDi quattro avant - C4
                  1976 RD250E / 350LC cafe racer

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                  • #10
                    Cheers Andy, i did manage to find some 10.9 ones in the right size on ebay so all good
                    sigpic

                    1992 3b S2 Coupe

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                    • #11
                      Good photos, thanks for taking the time to share.
                      Copious amounts of copper paste will be your friend on re-assembly.

                      Enjoy the end results.





                      Last edited by macspring; 16th September 2017, 04:24.

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                      • #12
                        Looking good David. I have been down this road before so let me know I can assist in the sourcing of parts or info. Best of luck!
                        '95 RS2 America
                        If you would like to see more frequent updates and this project finished please PayPal a few quid/euro/dollars to my forum name and at gmail.com. See HERE for more info. Cheers, Tom

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                        • #13
                          so between crazy work and a US business trip, i have nudged this forward a bit...

                          Managed to split the prop, though the bearing caps were well stuck in place after 25 years of going round in circles. Eventually i managed to get them out using a 16mm socket and hammer and a 27mm socket on the other side to enable the opposite side to move out. Use of an adjustable pliers on the caps rotated them free of the yoke



                          Needle bearings everywhere


                          Cap removed and the needle bearings stayed in place so you can see how they fit

                          old UJ removed and inspected. Amazingly little visible wear and no obvious scoring etc to the 4 ends..


                          cleaned up with the grease zerk removed


                          Next challenge to split the yoke carefully to gain access to the centre bearing and break the hold on the 17mm bolt - use of the vice to enable the bolt to be undone, actually gave up its grip pretty quick




                          removed the bolt and found a longer version to enable me to undo it against a long socket through the holes for the bearing caps on the Yoke so it came off square


                          Here she comes...


                          and parted..
                          Last edited by s2driveruk; 9th October 2017, 21:08.
                          sigpic

                          1992 3b S2 Coupe

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                          • #14
                            Good work, thanks for documenting too. Hopefully not a job i'll need to do in the near future though
                            Greg

                            S2Forum.com Administrator & Webmaster

                            '93 Coupe with a few tweeks

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                            • #15
                              FAG bearing original on the centre, I tried to take a picture of some of the other numbers but hard to get them visible



                              Had to drive off the little collar too which came off with the bearing


                              prop minus old centre bearing


                              Last edited by s2driveruk; 9th October 2017, 21:59.
                              sigpic

                              1992 3b S2 Coupe

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