Pissed off at the mk2, and a warning to all!!!

[scirocco81@vwmail.net (Eric S)]

Well...today was a nice day, 75 and sunny.  I started the day with good intentions.  New front brakes and a-arms with poly bushings for the mk2.

Well, brakes were fine...confirmed my suspicions about my front end rattle...the anti rattle clips for the brake pads were no where to be found.  No biggie, I anticipated that and bought a new set.  So, everything is going smoothly, get the new a-arms in and go to bolt everything back together...thats when the fun begins!

The a-arms I purchased from an ex-lister.  He scrapped his Mk1 and it had these new a-arms with new poly bushings and new ball joints just sitting around.

So, everything is cool (I'm loving my air tools right about now), till...I go to bolt the ball joint in.  It slides in too easily...so I cinch it down real tight (big mistake later)...and a fucking thing still slides right out of the steering knuckle!!!!  I try to bolt it several times...I begin to think I am crazy...then for giggles, I compare the new one to the original that came out.  Sure as shit, the new ball joint is a smaller diameter!

A quick glance through ETKA marks my unknown mistake....there are 2 styles available for the A1 chassis.  171-407-356C and a 356F.  C is 15mm, F is 17mm.  Looks like 15mm was only used on early mk1s....crap.  So, none of the local FLAPs have the 17mm in stock...have to head to this VW place in Boulder (hour round trip from here).  Get back...and, you guessed it, my "cinching" it down earlier has now crimped the steering knuckle "clamps" so tight I can't get the proper sized ball joint in there.  2 hours later, and a bent chisel...its slightly spread..but still not enough to let the proper ball joint slide in.  I am pissed of, tired and dirty...and that damn mk2 is mocking me from the driveway up on one jackstand.

So, let that be a lesson to you all...there are 2 sizes of ball joints...make sure you get the right one for your steering knuckle!!!!

Oh, PS:  Prototype crossmember bar gets bolted to the mk2 tomorrow...pics to follow tomorrow night.

--
Eric
Northglenn, CO

79 VW Iltis
81 Scirocco S (*TDI* swap and complete restoration in holding pattern)
81 Rabbit Truck LX Diesel (Waiting for BAE Turbo Install)
83 Scirocco Wolfsburg
91 Cabriolet (2.0 Crossflow 8v swap and mechanical rebuild in progress)