A few weeks ago I gave the suspension on my Mk2 valver a major overhaul. Polybushes, Eibach springs etc etc.. All was well until it started creaking like a mo fo. So knowing that polybushes do create a bit more noise than standard bushes for the third time I checked all the torque settings and the bushes. I found that the rear wishbone bolt (the one with the big round bush that bolts into the chassis leg directly under the floor) was spinning in it's captive nut making it impossible to tighten.. bottom! It didn't feel like it was threaded, it felt like the captive nut had broken loose from it's tack welds and was just spinning with the bolt. Did a few searches on here and vortex and realised that it's quite a common fault.. not being able to find some good images on the fix I took a few on the weekend.. Access plugs in the floor are by no means big enough to get at the bolt.. So I cleaned up the floor and made 2 cuts.. ..with a 1mm plasma cut disc.. Heat the metal a bit with a blow torch and bend it back.. The bolt isn't actually a bolt, it's more of a dommed press fit flange thing.. and yes it was spinning with the bolt. The chassis is caked in wax so it needs scraping off before welding.. Weld the mother in place.. (a bit tricky) Tighten the bolt NOW just incase the welds don't hold. Once your happy it's holding firm spray the whole area with fresh wax, bend the floor back into place and tack it back down.. Seam seal the welds, and replace the plugs with more seam sealer. Then paint the exposed metal with zink rich paint to stop any rust.. Replace all the underlay and carpet.. job done! Took about 3 hours.. may take longer if the bolt is threaded as it'll need replacing.
Useful info, mate - could put it in the FAQ section at some point. What is a '1mm plasma cut disc'? (I can't see the pictures here at work). Edit: Aha, I think I have found what you mean now. Ultra thin cutting disc: http://www.machinemart.co.uk/product.asp?p=060532050 Edited by: Trev16v
Yeah Plasma cut discs haven't been out long, made by Clarke.. very fragile but excellent for cutting sheet metal leaving only a 1mm gap. Cheaper than buying a plasma cutter
Right, definitely going to get myself some of those discs. I've had to do some much bigger plating repairs on my project MK2 shell in that sort of area on the passenger side. I even have got brand new VAG jacking area panels should things get that bad...
Whilst in that area I did notice some suspect creasing around the jacking point?! Not surprised seeing how some a-hole mechanics just ram the jack under and slam the car down after. Saying that it's not a very strong area really!
Good write up mate ! I need to remove the captive nut part from the floorpan, best way to go about this is ? Can i get a new one from VW if its cross threaded aswell ? Just tried to get the captive nut from VW the bloke was very helpful but couldnt find it ! DOH Mart
Also finding this very useful. I was just finishing replacing my wishbone when i snapped the bolt clean off inside the captive nut. Any ideas on how i can remove this? thanks
