The All New, New "What have you done to your Bay today" thread.

Not an E I E I O?

 

Not the ball joint but theres a neat hole in the boot like it was hit by something.

Decided to change the other joint a few days ago .. because a few years back I got knackered after hacking three out in a day, left the fourth as it was only a bit wobbly . Move forward to today. No 4's boot had split badly, and the joint had worn some more so I might as well fit the new one I had in the box..

 

Got bored with sorting oil leaks, so moved on to wind noise and rattling.
My sliding door rattles when closed on anything but really smooth roads ( so that’s all the time).
New seal, rollers etc. have failed to cure the problem. The top roller runs nice and tight in the channel, until it reaches the closed position, where the curved part of the channel is suddenly much wider. … is this as VW intended?

 

Put the oil strainer in.

 

Are they nyloks holding your case together?

 

Loosen the nut on the bottom of the roller it will slide in the bracket. Using trial, error and judgement make it pull the door into the seal a bit i.e. move it to the outer side of the channel. It only matters exactly where this roller is when the door's shut. Technically you should adjust it so that corner of the door closes flush to the pillar which should do the same job.

 

Well guess what the VW Engine Company use. Doesn't get hot enough to melt nylon.

Also what comes in the Bag'o'bolts you can buy for putting engines together.

 

Obviously a world shortage of M8 nuts and washers...

 

Tried clamping the ball joint.. nope it spun inside the camber nut.

Used a Dremel with a carbide burr to eat away the nut until I could shock it round with a chisel.

Jacked up the top suspension arm and pulled off the old boot , then had to use a puller to free the camber nut. New boot went on and then it all went back together.

Made up a set of brake pipes from the central front tee piece out to the wheels and from the flexi hoses to the calipers. To go with the new discs and stainless braided flex hoses..

Put both sides of the suspension together left it ready for camber adjustment..

Tomorrow rear flexi brake hoses and probably a couple more brake pipes to make up, if the nuts have seized on the ends and they twist..

Then brake bleeding and camber adjustment.

 

Why should you not use both washers and nylocks, just a bit more security.

 

VW didn't seem to think your crankcase would fall in half.

 

I’ve done that loads of times, but probably not since changing the seal…I’ll persevere……. but it’s flush with the pillar and still noisy.
It was a cheap seal from a show… the same stall had one 3 times the price…perhaps a false economy?

 

Yes.

 

I just had a big spare bag of them from some work I did on the bike. Thought they looked better.

 

I don't think it should be the difference but yu never know?
It's a common symptom of the top roller and the cure is adjustment, so if it won't adjust there maybe you need to move something else too. It's a balance isn't it?

 

The seal should be trying to fairly firmly push the door out of the aperture by pressing around the door edge when the door is flush. The roller is then pulling it in against the force of the seal for that last bit of travel, so it doesn't rattle.
As @Zed says, if the top front corner of the door is good, next check the striker plate position and bottom roller position, both of those could be pushing the front top corner of the door inwards , that would mean that the top roller doesn't have to do much pushing work so it rattles.

It could even be a bit of carpet or a doormat or similar interfering with the closure of the door, tilting it over..e.g. I have a doormat that slides out and wedges under the bottom of the door holding it open slightly.

 

After the last new gear stick snapped, I just fitted a CSP stick and so far so good. I’ve gone from stirred to sliced gear changes, happy!

 

Oh, and I changed the front gear linkage rod whilst I was at it. The old one had a groove worn in the bucket. Makes a big improvement to the slop!