A2 Rear Axle restoration – my journey

Received some hard to get bits form AT courtesy of Rick. I was going to change my mind re the bracket that holds the brake hoses to the spaceframe but forgot to delete it. So I will use it provided I can get the old one off easily.

The photo at AT looked like it might be galvanised but in the flesh it looks too shiny. So I will paint and maybe add a gasket of some type to stop galvanic corrosion. What material would make a good gasket?

Axle Bracket bolts and brake hose retained lr.jpg


Also in the picture are the 6 stretch bolts holding the 2 brackets to the spaceframe and I tested to see how they fitted to the brackets. There is plenty of room for aligning the axle to the front wheels.

Axle Bracket and bolt inserted lr.jpg
 
I'm getting concerned ordering the bushes. Initially I was looking at poly bushes and they came in 2 height sizes: 69mm and 72mm but poly were discounted as they were all too wide at the end to sit in the recess in the large washer and were likely not to fit between the jaws of the bracket. One manufacturer agreed and had withdrawn the product for A2s.

So I reverted to buying rubber bushes expecting to see the same height size choices but they are all 72mm +/- 0.5mm.

Here's my axle bush housing:

A2 Old Bush Housing.jpg


The max is just over 68mm. Now here is the old bush:

A2 Bush Old.jpg


As you can see there is no measurement near 72mm. The centre part is around 69mm and the rubber lip 80mm or 76mm.

Now the old bush has a metal outer sleeve that covers about 290 degrees. This allows some flexibility to compress.

But will 72mm compress to 68mm? What exactly are the suppliers measuring to get 72mm?
 
Alan_uk said:
I'm getting concerned ordering the bushes. Initially I was looking at poly bushes and they came in 2 height sizes: 69mm and 72mm but poly were discounted as they were all too wide at the end to sit in the recess in the large washer and were likely not to fit between the jaws of the bracket. One manufacturer agreed and had withdrawn the product for A2s.

So I reverted to buying rubber bushes expecting to see the same height size choices but they are all 72mm +/- 0.5mm.

Here's my axle bush housing:

View attachment 113139

The max is just over 68mm. Now here is the old bush:

View attachment 113138

As you can see there is no measurement near 72mm. The centre part is around 69mm and the rubber lip 80mm or 76mm.

Now the old bush has a metal outer sleeve that covers about 290 degrees. This allows some flexibility to compress.

But will 72mm compress to 68mm? What exactly are the suppliers measuring to get 72mm?
Click to expand...

Have you looked at 6Q0501541E rear axle bushes?

Perhaps you could compare these with your old bushes to see if they have the same dimensions.

Rear axle bushes 6Q0501541E

As you can see in the chart below, the Skoda Fabia MK1 used two types of rear axle bush depending on model.

Skoda Fabia MK1 rear axle bush
91J0501541CBonded rubber bush2
96Q0501541EBonded rubber bush2PR-0N7

Build code 0N7 means heavy duty rear axle, as shown in the chart below.

VW Codes Decoder
0N7 = Heavy-duty rear axle (design 2)

You can see in the chart below that the Fabia MK1 with build code 0N7 uses a different rear axle, ie. it's the sporty suspension model.

Skoda Fabia MK1 rear axle
16Q0500051AQrear axle beam
for models without
power steering		1PR-0N1
16Q0500051ASrear axle beam
for models with power
steering		1PR-0N2
16Q0500051ARrear axle beam
for vehicles with sports
suspension		1PR-0N7
16Q0500051BCrear axle beam
for vehicles with sports
suspension		1PR-0N7

The above 6Q0500051AR rear axle is also used on the Seat Ibiza with build code 0N7, so would include the Seat Ibiza Cupra.

As you can see in the chart below, the Seat Ibiza also uses the same two rear axle bushes as the Fabia MK1, but also has a third axle bush for the Seat Ibiza Cupra. It might be worth asking a VAG parts department if they can get 6LL501541.

Seat Ibiza MK3 rear axle bush
91J0501541CBonded rubber bush2PR-0N2
96Q0501541EBonded rubber bush2PR-0N7
96LL501541Bonded rubber bush2CUPRA"R",
"FR"
 
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Alan_uk said:
I'm getting concerned ordering the bushes. Initially I was looking at poly bushes and they came in 2 height sizes: 69mm and 72mm but poly were discounted as they were all too wide at the end to sit in the recess in the large washer and were likely not to fit between the jaws of the bracket. One manufacturer agreed and had withdrawn the product for A2s.

So I reverted to buying rubber bushes expecting to see the same height size choices but they are all 72mm +/- 0.5mm.

Here's my axle bush housing:

View attachment 113139

The max is just over 68mm. Now here is the old bush:

View attachment 113138

As you can see there is no measurement near 72mm. The centre part is around 69mm and the rubber lip 80mm or 76mm.

Now the old bush has a metal outer sleeve that covers about 290 degrees. This allows some flexibility to compress.

But will 72mm compress to 68mm? What exactly are the suppliers measuring to get 72mm?
Click to expand...
First, I have no practical experience of this job myself. But I think I can recall reading here that the org bushes actually dont have a metallic but rather a plastic outer, which compresses more than expected.
Am I the only one who has seen this described here? If so I am probably shouting up the wrong tree.
How does your new bushes look if you inspect them with this in mind?
 
Yes I have just done it for the second time. (FWIW I will not be doing it again!)
both times the bushes ( first were lemforder, second time Audi) are banded by some form of plastic. A tight fit but relatively easy to fit if you have the right tools.The job is made MUCH easier if you have the axle on the bench, but this creates other problems, see my recent post about flexi pipes.
Good luck!
 
simufly said:
Yes I have just done it for the second time. (FWIW I will not be doing it again!)
both times the bushes ( first were lemforder, second time Audi) are banded by some form of plastic. A tight fit but relatively easy to fit if you have the right tools.The job is made MUCH easier if you have the axle on the bench, but this creates other problems, see my recent post about flexi pipes.
Good luck!
Click to expand...
Thanks @simufly Do you think your housing were like mine in size - i.e. your (presumably) 72mm bushes did squeeze to fit a 68mm housing?
 
Joga said:
First, I have no practical experience of this job myself. But I think I can recall reading here that the org bushes actually dont have a metallic but rather a plastic outer, which compresses more than expected.
Am I the only one who has seen this described here? If so I am probably shouting up the wrong tree.
How does your new bushes look if you inspect them with this in mind?
Click to expand...
good call @Joga - I will check tomorrow morning with a magnet!

UPDATE: Yes they are non-metal. I can see that they have melted and turned white where the housing was heated to remove the bushes. Also, not metallic.

I made a wrong assumption as I once watched a YT video where a chap removed a bush by drilling all the rubber out and then having to cut out a metal outer layer as this had fused by rust to the housing. Probably was not an A2.
 
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carlston said:
Have you looked at 6Q0501541E rear axle bushes?

Perhaps you could compare these with your old bushes to see if they have the same dimensions.
Click to expand...
Thanks @carlston for a detailed reply. As a novice I've only checked for items with the Audi A2 part number, though I'm sure others would fit.

Looking at 6Q0501541E on Autodoc the ones listed are 70 or 71mm - so a closer fit. The listings usually only give 1 photo so it is not easy to see how they match to my old ones in cross section or in the fit with the large washer. As you see below. My old bush has a protrusion at each end and the protrusion at one end fits into a recess into the washer/shim (shown with the red arrow), If the new bush does not have this protrusion (for example, the Meyle one showed) then it may not fit between the jaws of the bracket - total length becomes 99.8 and not 98mm.


A2 Bush Bracket and washer.jpg
MEYLE -ORIGINAL Quality 100 710 0008 Axle bush.jpg



My old bush. Note the protrusions both ends. The right hand end fits into the recess on the shim/washer.

old bush side view lr.jpg
 
Perhaps try OEM part number 6R0501541C from the Audi A1. Some of the aftermarket rear axle bushes sold to replace this claim to have a diameter of 69mm such as Mapco 38933 and Febi 43745 as shown below.

Mapco 38933 (sold to replace 6R0501541C)

Febi 43745 (sold to replace 6R0501541C)

6R0501541C rear axle bush (from Audi A1)
1694544658136.png

1694544671254.png

1694544688315.png

1694544708150.png


There's two listings on ebay for genuine VAG 6R0501541C rear axle bushes.
www.ebay.co.uk

2X GENUINE AUDI A1 SEAT IBIZA IV VOLKSWAGEN BORA I V REAR MOUNTING AXLE BEAM | eBay

Genuine from main dealer - see pics as in the pics. There is a picture with a part number!
www.ebay.co.uk
www.ebay.co.uk

Bonded Rubber Bush For Rear Axle VW Polo 2015 - 2018 6R0501541C New Genuine Part | eBay

Part number: Alternative part numbers / supersessions: Description This is a Applications / fitment Volkswagen Audi Skoda Seat.
www.ebay.co.uk
 
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carlston said:
Perhaps try OEM part number 6R0501541C from the Audi A1. Some of the aftermarket rear axle bushes sold to replace this claim to have a diameter of 69mm such as Mapco 38933 and Febi 43745 as shown below.

Febi 43745 (sold to replace 6R0501541C)
Click to expand...

Thanks @carlston I think I will go for the Febi above. Size and profile looks right. Thanks for finding these.

In another thread https://www.a2oc.net/community/index.php?threads/rear-axle-bushes.52643/post-527403 Phil @philward said the ride might be too hard with other bushes but then says he heard the ride with Polo bushes is acceptable. These Febi 43745 are stated as being suitable for a Polo 2009-207 SE 1.4 TDi 5 door and that weighs 1179 kg compared to 990 kg for the A2 TDi SE.

It also states the Febi 43745 is suitable for the Audi A1 1.0 TFSI, 2015-2018,95 PS and that has a kerb weight of 1,035 kg, just 45 kg more than the A2 TDi. So gut feel says it will be OK.
 
Thought I better update this thread. There has been a bit of a hiatus for various A2 and non A2 reasons.

First up was getting 2 correct handbrake cables with all the right lengths, clips etc. Got there in the end (I hope!):

SOLVED? Handbrake Cable Lengths - utterly confused!

Just received my AutoDoc delivery and realised I got mislead by a part title and ended up with 1 handbrake cable and not the pair: STARK SKCPB-1050135 Hand brake cable for AUDI A2 (8Z0) Rear, Left, Right, 1075/814mm, Drum Brake I've just measured it and its 1100mm including the nipples; 1075...
www.a2oc.net www.a2oc.net

Next was getting copper-nickel brake pipes made. Difficult to post so looked for local companies but many don't do them or want to do them for others to fit. Found a company 2+ hours drive away and spent most of the day going/waiting/returning only to find that the nuts were not DIN. See:

Still need garage to make up Kunifer brake pipes in West Wilshire

I need to sort out new rear brake pipes for my axle restore. I see many on the forum recommend Kunifer. Can anyone recommend a company within 1 hrs drive of Trowbridge Wiltshire (we're 20 mins south of Bath) that can supply and competently make these using the old as a pattern? As a safety item...
www.a2oc.net

I will have one more try in the coming week, otherwise a member here has offered to help but will requiring posting both ways - 1.5m box.

I have sprayed the drums with 4 coats of heat resistant paint. Here they are with the masking still in place:

Painted Drums still masked off lr.jpg


Then I sprayed the brake hose bracket and clips and handbrake cable clips with 2 x primer, 2x gloss and 1x heavy duty lacquer (big bracket still needs lacquer):

Painted brake hose bracket and clips lr.jpg


I also sprayed the axle and back plates with heavy duty lacquer and plan to spray the ends of the handbrake cables with the same.
 
Molasses is a mega good trick but not at this time of year. Watch what I’m doing with my AMF. You would not regret an introduction to zinc plating.
 
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Update.

I did find a classic car restorer who made some brake pipes but the flares were wrong. So I got a refund. But the brake pipes are hopefully now solved as a member here has kindly offered to make them up for me. :)

Unfortunately, I've had very bad backache for some weeks and have been hobbling about. So I've decided to put the project on hold until the spring. The A2 will be 20 years old in the summer and getting the axle restored and some paintwork issues sorted, plus fitting some accessories will be the aim to celebrate 20 years, 19 in my ownership.
 
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