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Re: BB's TT

Posted: Sun Sep 20, 2020 6:40 pm
by BrianB
Mid August my air conditioning decided to stop working on the drive back from East Midlands Airport, it was fine until I came off the A50 to pick up the M6 and at that point I realised to it was no longer blowing cold air from the vents.
After some research I found that the clutch on the end of the ac compressor was not engaging and in addition the large cooling fan was not running when ac was selected on. Gaining access to remove the fan required the removal of the lower intercooler pipe and although the fans themselves aren’t to difficult to remove disconnecting the plugs proved a bit tricky but as with most things having done it once it would be easier the second time around. Once the small fan was removed I could then move the large fan across to where the small fan was and then down and out.

Re: BB's TT

Posted: Sun Sep 20, 2020 6:49 pm
by BrianB
Installation of the new fan was the reverse of removal. I also decided to change the fan control module which is underneath the battery tray given that it’s coming up to 18 years old and it contains relays associated with the operation of the fans.

Re: BB's TT

Posted: Mon Sep 21, 2020 6:26 pm
by BrianB
Getting better access to the ac compressor required the removal of the metal plate that attaches to the inlet manifold and supports the oil dipstick. While it was off I decided that this would be a good opportunity to send it off to be powder coated along with the lower intercooler connecting pipe.
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They both came back looking a lot better than when they were removed.
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Re: BB's TT

Posted: Mon Sep 21, 2020 6:42 pm
by BrianB
The clutch on the ac compressor can be replaced but since the whole assembly is coming up to 18 years old I found what I believe is a NOS genuine Sanden compressor on eBay, so bit the bullet and ordered it along with some new o rings and a drier from TPS.
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Removing the old compressor required the removal of the small fan again in order to get enough leverage on the bolts holding the two refrigerant lines onto the back of the compressor, taking the tension off the auxiliary belt and removing the two mounting bolts and disconnecting the plug.
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Re: BB's TT

Posted: Tue Sep 29, 2020 6:53 am
by BrianB
One thing I wasn’t aware of is the spacer on the top mounting bolt, so something to remember to look out for if anyone else changes their compressor.
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Drier replaced, a bit fiddly but better with the small fan removed.
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New compressor installed.
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Re: BB's TT

Posted: Wed Oct 14, 2020 9:04 pm
by BrianB
Next project hopefully to get started in a couple of weeks is to replace the upper and lower rear control arms and the rear diff support.
Had all the new and refurbished parts out to check I wasn’t missing anything.

Re: BB's TT

Posted: Wed Oct 14, 2020 10:08 pm
by AK47
Cor! They all look nice BrianB. I’m in the process of replacing all discs, pads, flexis and fluid on mine. All my control arms don’t look as good as these. Did you get new or refurb control arms?

Re: BB's TT

Posted: Fri Oct 16, 2020 7:01 pm
by BrianB
AK47 wrote:
Wed Oct 14, 2020 10:08 pm
Cor! They all look nice BrianB. I’m in the process of replacing all discs, pads, flexis and fluid on mine. All my control arms don’t look as good as these. Did you get new or refurb control arms?

The upper control arms are new from TPS, I just had them powder coated for an additional layer of protection.
The lower adjustable Forge arms are new but were free of charge from Forge as the ones I had fitted in 2016 are in my opinion quite badly corroded for their age and Forge agreed to replace them.

The rear diff support was second hand, I cleaned it up, had it powder coated and then put in new bushes.
All attaching parts are new.

Re: BB's TT

Posted: Sun Nov 08, 2020 9:27 am
by BrianB
A couple of weeks ago I started the process of changing the rear control arms and differential support, left and right upper and lower arms have now been removed. To remove the upper control arm inner bolt requires the removal of the rear subframe bolt which will have to be replaced as these are one time use bolts as are the control arm attaching bolts.
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The rear diff support has also been removed after a slight delay waiting for a low profile 1/2 inch drive m14 spline bit due to limited access to the bolts that attach the diff support to the subframe.
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Re: BB's TT

Posted: Sun Nov 15, 2020 9:28 am
by BrianB
Over the last week I have cleaned up some of the accessible areas of the rear subframe while the suspension parts have been off giving them a sanding followed by treating with Bilt Hamber Hydrate 80 and then a top coat of Eastwoods Extreme Chassis Black.
I then reinstalled the rear diff support and upper and lower track control arms.