Audi 80/ 90/ Coupe B3/ B4 steering gaiter replacement

Audi Nut Joined: Aug 07, 2012 Posts: 90

As my 1993 Audi 80 coupe 2.0 16v just failed its mot on the steering rack boot rubber, and the tester said it is a really common problem ( so all go and check, may apply to older models like b3, 90's etc).
Well, the part is stocked still by Audi, cost me £10 odd. I shall be replacing it this week when part arrives.
Is it worth me doing a 'how to' guide, as it is relatively easy for home DIYer, and not covered very well in Haynes manual?

Posted: Sun Aug 12, 2012 5:11 pm

yes please- I'll make it into a "sticky" and possibly put it on the homepage. If you struggle uploading the pictures (it shows them in reverse order of uploading) let me know and I'll see what I can do Wink

Audi Nut Joined: Aug 07, 2012 Posts: 90

Righto, leave it with me, I'll get it all sorted, and keep you posted. Got to wait until tues for part, but have to do it this week, 10 day window for mot retest! I can't stress enough that people need to go check. To fail an mot on such a simple part, I'm gutted!
If I struggle with pic's, I know where to come! Very Happy

Posted: Sat Aug 18, 2012 11:20 am

cheers

Audi Nut Joined: Aug 07, 2012 Posts: 90

Well, project 'pink Annie' passed her mot retest today! Very happy man. Zoomed to get the tax and all is well! Love it!
I'll do the write up of the gaiter tonight

Audi Nut Joined: Aug 07, 2012 Posts: 90

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Audi Nut Joined: Aug 07, 2012 Posts: 90

Well here goes steering gaiter replacement.
Please note, I am not a mechanic, and this is a guide only. You know if you are capable of doing it or not, if in doubt, use a garage.
Right, sensible bit out the way
You will need the following:-

I don't think the gaiter boot changed much over the years and this should fit most later models, 80, 90's and prob 100 and a 6 models etc. double check though. Mine is a b4 1993 Audi 80 coupe 2.0 16v ace
You will also need
Large cuppa tea
Socket with 17mm
Torque wrench
Flat headed screwdriver
Approx 2.5 foot of wood (not essential)
Blooming small hands

The offending article. It is located behind the engine and bulk head. It is held in place by the carrier which is the two 17mm bolts on the picture at end of boot gaiter

Now, undo these two bolts. You have limited room, they have probably been in place for 20 years, and mine were held fast
I used a short tyre wrench in the end to start them, then socket. Once you have nuts off the top leaving bolts exposed, DON'T try and bash them out. They are threaded.
Socket underneath and begin the slow long winded process of undoing them.
In the picture you can see one on its way out, with the carrier above and below the steering bar ( slightly rusty colour)

Once both bolts out, pull the carrier away from the bar towards engine block

This is the carrier free from bar. The bar is now underneath the carrier
Now you can either use the wood to wedge underneath the carrier pushing it up and towards engine giving you room to get at the boot, or just keep pulling it out of the way
Bear in mind the wood needs to be wedged under the carrier and down onto the ground, so under tray needs to come off. Mine was off for service and cleaning anyway.

Pull off the old boot, it may be held on by zip tie or jubilee clip.
Old one versus new one

You can see mine on the right has perished badly

Rescue the end plastic cap. Clean it and insert into the end of the new gaiter

Then to save time and a lot of messing about, put the jubilee clip on the other end and do it up just to hold it loosely in the right place. Audi kindly has moulded a groove on one end of the gaiter
Clean and grease the steering rod then slide new boot in place. Jubilee clip end on first and make sure rubber boot fits over the end of the power steering rack. You'll know when it's sitting properly
Other end of the boot, which has your recycled plastic end cap (shaped the same as the rod your sliding onto) slide into position so that you can see both bolt holes on the rod.

Tighten jubilee clip up. Or zip tie, as long as it is held in place.

Here, new boot slid into place, you can just see jubilee clip at other end. You need a long screw driver as its fiddly to get to

Now remove wood from under the carrier (if you used one or did what I did and just keep moving it out the way!)
And slide rod back in between the carrier.
Line bolt holes up( might have to have a helper slightly turn steering wheel to line up properly)

Put bolts in holes and tighten up with socket

Torque bolts up and job done
And because I'm anal, I put one bolt in upside down
So if one shears/fails/ comes loose, the other should hold it

Allow an hour, only because the bolts could be stubborn coming out like mine were.
Hope it helps
Made my car pass its mot anyway
Good luck, please please go check your gaiters
It's not worth an mot failure, and will keep the crud out of your steering box, so no premature failure

Now have another large cup of tea or something stronger

Posted: Sun Aug 19, 2012 4:10 pm

thanks for the write up- will make this a "sticky" and add to the home page Wink

Audi Nut Joined: Aug 07, 2012 Posts: 90

No worries, hope it helps someone! Very Happy

Needs to get out more Joined: Jan 07, 2014 Posts: 107

yep will help me Smile

thought that did't look right so going to order a new one looks relatively simple to fit Very Happy