Forge DV repair?

**2K1Ultrasport** · 04-25-2008 12:32 PM

When I installed my K04 I switched the stock DV to a Forge DV.
I was under the impression that the Forges don't blow diaphragms and dont need maintenance unless a spring lost tension.
I've only had it for a few months and Im now getting a fluttering sound from the DV when it lets off boost as opposed to the normal pfush sound (very technical descriptions, I know).
anyone know if there's anything else that goes wrong on the Forge DV?

**zrowcool** · 04-25-2008 12:50 PM

take it off and try rebuilding it (glean old grease and put new on) It sounds like you may have too weak of a spring in there and it isnt holding long enough.

**2K1Ultrasport** · 04-25-2008 12:52 PM

which color spring should i be using with a K04 and Hammer file?
yellow or blue?
or perhaps yellow with some spacers?

**zrowcool** · 04-25-2008 12:55 PM

hammer file runs like 24 psi right? if it does then i owuld use the yellow with 2 spacers. if you run it to full boost all the time then blue would be the one without spacers.

**2K1Ultrasport** · 04-28-2008 12:27 PM

I just ordered the tuning kit fromm ttstuff.
I also emailed Forge to see what I should do if it's a blown o-ring or something not included in the tuning kit.
They just asked me for my address so they can ship me a repair kit.
Wonder if that means I ordered the tuning kit for nothing...

**creechsa4** · 04-28-2008 12:48 PM

nah it's good you ordered it, keep it on the shelf and when you do break an o ring or whatever, you can repair it on the go. put a grip of synthetic grease on moving parts & orings to keep them in good shape. i'm still on og forge 004 o rings & 007 dv on my other a4. lube them every other oil change.

**pinky** · 04-28-2008 02:53 PM

to the OP, what dv are you using? 007?

**2K1Ultrasport** · 04-28-2008 03:19 PM

yep, 007.
hopefully the rain will hold up for a day soon so i can get under the car.

**2K1Ultrasport** · 05-06-2008 01:16 PM

weather cleared up and finally got a chance to get under the car to service the dv.
was a pretty easy job, remove, unscrew, clean, replace, relube and reinstall.
while i was at it, i finally stopped putting it off and replaced some vac lines.
so far just the dv line and the fpr line.
maneuvering my way under the intake manifold was a bit of a pain but finally got it with the help of some needlenose pliers (after 15mins of trying to contort my arm in impossible ways).
ziptied it all up, did an oil change for good measure and i was off.
feels like a new car, i guess i never realized how much power i was losing before.
dont know if it was the dv or the vac lines that were bad before, probably both.
the dv was definitely fluttering and the old vac lines came off pretty easy i.e. broke off/disintegrated when i pulled on em.

silicone vac lines + serviced and resprung dv = 50more hp on the butt dyno.

**GetBoosted84** · 05-06-2008 03:48 PM

Originally Posted by zrowcool

hammer file runs like 24 psi right? if it does then i owuld use the yellow with 2 spacers. if you run it to full boost all the time then blue would be the one without spacers.

Hammer file is spec'd to run at 1.4 bar (roughly 20 psi) on the race program according to Giac after I spoke with them. The Yellow spring without spacers is sufficient to run the race and/or pump gas programs.

Yellow spring is good to ~23 psi
Blue spring is good from ~23 to 30 psi