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Thread: C5 Allroad 2.5TDI suspension overhaul required, recommendations welcome

  1. #1

    Question C5 Allroad 2.5TDI suspension overhaul required, recommendations welcome

    Hi,
    I am an OzAudi noob with some mechanical skills.
    My newly acquired C5 Allroad 2.5TDI needs a suspension overhaul.
    Air shocks seem OK although car is nose up at with ignition off.
    Compressor has been recently bagpiped.
    Mostly the bushes, control arms, CVs etc need renewing.

    Recommendations for mechanics to do such work (in the Sydney area) would be welcome.
    Does it require a specialist Audi mob and/or equipment or can this work be done DIY?
    Are some of those eBay etc. suspension kits good quality and comprehensive?

    Thanks in advance, Peter
    2003 C5 Allroad 2.5TDI
    1996 B5 A4 1.8T (sold, still in family)

  2. #2

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    Hoskins Auto at Mortlake. Euro Specialist. 8765 8718. Ask for Ralph.

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    ginkgo (February 16th, 2018)

  4. #3

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    Quote Originally Posted by ginkgo View Post
    Hi,
    I am an OzAudi noob with some mechanical skills.
    My newly acquired C5 Allroad 2.5TDI needs a suspension overhaul.
    Air shocks seem OK although car is nose up at with ignition off.
    Compressor has been recently bagpiped.
    Mostly the bushes, control arms, CVs etc need renewing.

    Recommendations for mechanics to do such work (in the Sydney area) would be welcome.
    Does it require a specialist Audi mob and/or equipment or can this work be done DIY?
    Are some of those eBay etc. suspension kits good quality and comprehensive?

    Thanks in advance, Peter
    You probably need to decide if you want to do this or get it done. I've done a few B5 / C5 suspensions and it is easy if you know what you're doing and have all the tools. If not then it becomes a bit of a backyard job.

    If you are nose up and have no leaks then the height sensors need looking at. I replaced the front Arnott bags with newer design Arnott bags a few years ago, no issues. Upper and lower arms are easy , again if you know what you're doing. This applies to any mechanic too. Not all know any of the tricks for this model Audi. You need to loosen the front sub-frame for lower arms and replace certain bolts as they are one use only.

    Bottom line is that if you are professionally competent then the work is a no brainer or alternatively hand it over to a knowledgeable mechanic and it'll just happen (for a price).

    Personally, no matter where you get your parts from, use only OEM parts or a very high quality replacement. EBay stuff can be cheap and nasty or countrerfeit and the cost to redo is far more than you save.
    B5 RS4 : Lightly modified -- C5 2.7 allroad -- B5 A4 1.8 quattro 132 Kw -- UNIMOG 404 TLF8

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    ginkgo (February 16th, 2018)

  6. #4

    Cool

    Thanks sk67 and IchBautAuto for the good advice.
    After watching a few Audi suspension videos I have decided to do the work myself (yes I am that impressionable :) and brother has offered to help (a bonus).
    Job needs finishing by mid March so have 2 weeks of sussing, sourcing and planning, and two weeks to do the work (anticipating 1/2 day's work at best).
    I will probably document the process and post it to OzAudi.
    Now what the %@&%! are height sensors :)
    2003 C5 Allroad 2.5TDI
    1996 B5 A4 1.8T (sold, still in family)

  7. #5

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    You're the man if you can do that in 1/2 day. I did mine myself so obviously better if more than one on the job. Are you planning all control arms or just uppers? You can be lucky and all pinch bolts etc come away free or you can spend an hour or three on each one. One hell of a portion of your time will be determined by the existing condition of whats there and also the tricks to get stuff in and out plus buying everything that you forgot to order in the first place. A good number of suspension bolts are TTY (one use) so they need replacing. Plus subframe bolts too.

    The height sensors are a pot and arm for each wheel (attached to the suspension). Be careful and don't break them. Also, deactivate the suspension pump before you jack it up. Good breaker bar required and a few quality sockets. These cars respond well to quality worksmanship so a little TLC goes a long way. You will need to pre load the suspension before tightening the bolts. Do you have a car lift or hoist? Worth their weight if you do. Good luck, will be watching the story unfold. Feel free to PM if anything crops up, I may or may not have stumbled across it in my trials.
    B5 RS4 : Lightly modified -- C5 2.7 allroad -- B5 A4 1.8 quattro 132 Kw -- UNIMOG 404 TLF8

  8. #6

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    I think you might have just talked him out of doing it himself Tony. Lol.

  9. #7

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    Quote Originally Posted by sk67 View Post
    I think you might have just talked him out of doing it himself Tony. Lol.
    Hey, that was the good news story. Got to say that my allroad has been a dream to work on. Not one of the real issues that crop up for others (so far).

    The RS has been good too, a little more crap on the front of the motor before I cleaned it up, a few more bolts needing replacement, and a lot of things needed replacement due to age but the big issue has been just that little less working room between the C5 and B5. Makes all the difference.
    B5 RS4 : Lightly modified -- C5 2.7 allroad -- B5 A4 1.8 quattro 132 Kw -- UNIMOG 404 TLF8

  10. #8

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    Thanks folks, much appreciated.

    The control arm kit has arrived...
    Click image for larger version. 

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    Should I move this story to another forum?
    2003 C5 Allroad 2.5TDI
    1996 B5 A4 1.8T (sold, still in family)

  11. #9

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    Start a new thread on the forum of choice. Good looking kit, A bit of work and it'll all disappear and you'll wonder where it's gone. Anti seize on the pinch bolts is mandatory. I made up a jig to set up the steering ball joints, put the alignment exactly as it was before the work. Pretty straight forward otherwise, have you got all the torque figures?
    B5 RS4 : Lightly modified -- C5 2.7 allroad -- B5 A4 1.8 quattro 132 Kw -- UNIMOG 404 TLF8

  12. #10
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    I used this guide for A4 B5 1.8T Quattro:-
    https://www.blauparts.com/audi/audi_...rol_arms.shtml
    Took a whole day to do it on my own, and I have a pretty good tool collection.
    It really tested my skills, especially the upper pinch bolts. There are special tools developed for pinch bolt removal for good reason. Aussie ingenuity, my bearing puller, some g-clamps and a bit of trial and error. Be careful of the ABS Sensor, tone ring and wiring, suggest remove the sensor and give it a bit of a clean. Note the installed position of the sensor too.
    I was careful to mark and maintain the installed position of the subframe and steering tie-rod ends as well. It tracked beautifully, but I did get a wheel toe-in check and alignment done anyway.
    Next time I'll just cut the head off the pinch bolt and tighten the nut to draw the shaft out. Maybe a pin punch would work too.
    Followed the instructions and found the lower inner control arm bolts very tricky to undo as well, as the nuts are inside the subframe and hard to get a socket onto.
    I was pretty knackered at the end of it.
    Bought this kit for A4 B5 1.8T Quattro
    Cost AUD$280 shipped from USA
    There are some other kits now available from ebay suppliers too.
    I was really happy with detailed specifications for the unbranded kit that I bought, so won't enter into debate.
    http://www.ebay.com.au/itm/Audi-A4-A...-/201486692940
    Last edited by DirkOz; February 22nd, 2018 at 07:49 AM.

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    ginkgo (March 3rd, 2018)

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