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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
812 views
 
Are your arms MK1 or MK2?
4
Are your arms MK1 or MK2?
1506 views
 
Front Bush Diameter
5
Front Bush Diameter
1407 views
 
Homework!
6
Homework!
1546 views
 
Bush bolts to be removed
7
Bush bolts to be removed
2058 views
 
All bolt connections shown here
8
All bolt connections shown here
1786 views
 
View from above the arm
9
View from above the arm
1775 views
 
Passenger side bolts
10
Passenger side bolts
1553 views
 
Passenger side FRONT bolt
11
Passenger side FRONT bolt
1364 views
 
Passenger side REAR bush
12
Passenger side REAR bush
1356 views
 
Ball joint nuts (3)
13
Ball joint nuts (3)
1345 views
 
Ball joint nuts
14
Ball joint nuts
1237 views
 
Headlight leveling bolt being removed
15
Headlight leveling bolt being remove…
1497 views
 
Driver side arm
16
Driver side arm
1466 views
 
Front bush bolt
17
Front bush bolt
1340 views
 
Driver side arm, from below
18
Driver side arm, from below
1327 views
 
Driver side rear bolt
19
Driver side rear bolt
1372 views
 
Driver side rear nut
20
Driver side rear nut
1263 views
 
Ball joint end lowered
21
Ball joint end lowered
1318 views
 
Arm extraction
22
Arm extraction
1454 views
 
Pull straight out
23
Pull straight out
1484 views
 
MK1 "Recalled" Arms
24
MK1 "Recalled" Arms
1657 views
 
A single arm
25
A single arm
1810 views
 
OEM Front MK2 bush
26
OEM Front MK2 bush
1596 views
 
OEM Rear bush
27
OEM Rear bush
1687 views
 
Rear bush, from bottom
28
Rear bush, from bottom
1405 views
 
Front bush bore - after pressing out bush
29
Front bush bore - after pressing out…
1655 views
 
DSCN8029
30
DSCN8029
1577 views
 
Cleaned rear bore
31
Cleaned rear bore
1647 views
 
DEFCON bushing preparing for installation
32
DEFCON bushing preparing for install…
1758 views
 
Frozen bushing starting to sweat
33
Frozen bushing starting to sweat
1622 views
 
Rounding third base.
34
Rounding third base.
1647 views
 
Driven home
35
Driven home
1931 views
 
Now for the rears...
36
Now for the rears...
1947 views
 
Orientation of MK1 rear bush
37
Orientation of MK1 rear bush
2223 views
 
MK1 arms, Rear Bush
38
MK1 arms, Rear Bush
2180 views
 
MK1 Passenger rear bush
39
MK1 Passenger rear bush
1725 views
 
Placed for pressing.
40
Placed for pressing.
1596 views
 
Pressing tools...
41
Pressing tools...
1728 views