Huge Brake Upgrade on My Turbo MK4 R32

0:00 This is going to be a huge moment because we

0:02 are about to embark on a journey of valve cover.

0:10 I guess the good thing is it's probably not coming out.

0:16 So in the last video we were installing this part and one of the bolts broke.

0:20 Is it my fault?

0:21 Yes.

0:22 Did I overtighten it?

0:23 I don't think I did actually, but clearly I did.

0:27 I figure if it's so stuck that I can't get it out, probably not coming out.

0:32 Or we just gambled our entire build, our turbo,

0:36 everything on a stupid little bolt like that.

0:41 This is where it starts to get a little squirrely.

0:43 Okay, I'm stopping there.

0:45 I don't even think I tightened that other one that tight.

0:47 You imagine how many I would have broke if I would

0:49 have got the big ratchet that I was using at first?

0:51 That leg of our journey is over.

0:53 I'm actually feeling okay about this.

0:54 So we're we're not going to sweat it too terribly much.

0:57 Our valve cover still looks fresh.

0:59 Now we have a place where we're going to make some decisions.

1:02 So this is all the hardware for our valve cover.

1:05 And what's interesting is this hardware on the bottom

1:07 side actually holds the gasket in place.

1:10 So the gasket would live like right there.

1:12 This kind of drops in like that.

1:14 On these two, the studs come up out of the head, so just regular bolts are fine.

1:18 On the rest of them, this is the right hardware.

1:21 Black bolt with kind of a decorative-ish washer, a little rubber grommet,

1:25 and then this is where the gasket is held in.

1:29 But I don't like that.

1:30 Now we could have got some more of those, but I don't like that either.

1:33 So we're going to make ours look like that.

1:34 Now in order to do that, we need to separate the bolt,

1:37 which is captive, from this little seal piece.

1:40 I don't know what you'd actually call that.

1:41 So I have a 14 mil impact socket.

1:44 I'm going to take this, drop it upside down, and separate them.

1:49 So now I have this piece.

1:51 I have our black beauty washer since we're going up against purple.

1:54 I do remember like testing out a bunch of different ways to mount this up.

1:58 Uh like I bought these little rubber grommets

1:59 that would live in this little well right here.

2:02 And this was the best way I could find

2:04 that kind of gave me what I was looking for.

2:06 And it seems that I did all but two of these.

2:08 So, now I think you can buy these new if you wanted

2:11 to, which honestly just buying new

2:13 ones probably would have been completely acceptable.

2:15 Let's flip our valve cover over again.

2:17 We got our gasket here.

2:19 Now, this is a multi-piece situation cuz

2:22 you have these spark plug well gaskets, too.

2:25 And if you want, you can put a little bit of um JB Weld.

2:29 Not JB Weld.

2:30 Don't put JB I mean, there's probably a JB Weld that would work cuz

2:33 much like Kleenex and Xerox, JB Weld is a brand.

2:37 Um silicone.

2:38 Like oil pan gasket material.

2:39 Why can't I think of what it's called?

2:41 It's called RTV.

2:42 That's what I was trying to think of.

2:45 Uh I have a little one here that I'm going to open

2:48 cuz I don't know when we're going to need the next little bit.

2:50 God, by the way, if you didn't know,

2:51 when you have these tubes that are sealed like

2:53 that, a lot of times there's a little pin in the cap.

2:57 So, you can just take the cap, puncture it like that.

2:59 We'll do a little bit on the head side, too, but you don't need much.

3:02 Gasket's so powdery.

3:04 Why is it so powdery?

3:05 Probably cuz it's 5 years old.

3:07 So mad about that bolt breaking, by the way.

3:09 I don't remember the last time I broke a bolt installing one.

3:14 See how you can see that metal piece right there inside the gasket?

3:18 So, watch.

3:19 When I take this, I'm going through the hole, it sticks up,

3:23 and then you got to take the gasket and kind of lock it into place.

3:26 What's cool about that, though,

3:27 is that does make installing this a bit easier cuz you don't

3:31 have to like hold the gasket to make sure it doesn't fall off.

3:34 All right.

3:35 There we go.

3:35 We got our gasket.

3:37 Good job, us.

3:38 We'll put our spark plug well gaskets.

3:41 These are keyed, by the way.

3:42 Can see the little notch right there.

3:44 These you do have to pay attention to, though, cuz I have had these fall out.

3:47 If you are doing this and you're not using like beauty washers like we're doing,

3:51 you're going to see the bolt stick through like that.

3:54 It'll hang low cuz they move, but they're also captive,

3:56 so it'll kind of live like that.

3:57 We are doing this, which means it's time to put

4:01 this bad boy on the car hopefully once and for all.

4:18 Yeah, buddy.

4:19 I bought that.

4:22 Okay, not an ideal scenario of that bolt breaking.

4:25 And as you can see, I have the valve cover on the car.

4:28 I had another valve cover.

4:30 I sent it to powder coat.

4:31 Do I think we could have ran this valve cover with no issues?

4:34 Yes, yes I do, and I think it would have always been fine.

4:36 Some of you had a really good suggestion of like

4:39 tapping around the screw to kind of lock it in place,

4:42 which was an awesome thing.

4:43 But, since I had another valve cover, we're going to run with that one.

4:47 Now, I also installed this one because I wanted to test

4:50 fit how our beauty washers would go on and look and everything.

4:53 Once the new valve cover comes, we'll swap it out,

4:56 and then we can all rest a little

4:57 easier that we don't potentially have a problem.

5:00 But again, I think it would have been fine.

5:02 Now, here's the fun part of this job.

5:04 So, when you buy something like

5:06 this, it's not like buying IKEA furniture, right?

5:08 There's no instructions of step one, do this.

5:11 Step two, do this.

5:12 Assemble your pooply and then you're good to go.

5:15 You get a whole bunch of parts, and some of it's a little bit of figuring out,

5:19 which is why I had said very early on in this project,

5:23 I'm not torquing many things down cuz I might have to take some things back off.

5:26 The first thing we're taking back off today is going to be our turbo charger.

5:30 A couple of reasons.

5:31 One, there's some brackets that have to go on on the manifold.

5:34 One of my studs was too long.

5:36 We got to put our coolant fittings on.

5:38 So, we're just going to take this off.

5:40 All right, tighten that one more tighter than I had anticipated.

5:43 Another thing we're going to do while we're right here is we're going

5:46 to put a gasket on this between the exhaust manifold and the turbocharger.

5:50 That is probably not super necessary to put

5:53 that gasket on cuz I think I'd mentioned it before.

5:55 Those two surfaces, the mating surfaces,

5:58 are very likely machined flat so that a gasket isn't 100% necessary,

6:03 but listen, it's going to make me feel better.

6:05 We got a lot of taking of parts off to actually do.

6:08 We got this, we got our rear brakes, and the wheel bearing and all that.

6:13 This is heavy.

6:14 Now, the real question is where the hell am I going to put it?

6:17 So, you'll notice everything's a little cozy tight because right here,

6:20 we got a B5S4 that I was mid doing the heater core

6:24 on, and then I'm going to just not even BS you or sugarcoat anything.

6:28 I got sick of doing it.

6:29 I know it's not a hard job,

6:31 but the main problem was every piece of plastic I touched.

6:34 It's like I touched it, crumble.

6:35 Touch it, crumble.

6:36 Here's a good example.

6:38 This is the center console.

6:39 It's gross cuz I'd never clean the car since I've owned it.

6:42 This is where the rear center console mounts,

6:45 and look at all this is just gone, just crumbled away.

6:48 This is where it mounts to a bracket, broken.

6:50 And it looked fine.

6:51 Just the second you touch it, it crumbles.

6:53 And much much much like Volkswagen, Audi's support for older cars is terrible.

6:59 Hey, Volkswagen Audi customers, we know you love our cars.

7:03 We know that you want to keep your cool nice car on the road,

7:07 but we also don't care.

7:08 I want to say bad word, but I'm not going to.

7:11 What [snorts] I am going to do is take this manifold off.

7:13 There were a couple of brackets that needed to go on right here

7:16 that I didn't put on because I found them after I had gotten it on.

7:19 So, we're going to do that now and try and just get kind

7:22 of this area together enough where we don't have to come back to it.

7:26 All right, wrestle those little wrenchy boys.

7:30 So, I'm standing here ratcheting, and I glance over to my right here and think,

7:35 "Huh, have you noticed what's missing on this side?"

7:38 Let me know if you've noticed it.

7:39 I'll show you in a minute what happened.

7:41 Here's your hint.

7:42 If we refer to a fire as a thermal event,

7:46 then we can refer to that one as like a gravitational impact.

7:51 By the way, I'm sure these nuts are technically one-time use.

7:55 Too bad, we're using them more than once.

7:57 I'd probably have spent more than I spent on the car if

8:00 I replaced every single bolt that was one-time use in this car.

8:03 We're going to take this off and take it to the bench.

8:07 We're going to do a couple of things.

8:08 One, we're going to properly install the right studs.

8:11 These studs work just fine,

8:12 but I actually found the studs that came with the kit.

8:15 So, we're going to use those.

8:16 They're a little bit shorter.

8:18 We have a couple of pipes to put on.

8:19 Then when we go back together with this, we

8:22 have some brackets that need to go on.

8:24 So, these guys go like here to hold on the heat shield.

8:28 So, we got those guys on the bottom, those guys on the top.

8:31 We had one of these hitting the body of the turbo.

8:34 The overall length is about the same,

8:36 but this will sit in the manifold a little further.

8:40 Because it goes in further, we have less sticking out of the manifold,

8:44 then effectively our stud is shorter.

8:46 So, we shouldn't have to worry about hitting the turbo.

8:49 Before we get too crazy under the hood, I am so excited about this.

8:53 So excited that I have to show you.

8:56 This is what we're going with for the brakes.

8:59 So, these are 18Z's for the front.

9:01 We got install kits.

9:02 We got install kits for the rear and lines.

9:04 I'll give you all the specs on these in a little bit.

9:06 I just Would you just look at it?

9:08 Jeff, our powder coater near Poly D, rebuilt these.

9:12 I think in the last video I showed you that he text me and said,

9:15 "I had to do a lot of work." Um and they came out great.

9:17 These are incredible cuz they were nasty.

9:20 Color match looks great.

9:21 This is uh prismatic violet, I think.

9:24 A great question always comes up, "What are you going to do about the master

9:28 cylinder?" Cuz we're going from two pot front,

9:30 one pot rear each side to six pot and four pot.

9:34 The 18Z's and the 17Z's are a really common upgrade.

9:37 Half the people say, "My brake pedal is awesome." Half the people say,

9:41 "My brake pedal is terrible." I don't know the answer,

9:45 but we're going to find out at some point.

9:46 All I know is we got a lot of brake going on this car, which should be premo.

9:51 And these are actually the factory ones.

9:53 The only thing we're doing with these is we're using these for a parking brake.

9:57 So, we get to undo the thing that I did out of order last time.

10:00 Listen, this whole video [laughter] This whole video is basically me installing

10:06 a part and then taking something else apart

10:08 that didn't go on in the right order or I found another thing that, you know,

10:11 it's easier to to install with another part off.

10:15 So, this should be a lot of fun.

10:17 Parts come off, new parts go on, part I already installed probably goes back on.

10:22 But, look, this is how it goes.

10:24 Here's the gasket that we're running.

10:25 It's nothing fancy, nothing crazy,

10:27 but I'm going to run one just to be on the safe side.

10:30 If this surface was machined perfectly flat and the surface where

10:35 it mounts up to on the exhaust manifold was machined perfectly flat,

10:38 these two surfaces would very likely seal.

10:40 However, [sighs and gasps] look, it's probably going to be okay,

10:44 but once all that stuff gets put on, are we really going to want

10:48 to risk having to take everything back apart over like a $4 gasket?

10:53 I don't.

10:54 So, we're going to drop that bad boy on there

10:56 just like that and we're going to send it.

10:58 Something that I did not install was this coolant pipe.

11:01 So, this goes on the back below the turbocharger.

11:04 So, it's actually good that we have all this out of the way.

11:06 I'm just going to take these two bolts out

11:07 and then this is going to go like that.

11:10 So, because we're adding this turbocharger,

11:12 we're now putting a ton more heat right here.

11:16 We have our AC lines that are here.

11:18 We have our shifter cables that are here.

11:20 So, I bought some heat wrap and my goal

11:22 is to just kind of wrap the shift cables up.

11:25 And we'll get these shift cables in this bracket here.

11:28 I still want to make sure these plasticky bits

11:30 or moving bits or anything like that are pretty well protected.

11:33 For you keen-eyed observers that have noticed we have

11:35 a fender here and we have no fender on this side.

11:40 Let me regale you with the tale of what happened.

11:43 So, I was here and I was like,

11:46 you know what I need is I need the hood a little bit lower.

11:49 And so I loosened the I had vise grips on it, so judge if you want.

11:54 Uh I loosened it a little bit, lowered the hood,

11:57 squeezed the vise grip up so that it was holding

12:00 and then like a second later the vise grip popped forward.

12:04 I was still standing here.

12:06 I caught the hood but only after jamming the vise grip into the fender.

12:12 Into the freshly painted swear word swear word swear word fender.

12:18 Thankfully, our man Tom at Everything Euro who they did

12:20 the real body work of this car took the fender.

12:23 So, he's fixing my boo-boo, but still what a kick in the pants.

12:27 This is what I got for the shifter cables

12:30 and for a couple of other things and basically it's a heat wrap,

12:34 but instead of having to wrap it around or like

12:37 as a tube slide it on, it has Velcro.

12:40 So, we can just fold it over and then

12:42 it has these friction clamps that go around it.

12:45 So, I measured off the exposed area of those lines.

12:48 We're taking 15 bucks and 10 minutes right now.

12:52 Would it have been a problem?

12:53 Like I said, I don't know,

12:55 but I'm hopeful that now we just don't even have to worry about it.

12:59 I think we can put our manifold back on.

13:03 [music] Before we get our turbo charger put back

13:10 on, we need to put our coolant fittings on.

13:13 These are our two lines that we're going to be installing.

13:15 That is a dog hair from probably a white Boston Terrier.

13:20 This I feel like we could have easily done in the car as well,

13:23 but since we're right here, I think we should do it.

13:25 I'm trying to evaluate, okay, when this goes in the car,

13:28 it's going to sit like this.

13:30 Will I be able to get access not only to start the fitting,

13:33 but to actually tighten it?

13:34 Yeah, I'm pretty confident of that.

13:36 Bottom side is a little trickier,

13:38 but I'm still feeling like we could probably get to it.

13:40 The bevel box being on may prevent that.

13:42 So, we'll probably get these lines queued up before the bevel box goes on.

13:47 Boy, that is right up on that coolant line, isn't it?

13:51 That's hitting that coolant line.

13:53 So, what I'm going to do is I'm going to loosen this one,

13:55 and hopefully this is the last time we have any on and off of this turbski.

14:07 We are golden.

14:09 That should be it.

14:10 We shouldn't have to take this back off again.

14:12 Remember, our whole engine is actually going to sit more like here,

14:15 so we should have plenty of space around this.

14:18 And everything we do, we're reducing the amount of room we have left,

14:21 and that's good cuz that means parts are going on.

14:23 So, you know what we're going to do next?

14:24 We're going to put some spark plugs in so we don't have open engine hole.

14:27 We're going to squirt a little down in the cylinder just to have some lubricity.

14:31 We're relying on HPA here fully on this, but it

14:34 just seems a little strange to me.

14:35 They recommended factory R32 spark plugs gapped to 0.28 in.

14:42 To me, running a colder spark plug is usually the better,

14:46 like kind of the thing that you do, I guess, but I'm trusting HPA here.

14:50 Look, they've built a lot of turbo charged R32s,

14:53 so I'm hopeful that that's going to be just fine.

14:56 Especially new, every spark plug gets torqued.

14:59 "What do you do that for, Chuck?" That's a great question.

15:01 I'm glad you asked, audience, because when I was a very new technician,

15:05 the guy working next to me, his name was John, his name probably still is John.

15:09 He did plugs on like a AEG 2-liter, and later that day,

15:14 car gets towed in misfiring with the plug

15:17 just dangling out of the spark plug well.

15:19 Had to to the head, get the machine shop to fix it,

15:22 and I remember that vividly enough that I still torque spark plugs.

15:26 Remember, the manifold kind of goes up and over,

15:28 but you still see the end tanks, but I still wanted to use these beauty washers.

15:33 And so, I used the factory like retainers that hold

15:36 the gasket in, and then a beauty washer and an Allen.

15:39 And I think it looks real nice.

15:41 When I was putting the valve cover on, I

15:43 had this weird feeling about a piece of the gasket, like a little divot.

15:48 So, it's flat, dips down, and then comes up.

15:50 I got another gasket, and if you look on this gasket right here,

15:54 you can see that tiny little drop-down.

15:56 I'm almost 100% sure that gasket didn't have it.

16:00 Is that a big deal?

16:01 Yeah, it's probably going to be an oil leak if we don't fix it.

16:04 So, when we get our other valve cover, I'm going to put a new gasket on it,

16:08 and then I got a supercharger for the red car,

16:10 so we'll probably save that for that car.

16:12 We are possibly going to have to figure out a different oil return solution.

16:17 The one that comes in the kit comes out of this and goes

16:20 around to the full passenger side of our oil pan,

16:23 and we have a fitting right here,

16:25 which doesn't seem like it's that big of a deal,

16:27 but the hose is kind of getting bunched up if you try and mount it here.

16:31 Probably have to make a pipe.

16:32 Not a big deal, just one more thing.

16:34 This is why, no matter what, every freaking project is always different.

16:43 Before we can install those absolutely beautiful brakes,

16:47 we need to undo a thing that I did a quite a while ago,

16:52 and that's we have to remove the wheel hub

16:56 because all those brackets for the kit go behind it.

16:59 I knew this was going to end up happening.

17:00 I have another wheel bearing cuz we destroy the wheel

17:03 bearing when we take the uh the hub out.

17:06 Unfortunately, here is our slide hammer kit.

17:09 There's other ways to do this.

17:10 If we had a cone big enough to fit over the hub,

17:13 we wouldn't have to slide hammer,

17:15 but I don't even remember when the last time I used this was.

17:17 Shall we take bets on how many pumps it's

17:20 going to take to get this thing off of here?

17:24 One.

17:25 Two.

17:27 Three.

17:28 Three pump chump.

17:30 Four.

17:31 Five.

17:32 This is the one that's going to come off.

17:35 Let me show you why we have to replace the wheel bearing.

17:37 So, this piece with all the grease on it right here,

17:40 this is part of the wheel bearing.

17:41 You can see it left the wheel bearing in there, but it's separated.

17:44 Now, could we reuse it in some twisted crazy world?

17:48 Probably.

17:49 Is it worth it?

17:50 No, cuz wheel bearings are like $20.

17:52 And at this point, what's another $20?

17:55 So, we can switch to our wheel bearing kit.

17:58 So, I'm going to put a piece at the back.

18:00 Cone goes here.

18:01 We use the bolt and it'll just pull

18:03 the bearing away right out of the trailing arm.

18:06 And we'll do the same thing going back together with it, just the opposite.

18:09 Oh, it's close.

18:11 Oh, it's there.

18:12 Oh.

18:14 It's broken.

18:15 Just like our table.

18:18 All right, there we go.

18:19 So, here's our old {slash} new bearing.

18:21 No miles.

18:22 These are nice because they don't have a inside and an outside.

18:26 The Touaregs have the wheel speed pick up here,

18:30 and so you have to put it in the right way.

18:32 The B5 Passat, the inner race one side was wider than the other,

18:37 so you had to put it in the right way.

18:39 This one doesn't matter.

18:40 All right, so this is mostly in.

18:42 So, we can leave the back side, but we need a different piece for the front.

18:46 Uh the amount of times I have forgotten that snap ring is it is.

18:49 We'll just leave it at that.

18:50 Our rear rotors, which these are actually the same rotors

18:54 that the 337 and the 20th use in the front.

18:58 We have our Ris Pas kit.

19:00 We installed it on the other side just to kind of test it out and see.

19:03 This allows us to use the rear Touareg

19:05 brakes and retain the factory brakes for parking brake.

19:09 I got to tell you, for parking brake, I think there's probably better solutions.

19:13 In fact, the guys that make this has an adapter bracket for R8 brakes,

19:18 but then I started looking at how much the R8 parking brake caliper was,

19:22 and then I was like, "Not on my watch." This is also high temp threadlocker,

19:26 the same stuff that they tell you to use when you do wheel studs.

19:29 No torque spec, so we're just going to go snugtastic.

19:32 You need to support the backside of the bearing,

19:35 what I have with this piece right here.

19:36 It has to sit up against the inner race.

19:39 If you don't do this, all you're going to do

19:41 is rip the inner part of the bearing out.

19:43 This bad boy.

19:51 Ah, damn it.

19:53 Don't worry about that.

19:54 You know what else works really well to hold a rotor on like this?

19:57 It's an old drain plug, cuz they're the same thread pitch.

20:00 Outstanding.

20:04 For the carriers, I had to grind out

20:07 the middle because we're using a bigger rotor.

20:09 You'll notice where I'm putting this is the front side,

20:12 where the R32 normally has the caliper on the rear side.

20:16 You have to swap the left caliper and the right caliper.

20:18 We got to put some brake pad on that bad boy,

20:20 but I got some almost brand new factory brake pads that I'm going to put on.

20:25 If you're doing this setup and you don't

20:27 have five sets of brake pads sitting around,

20:30 I would buy the absolute cheapest brake pads I could find.

20:33 They're only parking brake.

20:35 Still leaving it in gear, so you don't have to go crazy,

20:37 but the cool thing about these calipers,

20:40 when we get pads for them, we can just drop the pads right in.

20:42 We don't have to worry about like pulling the caliper off or anything like that.

20:46 This is huge.

20:47 This is one of those big moments.

20:49 I know you guys have a ton of questions about these brakes, right?

20:52 What wheel can I run with those brakes?

20:54 Will I need a spacer?

20:55 I got to tell you, these are questions I don't have answers to right now.

20:58 I really don't know.

20:59 But what I do know is that looks good.

21:01 We should have no problem stopping this car.

21:05 I'm going to go hunting cuz I'm pretty sure I have a spacer and I

21:08 don't want to damage the caliper before we even get to drive the car.

21:11 Then, I know I have an Aristo.

21:13 We'll test it and see what happens.

21:15 So, this is a 13 mil no-name [snorts] spacer.

21:19 Depending on what spacer we need,

21:21 I'll probably talk to H&R and get like a really good high-end set of spacers.

21:25 God, I wish this wheel wasn't disgusting looking.

21:28 [laughter] That's probably about where we want to be.

21:30 Maybe we'll go 15.

21:31 It's going to really depend on this fitment here

21:34 cuz we're at like full droop of the suspension.

21:37 But, yo, when these wheels are so like bright

21:41 and shiny and the tire looks good and clean.

21:44 Oh, I'm so excited about this.

21:48 So, I'm not going to finish this brake job yet.

21:51 But, we have the parking brake cables and then we have the brake lines.

21:54 So, these are rear lines from USP Motorsports.

21:56 We'll have to figure out the routing once we get all the rest of the stuff on.

22:00 And this is nice, too, cuz we're not losing a bunch of brake fluid cuz this car

22:03 hasn't had brake fluid in it for like 5 years, so.

22:08 The back came out so good.

22:10 We're going to do the front next.

22:11 Now, I have brand new knuckles with hubs with wheel bearings.

22:16 It even has a speed sensor on it, a ball joint on it.

22:20 I think I got these from One Love who has been a huge part of this.

22:24 Like, that's where our transmission came from.

22:26 We got a killer dust shield.

22:27 So, these are 18 Zs out of a V10 TDI Touareg.

22:30 They're six-piston compared to the two-piston

22:33 that the car came with from the factory.

22:35 What I'll tell you is I have driven several R32s on stock

22:38 brakes at Tail of the Dragon in auto crosses and they've been great.

22:43 Would a brake setup like this been better?

22:44 Probably.

22:45 The only time I've ever ran into a brake issue

22:48 with stock-size brakes was I bought some G-Loc street pads.

22:51 They were awful.

22:52 I had brake fade on an auto cross.

22:55 That ain't it.

22:56 Let's get this old brake line out of here.

23:01 There we go.

23:02 Bye-bye, yucky piece.

23:03 So, this kit came from ECS Tuning.

23:05 I already had the calipers, so I did not buy the calipers from them,

23:09 but we have the two-piece rotors, we have the mounting bracket,

23:13 we have all the hardware, it came with brake lines.

23:16 I got to say, they had a pretty thorough setup for what we're trying to do.

23:20 Now, before I put the rotor on, even though this hub is new,

23:23 I'm going to just clean some of the surface rust off of it.

23:25 For us, that really wasn't that bad, but if you have a setup where there's a ton

23:29 of rust or oxidation or grime or grit or dirt,

23:32 whatever, when you go to mount the rotor to it,

23:34 it's not going to sit flush, and so your torque's not going to be right,

23:37 you run the risk of having noise or brake parts loosening up on you.

23:41 Is that insanely extreme?

23:43 Yes.

23:44 Is it real and it could happen?

23:45 Yes.

23:46 But, in a like, let's do our brake job the right way, kind of way.

23:50 Someone was talking to me about bleeding these calipers

23:53 on this setup and how it can be a bit challenging.

23:56 We have no brake fluid, which means we have to do the ABS bleed on it anyway,

24:00 so this may not apply for us.

24:01 They said, if you take a rubber mallet while you're bleeding,

24:04 so pressure on the system while you're bleeding,

24:05 and just tap along like where the pistons are,

24:08 if there's any air pockets, it usually jars them loose.

24:11 Another question you might be having is,

24:13 Charles, what pads are you going to run?

24:15 I'm not sure yet.

24:16 My favorite brake pads that I've ever had were on my yellow car,

24:19 and they were the Ferodo DS 2500s.

24:22 They were incredible.

24:23 They stopped the car so well.

24:24 So, if they make those for this setup, that's probably what I'm going to do.

24:28 If you have this brake setup, and you have any pad suggestions, let me know.

24:32 I showed you step-by-step on the driver side,

24:34 and shockingly enough, the passenger side is exactly the same.

24:38 Really, the only caution I'll tell you is if you get this exact kit from ECS,

24:41 make sure you put the left rotor on the left

24:43 side and the right rotor on the right side.

24:45 Be sure your calipers have the bleeders facing up,

24:49 and then make sure you tighten everything down properly.

25:03 In a previous video, I tried to put the serpentine belt on and I struggled and I

25:07 struggled and then I might have thrown the serpentine belt across the shop.

25:14 [laughter] I heard back from HPA and they said they use

25:16 the stock Mark 4 R32 serpentine belt even though we have,

25:20 you know, that much more distance now that we need in the belt.

25:23 So, I'm going to try again.

25:26 Perhaps I was just having the dumb.

25:28 There's that.

25:29 That is on correctly.

25:31 This just feels wrong, but Jesus.

25:38 [sighs] Unless this is the wrong belt in the package.

25:41 Okay, I have put on Lord knows how many VR and other VW Audi serpentine belts.

25:47 Tried and struggled then I reached out to HPA and they're like,

25:50 use the factory belt.

25:51 I was like, "Dude, I struggled.

25:53 You guys you saw me seconds ago struggling.

25:56 So, 6DPK1320 is the belt they told me to use.

26:01 I don't know if you can read what that says.

26:03 That says 6DPK1285, which means it's 35 mm too short,

26:09 WHICH EXPLAINS WHY IT DIDN'T FIT.

26:12 LAST VIDEO I I ranted so much about VW's terrible support for their older cars.

26:18 Uh now I'm going to rant about the absolute

26:22 garbage way so many aftermarket companies present their parts.

26:25 Here's the lesson, double check the parts that you put

26:28 on your car before you try and put them on your car,

26:30 otherwise you might end up with a 35 mm too short serpentine belt.

26:36 Plenty of people on the Tik Tok were like, "Oh,

26:38 you should have checked the parts." Yeah, I should have.

26:41 So, here is our new serpentine belt made made by Mitsubishi apparently.

26:46 6DPK1320, so this belt should go on.

26:49 You got to hold your mouth right a little bit, but it shouldn't be hard.

26:53 The nice thing about these is there's a bolt

26:55 in the tensioner that holds the tensioner open,

26:58 so you don't have to hold the tensioner

27:00 open while you're trying to get the belt on.

27:02 Oh yeah, this is This is like a hundred times better already.

27:05 And oh, look at that, it went right on.

27:08 No problem.

27:09 Here is a little tip though when it comes to serpentine belts,

27:12 make sure you look at every single pulley.

27:16 Make sure it's on the ribs all the way.

27:18 That way when you start your car up it doesn't rip the belt

27:20 in half and now you got to get another belt and Listen,

27:23 I don't want to fear-monger or anything,

27:25 but I've seen serpentine belts come apart and cost engines.

27:29 It'll get sucked behind the timing cover,

27:31 it'll get in the oil pan, it'll make a car jump time.

27:35 A serpentine belt is kind of like an oil change.

27:37 For most cars, very easy, but just like with oil changes,

27:41 those are the jobs that people snooze on and then you end

27:43 up making a mistake and it costs you a ton of money.

27:46 And yeah, make sure you get the right belt.

27:49 In a prior video, we were talking about tools and I

27:52 had mentioned there was a tool that sounded out there,

27:55 but everybody at some point is going to want one on their toolbox.

27:58 And that was a 3D printer.

27:59 So we have our Haldex controller wires.

28:02 I tried to get it through the factory grommet and it just it it's not.

28:07 It ain't doing it.

28:08 So I printed this grommet.

28:10 Look at it, it's squishy.

28:11 This is printed from TPU.

28:13 There's people printing bushings for their car out of similar material,

28:17 different hardness, but same material.

28:18 And so we'll run our wires right through.

28:20 It'll sit just like the factory grommet was.

28:22 But the reason I did this is because I could split it in half in the slicer.

28:26 We can put half of it up and then we can

28:28 put the other half up and I'll just glue it together.

28:31 OH MY GOSH, IT WORKED.

28:33 I'm so happy about this.

28:34 Here's the deal, we've put a lot of parts on this car

28:37 that were made or designed or whatever by someone else.

28:40 Trying to not like oversell it, but this is a part that I made.

28:44 And I think that's really neat.

28:46 When I rehabed our power steering rack,

28:49 what I found was in some spots on these two hard lines, it looks okay.

28:53 Like right there, not worried about that.

28:55 Then there's some places like this area here where it looks really un-okay.

29:00 Pretty much only a matter of time before that becomes a problem.

29:04 So, I tried to find the right tool to make the ends,

29:08 cuz they're kind of a weird end.

29:09 I couldn't find the right deal.

29:10 Then I found there's some places in Canada that you can just buy the lines.

29:14 Easy, right?

29:15 Except all of them are out of stock or not shipping to US.

29:18 The real kick in the area is that I had a body and these lines from a Mark 3,

29:25 which I'm pretty sure they're all the same, sitting in the shed.

29:28 And what did I do with it?

29:29 I said, "I'm never going to need this." Right in the bin.

29:32 Outback, I have a Beetle and we're just going to rob

29:35 these two lines off of that Beetle cuz it should be the same.

29:37 So, once I get the Audi out of here,

29:39 we'll bring the Beetle in and we'll swap these lines over.

29:42 What is a job for right now is the fact that I

29:44 found the tool that I was talking about in the last video.

29:46 So, this is a tie rod tool.

29:48 You put the tie rod through here, that's why it's super like a long tube.

29:52 Then you can tighten and we should be able to crack this baby loose.

29:58 I I won't say struggled,

30:00 but I worked pretty hard at it on the last video with just a pair of pliers.

30:03 That's normally how I do it when they're in the car,

30:05 but this tool works really, really well.

30:07 Watch.

30:09 All flop.

30:10 Come over to this side, it's fully standing at attention.

30:14 So, that's looseness in this ball joint right here

30:17 or lack of grease in this ball joint right here.

30:19 For how easy of a thing this is to change,

30:21 especially right now, there is no reason not to put one on.

30:26 And bevel box.

30:29 Oop, it's it's leaking.

30:31 It's juicing.

30:33 That's all right, we got to drain the fluid out anyway.

30:35 This is our bevel box.

30:36 So, this is the piece that mounts up to the transmission and look at the seals.

30:41 Look at how yuck those seals are.

30:43 Luckily, I got new seals.

30:46 Now, nice and easy, right?

30:48 We have the seals.

30:49 Easy, good, fun.

30:50 Unfortunately, this other seal, right here, is obsolete.

30:55 Shall I say it?

30:57 Thanks, Volkswagen and Audi for terrible part support on your older cars.

31:00 The most enthusiast cars that are on the road for your brand,

31:04 and you're just like, "Nah, dog.

31:05 We don't want to help you out." Luckily, I have one.

31:08 I ordered this.

31:09 Check this out.

31:10 August 21st of 2020.

31:13 What I wish this told you was the size of the seal,

31:16 but I think I have the part number.

31:18 So, maybe we can figure out what size the seal actually was.

31:21 Try and find the seal.

31:22 Cuz like, ultimately, it's just a small seal.

31:24 Putting on the bevel box is pretty easy.

31:26 It's four bolts that bolt it to the transmission,

31:28 two bolts that bolt it to the engine,

31:30 one bolt that goes through the whole housing

31:33 and comes out here that bolts to the diff.

31:35 These are specialty bolts that are for the bevel box specifically.

31:40 It's a wider bolt near where the head is.

31:43 That's to keep the bevel box in place.

31:45 Otherwise, it can wiggle around.

31:46 If you use the wrong bolt, you're probably nuking your bevel box.

31:49 So, we're just going to use this to support

31:50 our prop shaft so it's not hanging on the joint.

31:53 The reason I'm doing the bevel box now, the oil return line I showed you guys

31:57 comes out of the bottom of the turbocharger, right?

31:59 And the line from HPA goes down, and you're supposed to drill a hole right here.

32:03 We went with this pan from EuroWise.

32:05 I don't think I'm going to be able to use

32:07 the HPA line because instead of going to here,

32:11 I'm going like right here on the backside of the pan.

32:14 So, we're probably going to have to make a new line.

32:16 Before I can do that, I need to get the bevel

32:18 box on, the axle in, and make sure that we're not going

32:21 to have any interference with either one of those two parts

32:23 because if we have a rotating part hitting our oil return line,

32:27 I'll give you one guess what's going to happen.

32:29 You know what's going to happen.

32:30 Sadness.

32:41 What the hell?

32:45 I was struggling to get it lined up.

32:46 There's two pieces that you need to get lined up.

32:49 There's this splined piece right here.

32:52 And then inside of here is also a splined piece.

32:55 So, I just rotated around till it lined up,

32:59 I think, and hopefully lift this guy right up there.

33:04 There we go.

33:05 I just got to put those special tie bolts

33:07 in, tighten the one that goes through the housing,

33:09 prop shaft on, we're good to go.

33:12 All right, we'll come back and torque these just cuz these are brand new.

33:14 I don't know what the torque spec is.

33:16 We've had some victories though.

33:17 We got our brakes on, we got our bevel box on.

33:20 I'm about to drop the axle in just as a test fit.

33:23 This is really good.

33:24 I'm feeling really good.

33:25 I need this because the next bit that we got happening is

33:29 going to be so much little minutia and like where does this go?

33:33 Where does this go?

33:33 What is this?

33:34 When you buy a kit like this, they don't give you like step one, do this.

33:37 Step two, do this.

33:38 This is not IKEA.

33:39 That's kind of where our axle's going to be.

33:42 So, that's not too bad.

33:43 We won't know the exact spot until we get the subframe

33:46 in, but we can kind of plan for that to be about right there.

33:51 I think we're going to have a nice path to get to here,

33:55 which means we may need to change what kind of fitting is here.

33:58 That's not a big deal.

33:59 And cuz even though this line shouldn't have any movement,

34:02 our axle's going to have movement up and down,

34:05 side to side a little bit, forward and backward.

34:07 We really have to make sure we pay attention to where this goes.

34:10 Not that it doesn't rub it or touch it, that it doesn't come close.

34:13 Let's do a quick test fit of our down pipe.

34:16 And it's going to be somewhere in this ballpark right here.

34:19 We should be all right with getting this oil drain in here.

34:23 This is a kit of dash 10 fittings that I'm likely going to use.

34:27 So, look at how close it is to the axle.

34:29 So, any up and down movement, this is going to hit.

34:32 And if we go here, that oil probably isn't going to drain the way it should,

34:36 which means none of those are really the right thing.

34:39 This is just for demonstration.

34:41 This is our power steering line.

34:42 So, this has a banjo fitting on it.

34:44 And what I'm thinking is if we get a banjo bolt,

34:47 we can kind of go right like that and maybe even make

34:51 a little like a bracket or something right here to hold everybody in place.

34:55 Checkbox for problem solved, and I'm really happy about that.

34:57 There's one other thing I want to do.

34:59 So, this is the template that I made to fill in this big gap.

35:02 I think that's going to fit real nice.

35:04 We'll make a metal one.

35:05 We'll have this bad baby bolted up, ready to go.

35:09 Big day.

35:09 This is awesome.

35:10 Now, I'll see you on the next one.