Another one? The Journey of Chad.

[datsundrew]

Having never seen an OSS open, I wasn’t sure what opened and what stayed, I don’t want to glue a panel in and glue the roof shut, even if it would never open again…….but with a lot of careful encouragement, the roof sprang into action and opened!!! Result!!
I can now see how it works and can get the panel cut out carefully so as not to ruin the OSS, plus in the future I may be able to replace the panel with a replacement.

 

[datsundrew]

Oh, and whilst I was messing about, I noticed the clutch fluid was very dark, so flushed it through with new to each wheel and the clutch slave, I didn’t finish until 9.30pm!!

 

[A2Steve]

So, today I had a day on this, and I’m a bit further ahead, and then back a little, lol.
the new driveshaft and clutch arrived in the week, so today was gearbox out, new clutch and back together and new driveshaft on the NS.
the good news is the clips much lighter and smoother, the bad news is the noisy release bearing wasn’t and it’s the gearbox. A loud whirring noise at tickover with the clutch up, silent when clutch is down. Raising the revs sligh and it goes, so it’s an input shaft bearing. I’m not overly fussed about it, and it’s given me an idea. Rather than buy a standard box, I could go 6 speed in my nice A2 thats my commuter to Wales each week and use that box to replace the noisy one. I’ll think on that one.
the driveshaft I took off was really rough and jammed up when I took it off, and then somehow went very loose, all a bit weird, the grease was very old and sticky, definitely seen better days.
As a short to mid term fix, I’ve got some foamex board in 5mm on its way to make a panel to go where the broKen glass is. Chipping the glass offis a proper bas##rd of a job, and Im about 1/3 way. The glass is bonded to the rubber underneath, and the rummier to the steel under that. where the steel is rusty, the rubber comes off easily,

Replacing the whole oss cassette as one unit is a much easier job than trying to repair the one you have. Headliner down, about 6 10mm bolts at the front, 8 at the back and then 2 torx screws under the first moveable panel. It’s about 2 hours work for someone who hasn’t done it before.

I had a good working unit here until last Wednesday but it sold to a member at £150. Worth thinking about for the future.

 

[Spen]

I can strongly recommend Adam ( Kleynie ) I picked my car up Monday with a replacement roof refurb, what he does is amazing. He replaces old parts with extremely superior manufactured ones,

good luck with the project,

 

[Alan_uk]

Having never seen an OSS open, I wasn’t sure what opened and what stayed, I don’t want to glue a panel in and glue the roof shut, even if it would never open again…….but with a lot of careful encouragement, the roof sprang into action and opened!!! Result!!
I can now see how it works and can get the panel cut out carefully so as not to ruin the OSS, plus in the future I may be able to replace the panel with a replacement.

Well I never! Audi using a steel plate on an A2. That's a horrible job you're tackling. From what Steve is saying a whole OSS may be easier that a panel (which may need a whole OSS as a donor unless you can find an OSS that has another panel broken and get it dirt cheap). I hope you can find a permanent solution soonish. I'll look out for you around Trowbridge.

 

[datsundrew]

Well I never! Audi using a steel plate on an A2. That's a horrible job you're tackling. From what Steve is saying a whole OSS may be easier that a panel (which may need a whole OSS as a donor unless you can find an OSS that has another panel broken and get it dirt cheap). I hope you can find a permanent solution soonish. I'll look out for you around Trowbridge.

Yes!!! And a rusty panel at that! Horror!! So where are you based?

 

[datsundrew]

I think the long term plan will possibly be just look out for another roof, but seeing as this works at the moment, I’ll be putting a plastic panel glued in. I got the template cut today which wasn’t easy, so once the 5 mm plastic arrives I’ll get it gut and fixed. So far it looks like this:

 

[Alan_uk]

Yes!!! And a rusty panel at that! Horror!! So where are you based?

if you hover the mouse over their "icon" on the left (yours is a D as you haven't uploaded a picture) then you will see a pop-up giving the user's location and other options. If you then click on their user name then you will go to their profile page.

 

[donp38]

Can someone confirm that panel should be Fe metal?
A2Steve?

 

[datsundrew]

if you hover the mouse over their "icon" on the left (yours is a D as you haven't uploaded a picture) then you will see a pop-up giving the user's location and other options. If you then click on their user name then you will go to their profile page.

No way!! so do you have an a2? Is it a black one?

 

[Alan_uk]

Its

No way!! so do you have an a2? Is it a black one?

It's Crystal Blue TDi. Had it since 2005. Only got the one I did see a black A2 in Tesco's car park about a week ago.

 

[datsundrew]

Can someone confirm that panel should be Fe metal?
A2Steve?

Its

It's Crystal Blue TDi. Had it since 2005. Only got the one I did see a black A2 in Tesco's car park about a week ago.

Cool! So look out for this one or either of the other 2 silver ones we have

 

[datsundrew]

Update today, an afternoon on ’Chad’ the name given by the previous owners……
I rust treated the steel panel, and once dried out I did some final shaping of the plastic and stuck it on with tiger seal.
I had to get clever to try to hold it in place whilst the glue set, so gaffa taped full containers in appropriate places! I then got the wet vac out and gave the interior a big clean, and it’s come up very well, much better than I expected

 

[datsundrew]

Whilst I was in the boot with the wet vac, I noticed an extra fused wire to the battery, so traced it back to see where it went, and what I discovered is super exciting………it’s got a tow bar!!!!
I have been looking for one for my main A2 for ages with no luck, and was all set to buy one on eBay from German.
its obviously missing the swan neck, but everything else is there. A text to Cat the previous owner confirmed she knew it had one, but removed it years ago, but it may still survive on a shelf, and they will have a look……amazing!!
If not, I’m sure it’s a fairly common fitment to other cars??

 

[datsundrew]

Darlingtheyoung….you were spot on!
so having replaced the near side shaft there was a big improvement, but there was still a wobble on acceleration, today the off side shaft arrived and I replaced it, the amount of wear and slack in the inner Joint was huge- literally 1/2” sideways movemen, and the 3 rollers were very loose.
It is now totally transformed.
also I replaced the rusty rear shocks, as the old ones looked terrible.

 

[Erlingtheyounger]

Just call me Darling darling

 

[CrispyEdd]

Whilst I was in the boot with the wet vac, I noticed an extra fused wire to the battery, so traced it back to see where it went, and what I discovered is super exciting………it’s got a tow bar!!!!
I have been looking for one for my main A2 for ages with no luck, and was all set to buy one on eBay from German.
its obviously missing the swan neck, but everything else is there. A text to Cat the previous owner confirmed she knew it had one, but removed it years ago, but it may still survive on a shelf, and they will have a look……amazing!!
If not, I’m sure it’s a fairly common fitment to other cars??

That's a massive stroke of luck

 

[datsundrew]

Just call me Darling darling

Oops! Sorry about that!

 

[datsundrew]

That's a massive stroke of luck

It is, just hope they can find it

 

[nod]

It is, just hope they can find it

You can pick up replacement (second hand) towing hitches on eBay will look out the part number in a bit.. I paid around 50-60 a year or so ago. Cheers