My R32 DSG full rebuild

[J_U_K_I]

First I'd like to apologize using english.

Not much to show at the moment, but here's finally my R32 DSG full rebuild thread.
First I'm rebuild all the suspension and drivetrain components, and fixing problems on under coating. Next winters plan is full respray.

For last year and half have been gathering a lot of parts, mostly original and some parts just incase as they will not be available forever.
Still some parts missing and trying to find place to buy them, but not much luck and prices are getting really expensive.

This is where it started and show's worst part of before rebuild.

 

[J_U_K_I]

Todays work, I had previously installed stock rubber bushings on rear trailing arms, but I found few sets of stock bearings so I decided to use them despite that the car never came with them. All new bearings, bushings and bolts, everything repainted.


Also assembled painted rear diff carrier with new bolts and bushings.
The diff is also new, cheap find.

 

[J_U_K_I]

New front wheel bearing housings with new bearings and hubs.

Old wheel bearing housings had ABS cracked sensor brackets and one of the previous owners had tried to weld them, they held up fine until I removed the sensors.

 

[crs]

Is there a rust hole in the front axle? *schock*

That is crazy! I also rebuild my whole front axle this winter but didn't found any major rust on it.

But you are doing great work! Looking forward to see progress. :great:

 

[J_U_K_I]

Yes, that is a rust hole in the front axle.


That's what 10 years on salted roads does.

 

[Kenny]

Perkele! Finally it gets going on the finnish front :great:

Good luck, looking forward to see the results, and yeah the icy roads of nordic countries are not kind to our underframes

 

[J_U_K_I]

Got some new parts today.

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[J_U_K_I]

Powder coated 19" Ultraleggeras, valve cover and a brand new DSG-spec sub-frame powder coated inside-out.

 

[J_U_K_I]

Took the dash out to change the heater core and check the foam on the blend doors.

 

[J_U_K_I]

Not the easiest job to take the cross bar out to get heater box out.

Engine bay side is a little bit easier.

Blend door foam in great condition, so only changing heater core.

 

[J_U_K_I]

Stocking parts for the future.


Door window seals.

Trunk lid seal.

Lower driver side dashboard trims.

Drive shaft rear coupler.

Right side dash trim piece, DSG shifter knob and shaft trim, DSG brake pedal cover.

 

[.:r-line]

Where did you get the right side from?

 

[J_U_K_I]

It is still available from VW, at least a few weeks back I was able to order it, Online-Teile lists it still available also.

Left side with door is more of problem to find.


More and more parts are becoming to be no longer available or prices are getting really high for remaining parts, so now it's final time to get the parts.

 

[Gast9835]

Nice stuff!


Do you know how to change a DSG shifter knob? And can you explain it to me?


thanks
mecki

 

[.:r-line]

It is still available from VW, at least a few weeks back I was able to order it, Online-Teile lists it still available also.

Left side with door is more of problem to find.


More and more parts are becoming to be no longer available or prices are getting really high for remaining parts, so now it's final time to get the parts.

And they are also with the soft coating?

 

[J_U_K_I]

And they are also with the soft coating?

I really can't tell, it's smooth, but I'd say no soft coating.

 

[J_U_K_I]

Nice stuff!


Do you know how to change a DSG shifter knob? And can you explain it to me?


thanks
mecki

I don't know yet how to change a DSG shifter knob, but eventually I have to learn. I can explain it once I have tried.

 

[J_U_K_I]

Dashboard went back in the car, not a job I'd like to do again soon.

Then took the front fenders off to fix rust issues behind them, nothing too bad, but something what needs to be done at this point.

[/url]

 

[J_U_K_I]

@mecki


These are instructions from factory service manual to remove shifter knob.


– First pull button far
enough out of knob that
a small gap is visible be?
tween knob and button.
– Secure button in this po?
sition with cable tie so
that after the knob is
pulled off, it cannot snap
back into knob.
– Push sleeve
downwards.
– Pull off knob.

 

[Gast9835]

These are instructions from factory service manual to remove shifter knob.


– First pull button far enough out of knob that a small gap is visible between knob and button.
– Secure button in this position with cable tie so that after the knob is
pulled off, it cannot snap back into knob.
– Push sleeve downwards.
– Pull off knob.

:great: Great! Thanks a lot! A very nice easter gift! :-D



greats
mecki





Übersetzung:


- Zuerst den (Daumen)Knopf weit genug aus dem Kopf ziehen, sodas eine kleine Lücke zwischen Kopf und Knopf sichtbar ist
- Dann den Knopf in diesem Position mit Kabelbinder sichern, so das nach dem der Knauf abgezogen ist, er nicht wieder zurück in den Kopf schnappen kann
- Hülse nach unten schieben
- Knauf abziehen.