Required bolts for a suspension refresh

R

Robin_Cox

Member
Later this month I'm getting the top strut bearings, shocks and drop links replaced. Ever since I've picked up the car last September (2004 1.4Tdi 75) the drivers' side TSB has been grumbling gently so I've decided to bite the bullet and do the lot in the run up to the MOT. I've got Febi TSBs, Bilstein B4s, and Lemforder drop links already in the parts pile. Have been considering TRW steering arms (1140 / 1141) if the existing pressed metal ones need it but I'm hoping to get by without this time. The springs still look brand new (there was an MOT fail 2 years ago for the nearside spring being incomplete so it looks as if they were both replaced then) so I'm hoping that these can be taken out and put back in with the new stuff.

Are there any other parts that are important in this process - roll bar bushings / dust covers / bellows etc that are essential but not otherwise included?

reading https://www.a2oc.net/community/index.php?threads/the-definitive-suspension-parts-list.27044/ and the linked-to thread on A2-freun, I noted that in post 1 Timmus lists a bunch of bolts / nuts for assembly (it isn't clear which are for the front and which are for the rear) - and on the German thread, there is considerable discussion of the need of getting the right bolt set because they are single use "stretchable" bolts (this is my interpretation of the word but I assume that the metal is malleable) that appear to get distorted as part of the assembly process? I assume therefore that these are imperative.

Where do we get these from - is there a one-off kit with everything in or do we get them one by one from TPS using the numbers in Timmus' list?

many thanks, Robin
 
Hi Robin,

Yes, knowing which are front and back parts in Tom's(Timmus) list would be useful.

All I can suggest is to inspect the parts diagrams for front and rear suspension and tick off which is which.

To get you started here is the rear.

https://audi.7zap.com/en/rdw/audi+a2/a2/2004-248/5/511-511010/

When you have finished send the list to Tom who I am sure will be happy to group his list into front or rear, or post it here for the benifit of everyone.

Andy
 
good point - thank you! I also need to work out which ones are required if one isn't replacing the arm. When I was changing over onto my summer wheels yesterday I had a good look at the pressed arms and apart from small bits of surface corrosion they don't look bad - certainly nothing like the horror-show photos that others have posted here recently.
 
After a lot of reading and looking at the exploded parts diagrams (for all A2 models, not just 2004 1.4tdi) and online parts places, I have come up with the following - I will happily accept any suggestions of corrections or amendments as I am a non-expert. Some of the part numbers on the exploded diagrams have been replaced by updated versions, which explains why the part numbers cited on the diagrams do not correspond obviously to the ones listed either on oemepc or 7zap.

http://www.oemepc.com/audi/part_sin.../407/subcategory/407011/part_id/265885/lang/e

Divided into front and rear :
Front.
N 102 078 04 – Bolt (x4) -M12x78 pinch bolts, front shock absorber to wheelbearing housing. paired with N10106402 nut. vagbolts (ebay) supply the pair for ~6.85, vwspares have the bolts and nuts separate slightly cheaper. Items 19 and 20 on above diagram, N10207804 has replaced p/n N10207803.
N 019 530 8 – Bolt (x6) - M8x25 appear to be front top strut bearing securing bolts (?supplied with Febi TSB kit?). replaces p/n N0195303
WHT 005 480 – Bolt (x4) - ARB bush bracket, sets of 4 around £5.50-£6 from various Ebay sellers. WHT005480 replaces p/n N10138902
N 909 081 02 – Nut (x2) - M10x1.5 secures drop link to shock absorber. ? supplied with Lemforder drop link? replaces p/n N90908101
N 104 018 01 – Nut (x2) - M14x1.5 top of front shock absorber rod, supplied with shock (Bilstein B4)
N 101 064 02 – Nut (x4) - M12x1.5 locking nut, paired with N10207804. (aka Febi 14392). front shock pinch bolt.
N 102 613 10 - Nut (x2) - M10x1.5 secures drop link to ARB. (aka Febi 30155). ? supplied with Lemforder drop link? replaces p/n N10261302

Rear.
N 905 173 04 – Bolt (x2) - M10x75x45 - cited on vwspares.co.uk as being for rear shock. Replaces p/n N90517302.
N 906 484 02 – Bolt (x4) - M10x35, appears to secure rear top mount bracket in place in various VAG cars. Replaces p/n N90648401.
N 102 861 10 - Nut (x2) - M10, (aka Febi 22263). Paired with N90517304, secures bottom end of rear shock. replaces p/n N10286102

I can't right now work out why there are 4 N10207804/N10106402 combinations listed as there is only 1 used on each shock to wheelbearing clamp on the diagram suggesting that 2 are needed in total for the front. It doesn't seem to feature on the rear. Any thoughts?
 
Robin_Cox said:
Rear.
N 905 173 04 – Bolt (x2) - M10x75x45 - cited on vwspares.co.uk as being for rear shock. Replaces p/n N90517302.
N 906 484 02 – Bolt (x4) - M10x35, appears to secure rear top mount bracket in place in various VAG cars. Replaces p/n N90648401.
N 102 861 10 - Nut (x2) - M10, (aka Febi 22263). Paired with N90517304, secures bottom end of rear shock. replaces p/n N10286102
Click to expand...
Thanks for putting this list together - seems like a good price https://www.ebay.co.uk/itm/173343051674 (these are for one side only)
 
This is a very timely thread. Having just done the rear of my 1.4 AUA I had the front wheels off to have a good look and was thinking I should probably tackle the front. I found a supplier on the bay that supplies a complete Febi top mount kit including the 3 bolts that secure it and the stretch nut/bolt for the bottom but there plenty of others it seems. I took loads of photos and am currently matching part numbers to the diagram but haven’t finished or double checked yet

A15C366C-89F1-44C3-8B58-332743927B91.jpeg
 
I don't believe these are single use stretch bolts. I just reuse them with new high tensile locking nuts, been doing that for 170k miles. I believe they are standard 10.9 grade bolts..
This confirmed it for me. My Golf has the same 10.9 grade bolt at the bottom of the rear shocker as the A2. Golf torque 70 Nm reusable, A2 55 Nm (I think) renew. If it doesn't stretch on the Golf it won't on the A2.
Edit, scroll down to the section on buying new or reusing fasteners, https://www.a2oc.net/community/index.php?threads/how-to-repair-restore-your-audi-a2-rear-axle.44808/
 
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