Thanks guys. Its been a labor of love. I love the way she drives but man she asks for a lot of attention. She's a daily driver and frankly I haven't had the money to do what I really wanted and now I'm nervous of dropping serious loot into something with this many miles. So its been a history of...this breaks...replace with something better.
She's a B5.5 1.8T FWD Manual Wagon. She went into service in late 2003. I picked her up in 2007 with 30k...a mere fledgling. Seven years...170k...25k per year...nothing wild.
In that time, I have replaced the driver's side axle 3 times and the passenger side axle twice. Its a horrible design. Not too stoked with Marty at Raxle either. After replacing with a generic the first time...figured it'd be worth spending some dough for Marty's. Except when it went and he circled around the warranty. Ask me...its not worth the money.
Had to fix the dreaded wagon rear washer fluid elbow located behind the driver's side tail light. Horrible design. Nothing a little electrical tape hasn't taken care of. Also with the rear wiper, the stupid nozzle for the washer gets frozen in place and then shears off in the body spurting washer fluid in the hatch. I removed the nozzle and the cover and now I have my very own James Bond washer fluid sprayer for tail gaiters who get too close.
The original engine mounts are fluid-filled and those blew a little while back (oozing purple goo). So I replaced all the engine and trannie mounts with the 034 street density. Noticeably vibratory...noticeably more responsive. I will say that the modified snub mount holder that 034 makes broke. I need to reach out to those guys to let them know.
Got a good deal on a Techtonics Tuning downpipe and exhaust here on PassatWorld and had to jump on it. The downpipe is stainless and other than the covering on the flex-section and corrosion on the spare O2 bung...its fine. The aluminumized exhaust (with the exception of the stainless Borla) has utterly failed after 3 years. Every mandrel bend and every weld has corroded through. ONLY buying stainless for all exhaust parts from now on.
Was getting some surging from the turbo, so I replaced the diverter valve with the Forge 007.
Two years ago I put in Koni FSD's. I think I wanted more performance than they deliver but it did get rid of some serious ass waggle.
Last year I completely rebuilt the front end (was getting a little squeak and it was time)...replaced all the control arms, tie rods (inner and outer) and sway bar links and bushings. Noticeably tighter handling. Have always had trouble keeping her in alignment though...always pulls left.
Replaced the timing belt twice. Once at 120k (very late). Then had what I thought was a failing cam chain tensioner about 30k later...BAD metallic sound. Turns out it was the new(ish) timing belt tensioner...thank god nothing skipped. At that time, I replaced the cam chain tensioner (which was still good), the timing belt tensioner and the camshaft seals. Just recently the water pump started leaking and this past week I replace the belt, tensioner, pulley, pump, and thermostat again.
Had to replace the coolant flange at the back of the engine. HUGE pain in the ass. Hope this never fails...wouldn't wish it upon my worst enemy.
Replaced all the vacuum tubes with silicone when one of them fell apart. Also replaced the vacuum pump which failed. At this time I installed the turbo gauge and replaced most of the hoses that make up the breather/recirc system.
Had a few coolant hoses fail. And most recently the nipple from the coolant reservoir broke up. Brought up the parts and reinstalled in the dealership parking lot in 20 min.
Had a couple ignition coils fail before the recall. Sudden loss of power and throwing codes...probably a coil.
Moved to a K&N air filter. Those guys are great by the way. Had an issue and they warrantied out a filter that was 4 years old. Replaced the fuel filter once cause it was time. And the cabin air I replace every-so-often.
Just replaced all but one of the power steering hoses. One was worn out and could never get it to seal producing a slow leak. And it was time. Hoses only have so much in them.
Had an issue with the turn signal relay (which is in the Hazard switch). Also had to replace the ignition which surprisingly helped with a lot of strange electrical issues.
I replaced the brake fluid with Super Blue (as well as bled the clutch slave) only to find out that it fucks with the seals. To this day I have a squeak when I depress my clutch. Of course the bleed valve on the clutch slave is plastic and despite your best attempts will get rounded off.
After all this time, I am starting to hear some whining from the turbo but its still cranking. On the original clutch. No issues with the trannie except when its cold I have a little trouble with the synchros getting into 2nd (replaced the fluid with Amsoil a few years back despite the fact they say the original fluid is for life and that helped a lot). No sludge issues but I always have used full synthetic which I run pretty long. I do have some oil loss mainly from the valve cover and its not much. Corrosion is starting to catch up on the under side and makes some things a bitch to get off (I replace the long pitch bolt on the steering knuckle every year after the fight I had with both of the original fuckers).
....But man she still takes off on command and nothing beats that double-wishbone suspension.
-g