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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.

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DEFCON status - States in red have been 'compromised' - 26JAN07 pm
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DEFCON status - States in red have b…
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DEFCON status - Countries in red have been 'compromised' - 19JAN07
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DEFCON status - Countries in red hav…
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Ringy TT
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Ringy TT
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812 views
 
Are your arms MK1 or MK2?
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Are your arms MK1 or MK2?
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Front Bush Diameter
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Front Bush Diameter
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Homework!
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Homework!
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1546 views
 
Bush bolts to be removed
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Bush bolts to be removed
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All bolt connections shown here
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All bolt connections shown here
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View from above the arm
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View from above the arm
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Passenger side bolts
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Passenger side bolts
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1549 views
 
Passenger side FRONT bolt
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Passenger side FRONT bolt
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Passenger side REAR bush
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Passenger side REAR bush
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Ball joint nuts (3)
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Ball joint nuts (3)
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Ball joint nuts
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Ball joint nuts
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Headlight leveling bolt being removed
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Headlight leveling bolt being remove…
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Driver side arm
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Driver side arm
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Front bush bolt
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Front bush bolt
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Driver side arm, from below
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Driver side arm, from below
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Driver side rear bolt
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Driver side rear bolt
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Driver side rear nut
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Driver side rear nut
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Ball joint end lowered
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Ball joint end lowered
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Arm extraction
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Arm extraction
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Pull straight out
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Pull straight out
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MK1 "Recalled" Arms
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MK1 "Recalled" Arms
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A single arm
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A single arm
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OEM Front MK2 bush
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OEM Front MK2 bush
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OEM Rear bush
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OEM Rear bush
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Rear bush, from bottom
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Rear bush, from bottom
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Front bush bore - after pressing out bush
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Front bush bore - after pressing out…
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DSCN8029
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DSCN8029
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Cleaned rear bore
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Cleaned rear bore
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DEFCON bushing preparing for installation
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DEFCON bushing preparing for install…
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Frozen bushing starting to sweat
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Frozen bushing starting to sweat
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Rounding third base.
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Rounding third base.
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Driven home
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Driven home
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Now for the rears...
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Now for the rears...
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1943 views
 
Orientation of MK1 rear bush
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Orientation of MK1 rear bush
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2213 views
 
MK1 arms, Rear Bush
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MK1 arms, Rear Bush
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MK1 Passenger rear bush
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MK1 Passenger rear bush
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Placed for pressing.
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Placed for pressing.
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Pressing tools...
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Pressing tools...
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