My S6 Avant Fixing Things Thread

[R490]

Well, that was terrible getting the suspension done. I really should have replaced all of the hardware.

There were some issues with fitment on the passenger side, the upper "stud" bolt is a little damaged since it wouldn't align well and was a pain to get into place. Luckily, the inside of the knuckle isn't threaded I don't think.

I also had issues fitting the upper rearward control arm, I used a c-clamp per advice of some local B5 owners.

I need an alignment and I'll probably have the shop double check everything is torqued correctly.

The drivers side upper mount has a stripped hole in it that I couldn't see until I was tightening it down. I ordered the replacement, so I just have to fit it. I might just tap the existing hole and throw a bolt in there for now though.

All lessons learned for the future. I haven't driven it yet, so hopefully it doesn't all collapse.





I'm happy with the higher ride height, it feels much more functional now.

I also changed the oil today, and recreated Niagra falls, but with oil on my driveway. The engine is a bit quieter, so I don't know what the hell the previous owner had in there.

Next up is power steering. I think I'll flush the fluid first and see if that works. Figure I pump the reservoir out and remove the return line.

[R490]

Did a power steering flush.

I don't know what kind of fluid was in the system, but it was yellow. Which isn't right for sure. Replaced it with CHF 11 (which was $40 a bottle at the local Autozone).

Flushed about a liter through until it came out clear. Wow, was it dirty.

Hopefully, the steering quiets down now.



Tomorrow, I'm going to install the new passenger side top hat for the shock assembly, and retorque everything properly. I have a few bolts I want to replace as well.

Next up, I'll do the fuel filter and see how everything is getting along then.

[ShelbyM3]

Did a power steering flush.

I don't know what kind of fluid was in the system, but it was yellow. Which isn't right for sure. Replaced it with CHF 11 (which was $40 a bottle at the local Autozone).

Flushed about a liter through until it came out clear. Wow, was it dirty.

Hopefully, the steering quiets down now.



Tomorrow, I'm going to install the new passenger side top hat for the shock assembly, and retorque everything properly. I have a few bolts I want to replace as well.

Next up, I'll do the fuel filter and see how everything is getting along then.

That is some nasty looking PS fluid, Man. Good on you for doing a solid flush. I bet the pump and rack will be much happier, and hopefully quieter.

I feel like you’re getting really close!


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[Audibot]

Car looks good!

That old fluid has been toast for ages. My first allroad was like that too. New stuff should be nice and green.

I really hope your rack quiets up. I had to replace the return line from the rack to the cooler on my RS that was leaking... what a pain. And it still isn't 100% quiet, which means I will be doing some lock-to-lock to see if it quiets. Feeling like Sreten here.

Otherwise it's the pump. Zero air bubbles or leaks.

[R490]

Thanks guys- hopefully I'm on the right track with this thing

Unfortunately, I went back out this morning and it's still making making some noise close to full lock. But it went away after a few lock to lock turns. Somehow, air is still getting into the system. I was hoping it would have been the fluid, since it was super dirty and the wrong color.

It only makes noise when it's under 60 degrees outside. Very strange.

[Bordom]

On my old 01.5 S4, I had issues with the power steering feed line being dry rotted. When started, the pump would have some air, but you could work it out after a few lock to lock turns. The issue would return after a few hrs due to the hose being rotted.

Something to consider

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[R490]

Hmm, so it looks like the banjo bolt is still leaking. Don't know if I should replace the fitting, or just the washers.

[Audibot]

Hmm, so it looks like the banjo bolt is still leaking. Don't know if I should replace the fitting, or just the washers.

Do you have any pictures?

Sometimes the leak is not from the banjo or fitting itself, but up the line. That's how mine was. I replaced the offending line with a do88 silicone one. I also replaced the feed from the reservoir to the pump.

Washers are the easy thing to try monetarily. I got this set of crush washers because it has the right M18 ones.

[R490]

I thought I had fixed it, but I guess I didn't. Could having the wrong fluid in it have done something?

The lines themselves appear to be okay. I assume this leak is causing air to get into the system, and once it's pressurized, it somehow doesn't let air in?

[Audibot]

Is this from the top or bottom?

[R490]

Is this from the top or bottom?

From the bottom, but it can be seen from the top too. I just can't see any splits or damage to the line.

[Audibot]

Banjo certainly looks plausible, though I am concerned about how it's leaked around the front of the pump there. I never saw any active damage to my lines either.

Might be worth it to try to clean that off with Brakleen and see if you can see any active weeping when it's running.

[R490]

Banjo certainly looks plausible, though I am concerned about how it's leaked around the front of the pump there. I never saw any active damage to my lines either.

Might be worth it to try to clean that off with Brakleen and see if you can see any active weeping when it's running.

Good idea- I'll try that on Saturday. I'm not used to having so much space in the engine bay, coming from owning 2.7t cars for years.

It may be leaking down from the shaft too I guess, now that I look at it more. Either way, I was planning on having to replace it eventually.

[B5SoftToast]

I’ve been snooping around your thread. I just bought a 2002 s6 avant- with 56k miles but drives really rough… definitely will need to get new tires & brakes. I was wondering if any one has an idea about P0150 code for a 02 sensor. Quick fix ideas?
Also timing belt was never done, does anyone have a suggestion on a good mechanic in the bay area for older Audi’s?
I’m new to the car scene but love the way these cars look, but rather slow when it comes to wrenching.

[Bordom]

I’ve been snooping around your thread. I just bought a 2002 s6 avant- with 56k miles but drives really rough… definitely will need to get new tires & brakes. I was wondering if any one has an idea about P0150 code for a 02 sensor. Quick fix ideas?
Also timing belt was never done, does anyone have a suggestion on a good mechanic in the bay area for older Audi’s?
I’m new to the car scene but love the way these cars look, but rather slow when it comes to wrenching.

If you start your own build thread, you'd get more traction for your questions. Plus, it's a great way to keep a log of all the work you've done to the vehicle!

To answer your question: replace both primary O2 sensors as a starting point. It's likely fouled, or you can try unplugging and reconnecting, then clear the ECU to see what codes come back (definitely do this part first before spending money on sensors)

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[R490]

I’ve been snooping around your thread. I just bought a 2002 s6 avant- with 56k miles but drives really rough… definitely will need to get new tires & brakes. I was wondering if any one has an idea about P0150 code for a 02 sensor. Quick fix ideas?
Also timing belt was never done, does anyone have a suggestion on a good mechanic in the bay area for older Audi’s?
I’m new to the car scene but love the way these cars look, but rather slow when it comes to wrenching.

Nice buy! Probably one of the lowest mileage cars still out there. x2 on the build thread.

[R490]

Had the alignment done.

It's making a twisting noise from the front end at low speeds when I either turn the wheel, or brake to a stop. I think it's isolated to the left side, where I replaced the strut top mount piece that the upper control arms bolt into.

Got it out on the highway and drove it to work for the first time in months. The power steering cooperated even though it was 40 degrees this morning. No clue about that. Next up, I found a side skirt from another forum member to buy and I'm replacing the fuel filter this weekend. After that, I think removing the sound system and probably some more PM.

[B5SoftToast]

Thanks for the tips and I’ll definitely start my own thread! Your journey motivates me!

[svt]

Had the alignment done.

It's making a twisting noise from the front end at low speeds when I either turn the wheel, or brake to a stop. I think it's isolated to the left side, where I replaced the strut top mount piece that the upper control arms bolt into.

Got it out on the highway and drove it to work for the first time in months. The power steering cooperated even though it was 40 degrees this morning. No clue about that. Next up, I found a side skirt from another forum member to buy and I'm replacing the fuel filter this weekend. After that, I think removing the sound system and probably some more PM.

My steering rack makes noises too when going full lock-to-lock at very low speed, like when I'm turning around in a parking space. We definitely need to do a side-by-side comparison of the cars. I'll help with the fuel filter if needed.

[R490]

Thanks for the tips and I’ll definitely start my own thread! Your journey motivates me!

Looking forward to seeing it! Great to see others keeping these cars on the road!

- - - Updated - - -

My steering rack makes noises too when going full lock-to-lock at very low speed, like when I'm turning around in a parking space. We definitely need to do a side-by-side comparison of the cars. I'll help with the fuel filter if needed.

Hmmmm, yeah let's do that for sure.

Sounds good- I'll keep ya posted, I think I'll probably do it on Sunday. Hopefully you'll have your car back.

[R490]

This is the noise I can't quite figure out. It's like a "jingle/rattle" over large bumps.



Everything is torqued to spec, all of the bushings look okay and I can't replicate it in the air.

Any ideas?

https://i.imgur.com/MLiFipL.mp4

[Audibot]

Bit muffled but to me it sounds like something is loose somewhere

[JTF]

Bit muffled but to me it sounds like something is loose somewhere

^what Audibot said

[R490]

It does sound like that.

I went in and tightened everything I had out, it was all tight. But it does sound that way.



My only other thought would be that maybe the spring his hitting the metal part of the perch over bumps? The weird thing is that the springs are seated properly and I'm not sure what's going on there. Never really done suspension work myself so more eyes is always useful.

[Audibot]

There should be the flat vertical end of the spring against that nub in the perch. Can't see it in this angle, so not sure if it's off.

Did you use new upper strut mounts in the front?

And have you tried the old "jack up a wheel and see if you can shake it from 12/6 or 3/9"?

[R490]

There should be the flat vertical end of the spring against that nub in the perch. Can't see it in this angle, so not sure if it's off.

Did you use new upper strut mounts in the front?

And have you tried the old "jack up a wheel and see if you can shake it from 12/6 or 3/9"?

It is up against it and yes, I did not replace those, they looked in good shape when I took them off. I did replace the strut mount bracket because one of the holes was stripped out.

I did jack up the wheels and there is no movement whatsoever in any direction.

[Bordom]

The top strut mounts typically cause noises like that when they get old. I would have replaced them since you had them out already.

[R490]

I would have, but they looked newer so I didn't bother. I should have, but I didn't.

I think the springs might not be seated correctly or something?

[R490]

No updates in the last month, I bought a new side skirt so the cosmetics should be better once that arrives.

I need to find a set of name brand coilovers for it next. I've also noticed a slight rattle on cold starts for about a second. My B5 S4 did the same thing. I'll probably replace the chain tensioners at some point....

I just got a new job and I'm going to be out of state for three months, so the project will be on hold for a while. I'll probably stick the old wheels and tires on and throw a battery tender on it.

[Caddylack]

No updates in the last month, I bought a new side skirt so the cosmetics should be better once that arrives.

I need to find a set of name brand coilovers for it next. I've also noticed a slight rattle on cold starts for about a second. My B5 S4 did the same thing. I'll probably replace the chain tensioners at some point....

I just got a new job and I'm going to be out of state for three months, so the project will be on hold for a while. I'll probably stick the old wheels and tires on and throw a battery tender on it.

Which state will you not be out of?

Strutmasters pays me every time I remind you that I still have the complete Strutmasters coil kit for sale and ready to mount.

I'm also kinda just plugging my parts.


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[R490]

Long time, no update.

I still have the car. I'm not happy with the suspension the way it is right now, so I'm going to find a set of quality coilovers and go from there. The power steering issue is still there, but I'm not sure how doable it's going to be immediately.

[alpine4]

Long time, no update.

I still have the car. I'm not happy with the suspension the way it is right now, so I'm going to find a set of quality coilovers and go from there. The power steering issue is still there, but I'm not sure how doable it's going to be immediately.

I installed Bilstein PSS9 on my last C5 S6 Avant. I also added H&R front and rear sway bars. Between the three the car handled like a weapon. The Bilsteins are not cheap but worth every bit. They ride very well too. Just insalled another set of PSS9's on my current b5 S4 Avant.

[R490]

Getting rolling again.

Changed out the side skirt that was cracked by someone's inability to jack the car up properly.

It passed state inspection and emissions with flying colors (both of which lapsed while I was away), so now it's almost road ready again. The inspector spent like 30 minutes looking it over, so I was worried for a second.

[Bordom]

Glad you're still rolling around with this thing! Congratulations on getting it back on the road

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[danspach]

Long time, no update.

I still have the car. I'm not happy with the suspension the way it is right now, so I'm going to find a set of quality coilovers and go from there. The power steering issue is still there, but I'm not sure how doable it's going to be immediately.

I'm in the middle of doing the suspension on my car. Both upper front spring seats were shattered so thought it was time to address the whole lot. I went with Bilstein B6 and H&R Sports with 034 Density control arms. It blossomed into 034 Density upper mounts and a Hotchkis rear bar as well so not done but will report back if you haven't pulled the trigger by then.

Glad to see you're back at it!

[jbain2]

I'm in the middle of doing the suspension on my car. Both upper front spring seats were shattered so thought it was time to address the whole lot. I went with Bilstein B6 and H&R Sports with 034 Density control arms. It blossomed into 034 Density upper mounts and a Hotchkis rear bar as well so not done but will report back if you haven't pulled the trigger by then.

Glad to see you're back at it!

I have the exact strut and spring combo as well as the rear sway bar. It’s planted but somewhat stiff. Ideally I’d like it a little softer but overall I can’t complain at the price point.


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[R490]

It previously had Koni shocks and H&R Sport springs. However, the fronts rubbed and the rears were way too close with the Rs6 wheels and OE Rs6 tire size, so I went back to stock. Ideally, I want to lower it again but I prefer coilovers.

[svt]

I'm in the middle of doing the suspension on my car. Both upper front spring seats were shattered so thought it was time to address the whole lot. I went with Bilstein B6 and H&R Sports with 034 Density control arms. It blossomed into 034 Density upper mounts and a Hotchkis rear bar as well so not done but will report back if you haven't pulled the trigger by then.

Glad to see you're back at it!

If you put silver S4 rotor wheels on yours, we'll have identical twins! I'm also running H&R Sports with I think OEM shocks (RIP soon probably) and stock control arms. One day I'll crawl under there again to check the condition of the control arm components.