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  1. #1
    [Dave B]'s Avatar
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    Dogbone Bush Problems!

    I've spent today doing some bits on the car, namely rear caliper return springs, some new aesthetic engine parts (covers etc) and the diesel dogbone bush.

    Everything went well apart from the dogbone bush, when trying to undo the 13mm bolts which attach the mount to the subframe, one of the bolt heads sheared clean off

    I've now aborted the job until I have new bolts, but I need some info/advice:

    1. Anybody know the part numbers for the 13mm bolts?
    2. Has anyone got any ideas how I can get the rest of the bolt out of the mount?

    At least the caliper springs went in ok (handbrake is great now) and the engine bay looks tidier....
    Last edited by [Dave B]; 6th March 2011 at 18:44.
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  3. #2
    Dani_B19's Avatar
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    Drill it out? Cant you buy a removal kit aswel?
    Driving the most secretive S3 on ASN

  4. #3
    [Dave B]'s Avatar
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    I'm not sure about drilling it out but I like the idea of a removal kit....it's google time.
    > S3 225 (03) - OEM+
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  5. #4
    3rd Gear

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    if you mean easi out, don't do it!! they snap off and they are the hardest thing to drill ever! i blunted 6 cobalt drill bits removing one once. did it snap flush? if not, mole grips and heat...

  6. #5
    s3dave's Avatar
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    Have you got the part numbers for the springs, and where to get them .....
    plenty of lube on the snapped bolt then try drilling and put a left hand screw in...or get a nice little chisel and tap away

  7. #6
    [Dave B]'s Avatar
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    Quote Originally Posted by steve bain View Post
    if you mean easi out, don't do it!! they snap off and they are the hardest thing to drill ever! i blunted 6 cobalt drill bits removing one once. did it snap flush? if not, mole grips and heat...
    It snapped flush to the dogbone mount so if I can get the mount off over what remains of the bolt then I might have something to play with. I'm not going to try until I have the new bolts though.

    Quote Originally Posted by s3dave View Post
    Have you got the part numbers for the springs, and where to get them .....
    plenty of lube on the snapped bolt then try drilling and put a left hand screw in...or get a nice little chisel and tap away
    The part numbers for the springs are 7M0 615 295 and 7M0 615 296. I got them from Stoke Audi off here, they were about Ł4 delivered, well worth it IMO. Dead easy to fit too, info here mk4 golf rear caliper - modification to help unstick handbrake - Club GTI
    > S3 225 (03) - OEM+
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  8. #7
    [Dave B]'s Avatar
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    Ok, I've had a look on vagcat and it looks like the 13mm bolts are part number N10268302...
    > S3 225 (03) - OEM+
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  9. #8
    Reverse Gear

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    just done my clutch this weekend and both my bolts snapped flush,any way a bit of heat and plenty of hammering got the mount off. The bolts were corroded into the aluminium mount and once that was off the remaining bits of bolt were only finger tight in the subframe, hope this helps

  10. #9
    Westy's Avatar
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    A 5 min job never always ends up being a 5 min job does it. That's some rotten luck there fella, hope you get it sorted soon.
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  11. #10
    wibble111's Avatar
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    Only way to remove the snapped bolt is to drill it and use some stud extractors to remove it, unless you get lucky and manage to get a small tipped cold chisel in there and try to 'unscrew' it by hitting it with a hammer, get some of these mate worth every penny IMO.

    Stud/Screw Extractor Set in Metal Box on eBay (end time 15-Mar-11 15:13:21 GMT)
    Last edited by wibble111; 6th March 2011 at 21:34.

  12. #11
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    I have done 3 of these, all snapped, the only way to remove the dog bone is to pry it off the snapped bolt, the thread into the subframe will be fine. Its the bolt to dog bone that seizes up.

    Don't drill it out!!!!

    Just take your take and keep levering away at the dog bone from the subframe, When you replace the bolt make sure to copper slip the new bolts up....
    Black S3

  13. #12
    Welly's Avatar
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    Quote Originally Posted by steve bain View Post
    if you mean easi out, don't do it!! they snap off and they are the hardest thing to drill ever! i blunted 6 cobalt drill bits removing one once. did it snap flush? if not, mole grips and heat...
    Molegrips, or 2 suitable nuts. Wind one nut on a bit, then wind the second one up tight to it. Then use a spanner on the first nut you wound on. It will clamp up to the second nut and becomes a make shift bolt head.

    A fantastic method for removing snapped studs - combined with lots of WD40 and possibly some blowtorch action.
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  14. #13
    [Dave B]'s Avatar
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    Thanks for the input people, this is why I frequent this forum

    I'm hoping the remainder of the bolt will come out when the dogbone mount is removed but if it doesn't I like the two nuts idea....many thanks Welly!
    > S3 225 (03) - OEM+
    > 205 GTI (90) - Limited Edition Miami Blue with full leather - 1 of only 300 made
    > Clio v6 255 (05) - Lethal Weapon

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  15. #14
    Welly's Avatar
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    Quote Originally Posted by Funky_Junky View Post
    Thanks for the input people, this is why I frequent this forum

    I'm hoping the remainder of the bolt will come out when the dogbone mount is removed but if it doesn't I like the two nuts idea....many thanks Welly!
    No probs dude - works a charm normally. Thats exactly how I wound the two snapped bolts out of my turbo - and they were in there big time!
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  16. #15
    mk1chopper's Avatar
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    Same thing happened to me this weekend, one bolt sheared off, the second one didnt but the dog bone mount crack and split off around the bolt. I just phoned bedford audi, part no. for bolt I was given is N10268304 62p each. Also part no for dog bone mount is 1J0199851R Ł46.55 so not as expensive as I was made to believe, although i just got one of ebay for a fiver . Mines going into TTS on friday for a service and removal of the bloody bolt.
    Last edited by mk1chopper; 7th March 2011 at 14:21.

  17. #16
    [Dave B]'s Avatar
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    Wooohooo it's done!!!

    The dogbone eventually came of the subframe by using the following techniques:

    - smacking the mount with a hammer
    - levering the mount away from the subframe with a screwdriver
    - applying WD40
    - applying heat via blow torch (obviously not at the same time as the WD40)

    I managed to get what remained of the bolt out by using Welly's two nut process, so thanks again welly.

    It's all refitted so all that's left to do is drive it....thankfully.....
    > S3 225 (03) - OEM+
    > 205 GTI (90) - Limited Edition Miami Blue with full leather - 1 of only 300 made
    > Clio v6 255 (05) - Lethal Weapon

    View: My S3 diary

  18. #17
    mk1chopper's Avatar
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    Result, had mine sorted today, hasnt made any difference to my gear change, guess the syncros are just worn on 1st and 2nd, but the engine seems smoother, was only charged 1/2 hours labour too which was a result, great service from TTS once again :-)

  19. #18
    Westy's Avatar
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    Excellent news. Welcome to the cabin vibration club
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  20. #19
    [Dave B]'s Avatar
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    Quote Originally Posted by Westle View Post
    Excellent news. Welcome to the cabin vibration club
    Don't say that you b@stard!

    I'm hoping it's vibration free otherwise its coming off!
    > S3 225 (03) - OEM+
    > 205 GTI (90) - Limited Edition Miami Blue with full leather - 1 of only 300 made
    > Clio v6 255 (05) - Lethal Weapon

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  21. #20
    Westy's Avatar
    Double Dark Side! Diesel & 8P

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    Quote Originally Posted by Funky_Junky View Post
    Don't say that you b@stard!

    I'm hoping it's vibration free otherwise its coming off!
    haha. I'm hoping mine will settle down but I'm going to check I torqued up the bolts correctly tonight.
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  22. #21
    mk1chopper's Avatar
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    Quote Originally Posted by Westle View Post
    haha. I'm hoping mine will settle down but I'm going to check I torqued up the bolts correctly tonight.
    did you fit the red or yellow one?

  23. #22
    s3dave's Avatar
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    Quote Originally Posted by Westle View Post
    Excellent news. Welcome to the cabin vibration club
    I must remember to take the yellow bush off my car,,,,, will feel as smooth as fook with a red one on

  24. #23
    Imteyaz's Avatar
    6th Gear

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    Quote Originally Posted by mk1chopper View Post
    Result, had mine sorted today, hasnt made any difference to my gear change, guess the syncros are just worn on 1st and 2nd, but the engine seems smoother, was only charged 1/2 hours labour too which was a result, great service from TTS once again :-)
    Have you tried setting the linkages up correctly?

    (Youtoob linky: YouTube - Volkswagen Group Shift Linkage Adjustment for year models 2000-2010). I
    had notchy gears until I tried this and it's nice and slick now.
    Imteyaz.

  25. #24
    mk1chopper's Avatar
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    Nice one will give that a go later

 

 

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