Suspension woes

Chrees

Member
Joined
Jun 25, 2017
Location
Florida
TDI
2006 Golf GLS TDI
Hey guys, I'm new to the forum. A month ago I picked up a 2006 Golf TDI GLS with two owners both of which are within the same family. The previous owner I bought it from decided to upgrade the stock suspension with OEM suspension components from a GTI. Another upgrade were what I assume are GTI brake calipers and stainless steel brake lines. Unfortunately, after inspecting it, I discovered that the beefy sway bar end links are hitting the brake line fittings at full lock. You can see in the pictures I'll provide down below where there are wear marks on the end links from striking it.

I've tried researching this problem through this forum but I can't seem to find anything close to what problem I'm having. I decided today to order some 23mm OEM swaybar end links hoping that they are smaller in width and will give me the clearance I need to keep the current suspension set up the car has. If not, I suppose I'll have to go back to an original TDI sway bar up front. Sound about right to everyone? If you have input on this problem I'd love to hear it!


 
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Chrees

Member
Joined
Jun 25, 2017
Location
Florida
TDI
2006 Golf GLS TDI
it's the endlink bolt that is the issue.

Is the endlink reversible?
That's something I didn't consider. I'll try that out. Thanks! My concern is that regardless of how the bolt is positioned the brake line fitting with strike the flat surface on the end link just based off the marks on them already. I'll see if I can flip them around and if not I've got some stock ones rolling in.
 

Chrees

Member
Joined
Jun 25, 2017
Location
Florida
TDI
2006 Golf GLS TDI
So I tried reversing the end links but since one bolt had a nut and the other bolt threads right into the lower control arm, the bolts can't change. So they're still striking. Still waiting on new end links to arrive so hopefully that fixes the issue! I don't see any brand or stamp on these end links so my guess is they're eBay specials.
 

Chrees

Member
Joined
Jun 25, 2017
Location
Florida
TDI
2006 Golf GLS TDI
Alright, so I switched the aftermarket sway bar end links to the OEM plastic ones. I am still having issues where the brake line fitting on the caliper is hitting the bolt at the top of the sway bar end link.

Anyone have any recommendations? Any additional information or pictures I can provide to get an accurate idea on what my issue is?
 

UhOh

Top Post Dawg
Joined
Dec 24, 2014
Location
PNW
TDI
2003 Golf GLS (2005 Mercedes E320 CDI)
Wondering whether there were different sway bars.... Perhaps you're going to need a different one?
 

Golfrunner

Veteran Member
Joined
Feb 19, 2011
Location
Saratoga NY
TDI
2005 Golf TDI
Maybe the brake line fitting to the caliper vary enough that going back to the OEM line set might provide adequate clearance? I'd guess that the dimensions of the fitting, and even the line orientation might be different for the SS line vs. the rubber OEM type.
 

UhOh

Top Post Dawg
Joined
Dec 24, 2014
Location
PNW
TDI
2003 Golf GLS (2005 Mercedes E320 CDI)
Follow-up to my previous post... Stabilizer bar (sway bar) shows as same part number for the TDI and GTI.
 

wonneber

Top Post Dawg
Joined
Oct 12, 2011
Location
Monroe, NY, USA
TDI
2014 Jetta Sportwagon,2003 Jetta 261K Sold but not forgotten
Going to ask a sill question.
Can the sway bar be in umop 3pisdn :)
 

Chrees

Member
Joined
Jun 25, 2017
Location
Florida
TDI
2006 Golf GLS TDI
Maybe the brake line fitting to the caliper vary enough that going back to the OEM line set might provide adequate clearance? I'd guess that the dimensions of the fitting, and even the line orientation might be different for the SS line vs. the rubber OEM type.
I'll try and source some OEM brake lines to see if there are any major differences between the set I currently have and the OEM ones. This isn't a racecar by any means so I'm not opposed to returning to OEM form if it gets me back on the road again!


Follow-up to my previous post... Stabilizer bar (sway bar) shows as same part number for the TDI and GTI.
Thanks for looking into that! I thought there were differences between the GTI and TDI sway bars. That eliminates replacing my current sway bar with an OEM one. Thanks for saving me some money!


What does the clearance & (vertical) angle of the endlink look like on the other side?
Both sides are identical in clearance and angle but I'll take some pictures tonight and post them immediately to provide more information on this issue.


See if you can get a button head screw instead of a cap screw for clearance
Button head screw. Got it! I'll look into that and see if that helps eliminate the clearance issue. I'd love to keep these calipers since I don't have a set of TDI calipers lying around.


Going to ask a sill question.
Can the sway bar be in umop 3pisdn :)
Good suggestion! After sourcing some images of sway bar replacements it looks as though my sway bar is installed correctly.
 

flee

Veteran Member
Joined
Sep 19, 2011
Location
Chatsworth, CA
TDI
2002 Jetta GLS wagon
Ultimately the judicious use of a grinder on the link will let it clear and not weaken it much.
Does the link have to be mounted on that side of the bar?
Some racer-types have run with the front bar disconnected on the MKIV, too.;)
 

Chrees

Member
Joined
Jun 25, 2017
Location
Florida
TDI
2006 Golf GLS TDI
Alright, what ended up happening was I got some OEM hardware and OEM end links. Problem solved. Still not sure what brand the other end links were or what car they were for but they were clearly not meant for ours. Thanks for your help everyone!
 
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