80k Mile Repair Items - '02 A6 4.2

[CAL4.2]

Hi All,

I've had my '02 A6 4.2 for almost 2 years now and replaced the following:

-Oil changes using Mobil 1 0W-40 and Mann filter
-Fuel filter
-Air filter
-Cabin filter
-Coolant reservoir
-Timing belt, water pump, tensioner, coolant sensor
-Plugs and coil packs
-Transmission fluid/filter change
-Brake fluid
-Front brake pads

My independent shop did a courtesy inspection and found the following at 77k miles:

-Valve cover gasket leak
-Power steering leak / dark fluid (last changed at 41k)
-Control arm bushing failure
-Sway bar bushing failure
-Engine mount failure
-Suspected oil cooler pipe leak
-Serpentine belt cracking

Any insights on which replacement parts I should use or avoid for the items above? I'm leaning toward the Meyle HD control arms and I know there is an aluminium oil cooler pipe that can be used. Should I go with the RS4 part by HT for the engine mounts?

Any other thoughts, and are these all pretty common items from your experience to be going bad at this mileage?

Thanks!
Wade

[02 A6 2.7T]

The aluminum oil cooler pipe is available here (http://www.gruvenparts.com/4-2l-audi-vw-billet-oil-cooler-tube/).
There are some additional gaskets required for the job, Audi p/n 077198405 (http://www.audiusaparts.com/oe-audi/077198405).

[rollerton]

The engine mount failure is almost guaranteed to be the torque mount- it's on teh right hand front side of the engine. Behind passenger side headlight.
Unless the valve covers are leaking and causing an issue I'd skip them and do them with cam chain seals...I'd venture to say that ANY shop that did a once-over on an Audi would proclaim the valve covers to be leaking. They will 'appear' to be leaking even after replacing them due to the nature of the design.
The oil cooler pipe is a thing to do if it's leaking- but don't let them screw you on it. It's a 5-6hour job average unless they screw something up (strip bolts etc), but many shops cash in on it and might charge a whole day.
Power steering leak? I'd demand more specifics- unless the rack has a bad seal it's typically a couple hose clamps that seep.

Just be careful, that list can EASILY add up to more than the car is worth.

[CAL4.2]

Thanks 02 A6 2.7T and Rollerton.

Below are my estimates on costs for all this with labor:

-Valve cover gasket leak - driver side only $275
-Power steering leak / dark fluid (last changed at 41k) - If it needs new washers / re tightening, $50
-Control arm bushing failure - $599 for arms, $600 for Bilstein shocks, 3.5 hours install + alignment =$1,600
-Sway bar bushing failure - $50
-Engine mount failure - $200
-Suspected oil cooler pipe leak $550
-Serpentine belt cracking - $75
Total estimate = $2,800 before tax.

Sound about right for an indy shop at ~$100 an hour? i'm still waiting for them to provide a comprehensive estimate and will share it when I get it back.

[carmudgeon]

The quote I got to do my valve covers was almost $1000 for both sides. And that was with a labor rate of $95 an hour. I did them myself, the center gaskets around the spark plugs are a PITA and require a lot of labor to clean them up.

[CAL4.2]

This next repair bill is going to hurt, but I absolutely love this car [az]

[CAL4.2]

Ok, here's the list of things I'll be doing for the 1st of 2 repair visits:

-Oil cooler pipe (Shop is ordering the Aluminum one from Gruvenparts)
-Front upper/lower control arm bushings (Meyle HD)
-Front swaybar bushings
-CV boots
-Front engine mount

Total - $2,478

I'm going to have him add front Bilstein HD shocks while he's at it which should add another $400.

Lower Control Arm Bushing Ex.
http://i44.photobucket.com/albums/f11/wademstout/31AF1D95-CB1A-4275-96DC-51141645C808_zps04erxwtq.png

Swaybar Link
http://i44.photobucket.com/albums/f11/wademstout/B8759E74-3429-4CA7-A408-D397788F86BE_zpsem3zpsz2.png

Upper Control Arm
http://i44.photobucket.com/albums/f11/wademstout/DD646B14-AB2F-4101-934E-89788A609310_zpsqskjtvpx.png

CV Boot
http://i44.photobucket.com/albums/f11/wademstout/CA055674-B529-4762-84D2-0F5F28DC7D93_zpsrnhr1cxo.png

[rollerton]

Another reminder why I am forced to do all my own work. Thats...$625 in parts (marked up retail) and around $2k in labor? I'd do it for 1/3 of that price...I hope it is a great shop.
[up]

[CAL4.2]

Hah, couldn't agree more, but dont have the time with a toddler at home. Oil changes and filter changes are about the only things I can negotiate enough time to do myself for the time being.

The Indy shop is run by a former Audi Master tech who warranties all work so I know I'm in good hands.

[CAL4.2]

In the meantime, fresh oil for the the new year! While I had the belly pan off, it looks like the front swaybar end links and bushings would be a 30 min job DIY, so i'll have my shop take that off the list and save some $. Parts on that can be had for $36 on Rockauto.
http://i44.photobucket.com/albums/f11/wademstout/IMG_1608_zps1zsrvh5t.jpg

[carmudgeon]

I love those ramps.

[CAL4.2]

I went with Mevotech front swaybar links and URO front swaybar bushings for a total of $37.00 shipped from RockAuto.com. Installed in 1 hour and made a nice difference in steering feel.

http://i44.photobucket.com/albums/f11/wademstout/IMG_16431_zpskkpsknsf.jpg
http://i44.photobucket.com/albums/f11/wademstout/IMG_16441_zps3zkn34ar.jpg
http://i44.photobucket.com/albums/f11/wademstout/IMG_16451_zpsuvyh3ola.jpg
https://lh3.googleusercontent.com/Tgr9K5QiTCmArvoUtbjhEE7Fzp-NXUEPCvNrp4JBXXGgiJfRZItrGbUT8TUolByWX3sf8RBncPy2G 8Gm2rTDr7mUo6rUq3r3iHBJvsrCrIpepVkEza45ji8zYe3CLuf QL0hTLhl0b27Vcohqqo_e3dwpU2yQW3XhMNkIk_nLR6b5Zf-9PC5TjiOhlTjLeYfRGXGOfJk4KJ2yTkg-2jDtscW3raR5qgr9UYmzKcSvR2EpAcw5XVPXUJwcZysEny_T8q HYGLONQPE3tK8bFKtP4hXGVeXIM5_9UWM38Lw17PWu0GIeQ2ie uHGsKfhor12SRL_VUmZL238Ah0bxLE6t10bmUkjBcP2vaIeAga 0bSw3t4k3XxhfeHpnU8eYVKkxikOJenYe8HQzBogUqw5Y7D11U R0Ieuv7lb6E_Yt9mWfLz-QwLEvD61-dBJIOUY9H1ACzBFaa2YI5ADysnvG1STtkzrzeP4Ns9pPj4VwER F1xeaBpdo6xMVyl12I1W3sD1bHna7N0RJpCq2s_AFGtWse2ANx 8zNJoA_oBatI2bdWVYDCS1viTUPTYAsgf60AX0Vv-7=w1287-h965-no

However, pulled the engine cover and noticed my intake linkage arms are done... Gruvenparts arms should be here tomorrow :)
http://i44.photobucket.com/albums/f11/wademstout/IMG_16191_zpsrl0mcvpa.jpg

[CAL4.2]

Gruvenparts linkage arms are in. A channel lock style wrench makes this job much faster - I tore up my fingers trying to snap on the new arms. The car definitely feels stronger at high rpm now.

https://lh3.googleusercontent.com/5pPr016OR_CALkcNwDELKjcf6w21Aa-nNA15O_truQXtMvGVXNylqOb2xz1H3tADeP7NWytldDZpEn49h Na0_iGowZDbjlhvUV3xejul8fy2s3ZExiXpPM0FcTurV3V-J_mB2T6ZdrvY-Sny31HFoqqONKQWFuZXVFam6aOdPi0G7JjVlO1MrtOfnThMT4S Rdag8-PQUX8iB_8i6x1Qbwn73SXOL7_GQQA_XsvL-Ttog5R3Xlp9jHKSyaRljG3aRWvd3DLoNZ0dYRqqQ_i8bkKazG9 FnQN5V47mhhf7s7rWpf_bCHwRwTFo-DHE13krCVb_jn1VtNWqiIaXnQBoz9XpN266qcDQ6A3gnXq6rXE 3sNLb3VZ8YfwXn3JAHWHmrbR1P74oAxVH_Nf0OqkAXz1XmY7MG m6hRCMXQhG9Ik876hNOdw3SLju5KIExEXi5kktjkhauesc4JXF dYf040NMbi3BXLZm-3j_nhOyiqDVPV8Mxud-0Th083FzYNuzLBUIrEAjjNW6dHDRvSlzGEZed_ByyromYwrKDg aobU2alKEaP8JqA0jWPTbi7b15vDXiBI=w700-h933-no

And installed:
http://i44.photobucket.com/albums/f11/wademstout/IMG_1648_zps2tfshy8t.jpg

[AllroadMass]

I can't believe that's how much shops are charging for control arms. Is that for all 4? The 2 upper and 2 lowers???

" -Control arm bushing failure - $599 for arms, $600 for Bilstein shocks, 3.5 hours install + alignment =$1,600"

[CAL4.2]

I can't believe that's how much shops are charging for control arms. Is that for all 4? The 2 upper and 2 lowers???

" -Control arm bushing failure - $599 for arms, $600 for Bilstein shocks, 3.5 hours install + alignment =$1,600"

If you read my post those were actually just my own initial estimates.

Actual quote for Upper and lower front CA bushings came in at $1,050.50 installed. I'm still waiting on a quote for just front Bilstein HD struts - decided I'll do the rear shocks another time myself to keep the costs down on this hog. Below are actual estimates from the shop for my appt in 2 weeks.

-Gruvenparts Aluminum oil cooler pipe - $663.65
-Front upper/lower control arm bushings (Meyle HD) - $1,050.50
-CV boots - $449
-Front engine mount - $138.65
-Front Bilstein HD Struts - $TBD
Total With Labor (so far) - $2,301.80

Saving the power steering leak, VCGs, accessory belt, and rear shocks for next year.

[AllroadMass]

I'm sorry but I'm a little slow on fridays. When you say front, do you mean both sides or just one side?

[CAL4.2]

I'm sorry but I'm a little slow on fridays. When you say front, do you mean both sides or just one side?

Upper and lower CA bushings left and right. He's re-using the OEM arms and throwing Meyle HD bushings in.

[AllroadMass]

Upper and lower CA bushings left and right. He's re-using the OEM arms and throwing Meyle HD bushings in.

https://www.fcpeuro.com/Audi-parts/A6-Quattro/Control-Arm-Bushing?year=2002&e=985&m=20&page=1

Bushings are 10s of dollars and you're paying for an arm and a leg in labor. They're charging you labor to take off the arm and press in a new bushing. You can take the arms off yourself with some wrenches and take it to a machine shop to have them press in the bushings for like $40 bucks. For the price that you're paying, why don't you just put in new arms everywhere? I replaced my wife's right side ( both uppers and both lowers with lemforder arms) for $300 bucks.

When I rebuilt the front end of my Passat, it's my driving school car and the kids trash this thing. Curbs, pot holes, you name it, we've gone in it/through it. I couldn't get the pinch bolt to move from all the rust here in MA so I ended up buying a used knuckle for 88 on Ebay and works great. You're in CA so your pinch bolt on the A6 should slide in and out like butter. You'll need to get the pinch bolt off to remove the upper control arms.

You can take off the lower rear control arms off in about 20 minutes with 2 wrenches and a pickle fork. I just don't want to see you spend $1k for new bushings, that's crazy! I can even write up something for you to use while taking off the arms.

[CAL4.2]

Thanks ARMass, definitely warrants me getting more details on his proposed install plan as I agree 7-8ish hours labor sounds like a lot. He did say replacing bushings would save me money over buying a complete arm set but I'll confirm again. I'd love to DIY the whole thing but having a full time job + 18 month old at home limits my projects to 2 hours max most of the time.

[AllroadMass]

I swear they all say that! DIY would be your best bet. Why don't we start with something easy like the lower rear arms. The link below is for the lower left side (driver side) but the right side should cost similar. - https://www.fcpeuro.com/Audi-parts/A6-Quattro/Control-Arm?year=2002&e=985&m=20&page=1&position=Front-Left-Lower-Rear

I own 2 driving schools, I have an 8 year old daughter with Cerebral palsy, and a 3 year old son with Autism. If I can do it, you can do it too! You should be spending your hard-earned money on the wife and kid or accessories for your audi. I have a wicked easy day on Tuesday so I will write up something for you and also take pictures of everything.


Removal - Jack car up, wheel off, lower link of the sway bar bushing off, remove nut from lower CA ball joint, remove bushing mounting bolt, move suspension forward to free control arm from sub-frame, pickle fork the CA ball joint from the knuckle.

Install - Mount new CA bushing into sub-frame (do not tighten), feed ball joint into knuckle and hand tighten nut, install lower link of the sway bar bushing, torque CA ball joint. Put jack stand under rotor hat to preload the suspension. Torque CA bushing.

[CAL4.2]

Thanks AllroadMass! I truly admire you managing a small business, having two children, and making time for yourself to do some wrenching.

By the way, how do you like the BMW 550i? How's the build quality and reliability so far compared to the Allroad? That car was on my consideration list before purchasing the A6, but ended up with the Audi due to finding a deal I couldn't pass up.

[CAL4.2]

Thought I'd share what satin black trim wrap looks like around the windows - I was getting tired of looking at the clouded brushed aluminum trim.

http://i44.photobucket.com/albums/f11/wademstout/IMG_1802_zpspfez2q0l.jpg

http://i44.photobucket.com/albums/f11/wademstout/IMG_1804_zpslhv1yorv.jpg

http://i44.photobucket.com/albums/f11/wademstout/IMG_1803_edit_zpss8zyc1yf.jpg

[CAL4.2]

Just completed 2 more DIY repairs:

1. Vacuum hose replacement w/ new t connectors and valve:
http://i44.photobucket.com/albums/f11/wademstout/IMG_1810_edit_zpswj4pyxkn.jpg

http://i44.photobucket.com/albums/f11/wademstout/IMG_1809_zps4omqs08u.jpg

Gave the engine a rinse and shined up the engine covers while i was at it:
http://i44.photobucket.com/albums/f11/wademstout/IMG_1811_zps1jm8qwlk.jpg

2. Replaced fogged up driver's side mirror

[Kaane]

pics dont work

[CAL4.2]

Just added Serpentine Belt, Fan Clutch, and Electric Fan to the list last week (now at 85,160).

[AllroadMass]

Just added Serpentine Belt, Fan Clutch, and Electric Fan to the list last week (now at 85,160).
Get those pics working! Can't wait to see it

Sent from my Nexus 7 using Audizine mobile app (http://r.tapatalk.com/byo?rid=87676)

[CAL4.2]

Just migrated the pics over to photobucket. They should be visible now :)

[AllroadMass]

I'm doing the same satin black trim on my wife's allroad. What did you use? I bought some automotive tape from Amazon and looks pretty good. Nice job on yours! How long have you had it on?

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[CAL4.2]

I used Avery vinyl wrap. It's been on for about 4 months now. Some areas have required some re-working. The trimbrite blackout tape from Pep Boys works well too and is pretty cheap.

[AllroadMass]

Good deal. Btw love your wheels and brakes!

Sent from my Nexus 7 using Audizine mobile app (http://r.tapatalk.com/byo?rid=87676)

[CAL4.2]

Good deal. Btw love your wheels and brakes!

Sent from my Nexus 7 using Audizine mobile app (http://r.tapatalk.com/byo?rid=87676)

Thanks, I love these brakes, but I'm not looking forward to the cost of new front rotors.. already had these resurfaced once..

[CAL4.2]

Just ordered Posiquiet ceramic rear pads from RockAuto.com ($28 shipped) and Bilstein B4 rear replacement shocks from FCPEuro.com. Those will be installed with new Lemfoerder rear swaybar end links. I can't find the rear swaybar bushings anywhere for the 4.2 size rear swaybar.

[CAL4.2]

Can't wait to get these rear shocks in. The original sport shocks are blown.

http://i44.photobucket.com/albums/f11/wademstout/IMG_2020_zps7shqc4ym.jpg

http://i44.photobucket.com/albums/f11/wademstout/80b82f49-0434-4aab-8335-501a2ce4aab7_zpsg26seosj.jpg

[CAL4.2]

Another DIY oil change (Hit 90k miles!)... and another problem.. ABS Module failed on the way home from work yesterday. I'm checking with a local shop "Module Repair Pros" how much it would cost to repair. If it's too much, I'll hit up Module Masters.

http://i44.photobucket.com/albums/f11/wademstout/oil%20change_zpsm11pjbrr.jpg

[rollerton]

ABS Module failed on the way home from work yesterday. I'm checking with a local shop "Module Repair Pros" how much it would cost to repair. If it's too much, I'll hit up Module Masters.

I have an intermittent ABS module failure and after browsing everywhere I can think of the cheapest place I have found for repairing it is in Colorado. They charge $50 + shipping. 2nd was on Ebay, at around $100.
I can dig up the info for the place in Co. if you want. I actually have a spare ABS module sitting in a box that I was about mail off...but the error cleared and hasn't come back in almost 2 months.
Seems like just having a spare fixed it!

[CAL4.2]

Must be the magic of having a spare :)

The place down the street from my house "Module Repair Pros" said it would be $149 if I have the Bosch unit or $99 if I have the non-Bosch unit.. I'm pretty relieved considering the new part is >$1,000.

[CAL4.2]

I checked under the car for a clicking noise and see my passenger ABS sensor wiring harness somehow got wrapped around the front axle (getting destroyed), and tore through the inner CV boot...

Good news is the sensor is only $25 and my ABS module is likely not fried.. Zip tie is holding the CV boot together at the moment.. Never a dull moment.

[JediJoker7169]

Nice 2B front brakes. 350mm?

[CAL4.2]

Nice 2B front brakes. 350mm?
Yes sir.

[JediJoker7169]

Nice 2B front brakes. 350mm?
Yes sir.
They fit under those RS6 wheels with no spacers? What wheels are they, specifically?

[CAL4.2]

They fit under those RS6 wheels with no spacers? What wheels are they, specifically?

No spacers needed. They are 18x8 ET35 Alzor RS6 Replicas from ecstuning.com.

[CAL4.2]

I decided to try paining my slightly rusted chrome stud ends rather than buying new ones. It was $8 for VHT Caliper paint, so I figured I'd give it a try. I saw this idea on a Porsche forum.

I'll post pics once they are done and on the car... and yes, I don't expect the paint to stay perfect given installation at ~80 lbs / ft.
http://i44.photobucket.com/albums/f11/wademstout/lugs_zpss3ye7m2o.jpg?t=1481045384

[JediJoker7169]

...and yes, I don't expect the paint to stay perfect given installation at ~80 lbs / ft.
80? I believe spec is 88.5.


Sent from my iPhone using Audizine (https://siteowners.tapatalk.com/byo/displayAndDownloadByoApp?rid=87676)

[CAL4.2]

Yeah, I mentioned ~80 since I hadn't looked up the spec recently. Thanks.

[AllroadMass]

I decided to try paining my slightly rusted chrome stud ends rather than buying new ones. It was $8 for VHT Caliper paint, so I figured I'd give it a try. I saw this idea on a Porsche forum.

I'll post pics once they are done and on the car... and yes, I don't expect the paint to stay perfect given installation at ~80 lbs / ft.
http://i44.photobucket.com/albums/f11/wademstout/lugs_zpss3ye7m2o.jpg?t=1481045384
Looks sharp! Nice work

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[CAL4.2]

Update - Last month the car got new valve cover gaskets and cam chain seals.

And now, new 350mm 2bennett rotor rings and Centric front pads going are on this week.. Old pads were less than 1mm and rotors wore the slots off! Now if I can only get the front calipers loose..
http://i44.photobucket.com/albums/f11/wademstout/IMG_2266_zpszjagqd9l.jpg?t=1491848624

[CAL4.2]

And I finally got everything put back together..

http://i44.photobucket.com/albums/f11/wademstout/installed_zpsyhs1cugt.jpg?t=1492465486

http://i44.photobucket.com/albums/f11/wademstout/close%20rotor_zpsyv6lkpub.jpg?t=1492465488

By the way, I'm looking to sell the car in January, so keep me posted if anyone is interested. It's going to be one of the best cared for and maintained C5 4.2's on the road.

[b7slineA4]

CAL, January 2018?

[CAL4.2]

Yes sir.

[AllroadMass]

Keeping my eye on it! Looks great as usual.

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