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TT "Arms Race" - DEFCON Install

This album contains the instructions needed to install the DEFCON system of components. This is the recommended install method, and will require the use of a heavy duty press. You can successfully install all the DEFCON components using a vise or arbor press - if the old bushes are not present. Unfortunately, in my experience, you will need a large press (at least 20-ton) to remove the OEM bushes from the arm, due to corrosion of the arm locking the bushes in to place. Harbor Freight has a 20-ton press available for around $200:

http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=37999

If you do not have a press, and don't want to use one, these photos may help your shop determine how to remove the old bushes, and install the new parts.

Re-installation Torque Specs:

Control Arm Bolts: 50 ft-lb (70 Nm) PLUS a quarter turn (90 degrees).

Note: Per the Bentley manual, these bolts should be torqued on the ground/with the arms "loaded".

Lower Ball Joint Nuts: 55 ft-lb (75 Nm)

Note: Post installation, a full 4-wheel alignment is strongly recommended. Altering suspension components can change your alignment, no matter how carefully parts are reinstalled. Improper alignment can result in significant tire wear in a short time, and/or poor handling characteristics.

Slideshow | Invite
DEFCON status - States in red have been 'compromised' - 26JAN07 pm
1
DEFCON status - States in red have b…
537 views
 
DEFCON status - Countries in red have been 'compromised' - 19JAN07
2
DEFCON status - Countries in red hav…
507 views
 
Ringy TT
3
Ringy TT
813 views
 
Are your arms MK1 or MK2?
4
Are your arms MK1 or MK2?
1506 views
 
Front Bush Diameter
5
Front Bush Diameter
1409 views
 
Homework!
6
Homework!
1547 views
 
Bush bolts to be removed
7
Bush bolts to be removed
2060 views
 
All bolt connections shown here
8
All bolt connections shown here
1787 views
 
View from above the arm
9
View from above the arm
1777 views
 
Passenger side bolts
10
Passenger side bolts
1554 views
 
Passenger side FRONT bolt
11
Passenger side FRONT bolt
1365 views
 
Passenger side REAR bush
12
Passenger side REAR bush
1358 views
 
Ball joint nuts (3)
13
Ball joint nuts (3)
1346 views
 
Ball joint nuts
14
Ball joint nuts
1238 views
 
Headlight leveling bolt being removed
15
Headlight leveling bolt being remove…
1498 views
 
Driver side arm
16
Driver side arm
1467 views
 
Front bush bolt
17
Front bush bolt
1343 views
 
Driver side arm, from below
18
Driver side arm, from below
1328 views
 
Driver side rear bolt
19
Driver side rear bolt
1373 views
 
Driver side rear nut
20
Driver side rear nut
1264 views
 
Ball joint end lowered
21
Ball joint end lowered
1319 views
 
Arm extraction
22
Arm extraction
1455 views
 
Pull straight out
23
Pull straight out
1485 views
 
MK1 "Recalled" Arms
24
MK1 "Recalled" Arms
1660 views
 
A single arm
25
A single arm
1812 views
 
OEM Front MK2 bush
26
OEM Front MK2 bush
1597 views
 
OEM Rear bush
27
OEM Rear bush
1688 views
 
Rear bush, from bottom
28
Rear bush, from bottom
1406 views
 
Front bush bore - after pressing out bush
29
Front bush bore - after pressing out…
1657 views
 
DSCN8029
30
DSCN8029
1581 views
 
Cleaned rear bore
31
Cleaned rear bore
1649 views
 
DEFCON bushing preparing for installation
32
DEFCON bushing preparing for install…
1759 views
 
Frozen bushing starting to sweat
33
Frozen bushing starting to sweat
1623 views
 
Rounding third base.
34
Rounding third base.
1648 views
 
Driven home
35
Driven home
1939 views
 
Now for the rears...
36
Now for the rears...
1948 views
 
Orientation of MK1 rear bush
37
Orientation of MK1 rear bush
2225 views
 
MK1 arms, Rear Bush
38
MK1 arms, Rear Bush
2184 views
 
MK1 Passenger rear bush
39
MK1 Passenger rear bush
1727 views
 
Placed for pressing.
40
Placed for pressing.
1597 views
 
Pressing tools...
41
Pressing tools...
1730 views