Audi 80 B4: Replacing Headlight Adjustment Motor

Hi there.
VW/Audi use the tool VW 3294 and pressure plates 3294/4 and 3294/1 for retracting and extending.
The tool kit is also used for other models.
I have the RLF (presumably a specific part or device). A garage solution for the 3294 is simple; only the pressure plates need to fit the guide bearing.
Does anyone know if the two pressure plates are simply flat discs?
hg
Herbert.

If you're dealing with cans like the ones in the photo, you can use a flat die (full impression).

"Thank you!"
My approach also involves inserting and removing the bearing bushings using flat pressure plates.
I've always made my own tools for these types of bearings. The experience is that assembly is much easier when force is applied directly to the bearing seat. Using a flat tool, I would end up pressing and squeezing the rubber during installation.
Therefore, the precise question is: what does print piece 3294/1 specifically look like?
hg
Herbert.

Hello!

So, I always made the printing blocks myself.
I now have a whole box full of various homemade tools, spindles, and other things.
I once had a friend cut a large number of steel plates for me, each measuring 15x15 cm and being 8 mm thick.
That's a good foundation for something like that.
The remaining parts are drilled, cut, or welded together.
Then there are also many different sections of pipe.
"These rubber grommets are actually suitable for almost all rubber bushings in various car models."
Also other types.


I also think that a regular license plate is sufficient for this car.

Quote:

With a flat tool, I would press and squeeze the rubber while inserting it.

If it's about cans like the one in the photo, you inevitably have to press down on the rubber part; there's no other way.

In the open design, pressure must only be applied to the metal from the outside.

Hi there,
The bearings are like the ones shown in the picture. My thought was that the printing plate doesn't rest on the rubber coating around the collar of the cylinder, but directly on the metal all around the collar and on the three crescent-shaped recesses in the rubber.
The pictures of the special tools used at Volkswagen don't show that.
"You can find suitable washers at the hardware store, as well as M12 screws. To provide support, I use a coupling or a short piece of pipe with an appropriate inner diameter."
Thank you.
Herbert.

Hello there!
After the repair was completed, I wanted to provide a brief overview of the parts used in place of the VW 3294 tool set, specifically mentioning the pressure pieces 3294/1 and 3294/4.
The guide bushings shown in the photo from Autoservice above were replaced with part number 8A0 504 541. The dimensions of this guide bushing are: bore diameter 56 mm, collar diameter approximately 70 mm, and length approximately 88 mm.
Basically, the extension and retraction are achieved using a screw that is supported on one side by a plate and a tube attached to the axle body, and on the other side by a pressure piece acting on the guide bearing to be moved.
Basic requirements:
- The pipe must be sized in terms of length and inner diameter to ensure that it can completely accommodate the guide bearing being extracted.
- The smaller bearing must be suitable for removal by the shaft housing, meaning its diameter should be less than 56 mm, but not less than 54 mm, to ensure it presses against the sleeve and not just the rubber of the bearing.
- The larger printing plate must completely cover the wider face of the guide bearing to ensure even pressure distribution.
I then used:
- M12 screw, 180 mm long (includes nut and washers).
- as a large printed piece, a steel disc measuring 79mm x 22.8mm with a thickness of 7mm (available from ironmongers).
- as a small printed piece, the inner race of a defective stainless steel wheel bearing;
- Two square tubes, 80mm in diameter and 3mm thick, from the metalworker: one 100mm long, the other 50mm long.
- various washers and a steel plate as a counter bearing.
Standard M12 machine screws only have a thread length of 40 mm, which is why you need to extract them first with the short piece and then with the long piece.
The tool VW 3294 has a stop for the protruding portion of the sliding bearing to be inserted. Instead, the protrusion dimension is: h = 18.5 mm, measured between the shaft body and the edge of the bearing sleeve (which is pressed by the shaft body).
Thank you for your help, especially to wolfi_b for the dimensions of the lever for the brake force regulator!
hg
Herbert.

Okay, I'll close it then.
hg
Herbert.