FabI Mod WishboneBushes

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Contents 1 Tools You will need 1.1 Bush fitting tool 2 Parts You will need 3 Steps 4 Useful Tips 5 Notes 6 Warnings 7 Related Articles 8 Disclaimer

[edit] Tools You will need

It is always important to make sure that you have all of the tools required for the job before you start work and allow yourself enough time to finish the job properly.

• Tool to fit Cupra bushes into Consoles [See Figure 1.0]
• Jack and Axle stands
• A strong socket set
• A senior hacksaw
• Mallet
• Large screwdiver
• Torque Wrench
• Silicon spray
• Ratchet strap

[edit] Bush fitting tool

This consists of an M12 x 150 long set screw, 2 M12 washers and 2 M12 nuts. These are readily available from your local hardware shop or Fixings supplier. You will also need to get a friendly local engineering shop to make the large spacers for you.

The spacers are 8mm thick with a 12.5mm diameter hole in the centre. You will need 2 x 61mm diameter and 2 x 71mm diameter.

[edit] Parts You will need

• 1 x Set Powerflex bushes - Part No: PFF85-601
• 2 x Seat Cupra Console bushes - Part No: 6LL407183
• 1 x Tube VW Special lube for fitting Console bush
• 6 x Bolts for Balljoints - Part No: N10127707 (Volkswagen Part Number)
• 2 x Bolts for Front Wishbone Bush - Part No: N10141801 (Volkswagen Part Number)

[edit] Steps

1. Jack up the car and support it on the cill jacking points with axle stands.
2. Remove wheels and engine splash guard.
3. Remove the 13mm nuts on the lower ball joint. [Figure 1.1]
4. Pull the hub outwards and slide the lower ball-joint out of the wishbone. [Figure 1.2]
5. Remove the 18mm bolt from the front of the wishbone. [Figure 1.3]
6. Slide the wishbone out of its front mounting. [Figure 1.4]
7. Remove the wishbone from the rear console bush. This is best done by rotating the wishbone to the 6 o'clock position a few times while maintaining forward pressure. [Figure 1.5]
8. To remove the old console bush I found it quickest to cut partially through the outer nylon casing with a hacksaw blade threaded through a void in the bush. When the casing is partially cut you can tap a blunt screwdriver between it and the console and the nylon will split. Tap the bush out from the rear. [Figure 1.5]
9. Clean the inside of the console with WD40 and a Scotchbrite pad.
10. To Remove the front wishbone bush from the wishbone you will first need to cut off the rubber flange from the rear side of the bush with either a hacksaw or knife. [Figure 1.6]
11. Fit a large socket over the remaining flange and a smaller socket on the cut side of the bush and using your M12 set screw, pull the bush out of the wishbone and into the socket. [Figure 1.7]
12. Fit the Powerflex bushes into the wishbone as described in their instructions.
13. Fit the Cupra bush into the Console. The bush should be fitted with the flush side towards the back of the car and with the hexagon hole flat at the top and bottom.
14. Lubricate the console and the bush with oil, place correctly aligned, into the console and tap it gently with a mallet to start the fitting.
15. Put a large spacer at the rear of the console and a small spacer at the front of the bush. Thread the M12 Set screw through the spacer, bush, console and spacer and fit the M12 nut at the rear.
16. Start to tighten the nut and check the bush is still aligned with the console.
17. Carefully tighten the nut and bolt until the bush is pulled through the console and is flush at the rear. [Figure 1.8]
18. Lubricate the hole in the Console bush and the hexagonal spigot on the wisbone with copious amounts of silicon spray.
19. Place the wishbone into the bush and start the fitting with a few taps of the mallet.
20. Place the ratchet strap around the rear of the console housing and round the Powerflex bush at the front of the wishbone.
21. Ratchet the strap to pull the wishbone into the console bush. It will be difficult and a few more taps with the mallet may help the process. The wishbone is correctly fitted when 3-4mm of the spigot protrudes at the rear of the console bush. [Figure 1.9]
22. Hinge the front bush into its correct position, as shown in the pic above, and fit a new 18mm bolt. Torque to 70Nm and tighten a further 90 degrees. [Figure 1.10]
23. Refit the lower balljoint back into the wishbone and fit new 13mm bolts. Torque to 20Nm and tighten a further 90 degrees.
24. Refit the splashguard and wheels and lower the car to the ground.
25. Get the tracking checked as soon as possible.
26. Your done.

Figure 1.1 - 13mm ball joint

Figure 1.2 - Lower ball joint

Figure 1.3 - 18mm bolt

Figure 1.4 - Removing Wishbone

Figure 1.5 - Removing old Bush

Figure 1.6 - Cutting old Bush

Figure 1.7 - Large Socket

Figure 1.8 - Fitting console

Figure 1.9 - Ratchet Strap

Figure 1.10 - New front bush

[edit] Useful Tips

• To remove the old console bush I found it quickest to cut partially through the outer nylon casing with a hacksaw blade threaded through a void in the bush. When the casing is partially cut you can tap a blunt screwdriver between it and the console and the nylon will split. Tap the bush out from the rear.

[edit] Notes

Please read and understand the guide before commencing as the hardest part of the process is the reassembly and at this point the car will be impossible to move if you can't finish the job.

[edit] Warnings

DO:

• Use eye protection when using power tools, and when working under the vehicle.
• Wear gloves or use barrier cream to protect your hands when necessary.
• Get someone to check periodically that all is well when working alone on the vehicle.
• Keep loose clothing and long hair well out of the way of moving mechanical parts.
• Remove rings, wrist watches etc, before working on the vehicle - especially the electrical system.
• Ensure that any lifting or jacking equipment has a safe working load rating adequate for the job.

DON'T:

• Attempt to lift a heavy component which may be beyond your capability - get assistance.
• Rush to finish a job, or take unverified short cuts.
• Use ill-fitting tools which may slip and cause injury.
• Leave tools or parts lying around where someone can trip over them. Mop up oil and fuel spills at once.
• Allow children or pets to play in or near a vehicle being worked on.

[edit] Related Articles

Related Guide - Guide that is related to this guide.

Related Page - Page related to this guide.

Related Part - Part description related to this guide.

[edit] Disclaimer

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