Differential Pinion Flange Repair – BMW F Body

The other day our new customer brought their BMW 528i xDrive to us and were able to perform a Differential Pinion Flange Repair. To back up a little, our customer had their BMW at the dealership about 5 days ago and were already having issues days after picking it up. For example, the issues included a heavy knocking check engine light, driveshaft flex joint (guibo) issue, thermostat faults, and a number of other problems.

Repairs

We were about to diagnose the thermostat, knocking faults, and other issues. The only thing we’ll say is, use a torque wrench at 19 Ft Lbs / 26nm is necessary when replacing spark plugs. For the flex joints the dealership did tell them that the front and rear joints needed replaced. We removed the exhaust, then the driveshaft flex joints, and last the driveshaft supports. We then noticed that the differential input flange was the cause of the guibo failure. As you can see from the video below, there was an obvious issue.


 

Firstly, we removed the Differential Pinion Flange 48mm nut, buffer seal, and rubber washer. Secondly, we pulled the repair kit that we keep in stock. The BMW Part No. is 33127607158 / 33 12 7 607 158. Additionally, this is in the BMW part catalog as “Differential Cover Repair Kit – BMW (33-12-7-607-158)”. The full install guide is located here.

Notes:

  • Read this entire guide in the link above. You MUST NOT move the larger 12pt nut on the differential or serious damage may occur to the differential.
  • The only way to obtain a new flange is to order an entirely new driveshaft.

After all the repairs were complete, we test drove the vehicle. Now their BMW drives very nice now.

For more information on how to get your BMW in the shop for some service, or maintenance, contact us at 425-254-0627. You can also schedule an appointment or receive a quote by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and at the westside of the Paccar / Kenworth plant.

Throttle Body Solution for a Early Audi 4.2L V8

Our 2000 Audi A6 4.2L V8 loaner car had a throttle body (TB) fail on it a few weeks ago and we needed a Throttle Body Solution.For the life of us, we could not find a ne, let alone a used unit. After searching the internet on and off for days end, we finally found a compatible throttle body. Apparently the Porsche 986 996 997 & GT3  uses the exact same 75mm housing. This is Part Number: 997 Same bolt pattern and casting for a 4.2L V8 – 2000 Audi A6. It’s also the same throttle body for a 2000, 2001, 2002 and 2003 Audi A8.

Harness Pin Diagram Throttle Body

 

Harness Pin Outs

The only a few slight differences that we found. Our throttle body and the Porsche TB both have 6 pin connectors. Although, the Audi pins are an even 6 pin pattern and the Porsches are an offset 6 pin pattern. This makes the connectors non-interchangeable. Also the pin outs are different. They are not a 1 to 1 pin out. As a result, I had to build a pigtail to plug directly into our harness. I could have repinned the OE harness with a different connector, but that was more work. After finding this out, I pulled the wiring diagrams from both vehicles and the schematics for the internal units are exactly the same. The wires got to different pin numbers. The wiring diagram for the pigtail  is shown below.

Connectors

As noted above the connectors are completely different, with a different patterns. The 75mm Porsche 911 throttle body uses this part found on Amazon. There is no part number that would could find in the Porsche parts catalog. But this part fitd perfect. For the Audi side of the pigtail, we purchased this kit, also on Amazon. We only needed the male part of this, but found it less expensive to purchase both sides. The other side can be saved for another project or ‘just in case’ situation.

Part Numbers

There are a few different 75mm Porsche throttle body part numbers that can be referenced. VW, Porsche and Bosch use different part numbers, however they all are the same part. The Porsche number, seen in the photo, is 997 605 115 01 / 99760511501. The Bosch part number 0 280 750 474 / 0280750474. The VW part number is 002 133 062 AJ / 022133062AJ, although no VW pr Audis that we know of uses this part. Porsche is owned by VW so naturally they put a VW part number on there. Fairly common throughout the history of VW, Audi and Porsche partnerships.

This throttle body bolts directly onto a stock 2000 Audi A6 and 2000-2003 A8s intake manifolds. With a custom built pigtail harness, will plug directly into the harness for the stock part number which was 077 133 062 / 077133062. This part number is NLA and is impossible to find new or used.

Performance Throttle Body Solution

Another thing that we noticed, the 2001 and up V8 Audis have a smaller throttle body plenum. This is either 65mm or 70mm. Unfortunately we ordered three different throttle bodies, and found this out the hard way. Furthermore, the bolt pattern on these is different. The inside plenum is also too small and would drastically reduced performance on our 2000 Audi A6 – if it happened to fit the bolt pattern, which they did not.

The part numbers that do not fit are the following: Bosch 0 280 750 487 / 0280750487 – Audi: 079 133 062 C / 079133062C. However, if you have a 2001 A6 / S6, A8 / S8, etc., with a smaller throttle body, this would be a great performance upgrade. We found a few companies online that sell the manifold and throttle body kits to install on a later model. You also might be able to hone out your stock manifold to open up to a 75mm opening. Although, you would need a adapter plate as the bolt pattern is slightly different.

For more information on how to get your Audi A6, 4.2L V8 Audi or any vehicles listed above, in the shop for service, maintenance or custom work, contact us at 425-254-0627. You can also schedule an appointment or receive a quote by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and at the westside of the Paccar / Kenworth plant.

Mercedes Benz TRP Order Form

If you are a NASFT shop and need to fill out a Mercedes-Benz TRP D1 Form, there is a work around to get this to work. What happens is when entering a VIN it will give you a note that pops up. It will say “More information for Mercedes Benz. It looks like this:

After that, if you attempt to enter the zip code from the dealership you are trying to submit your Mercedes Benz TRP D1 Form, you may see this error come up. You will not be able to choose a dealer. Anything you try, it will not populate a dealer. Those errors will look like this:

The only work around, that NASFT does not tell you is to enter a VIN that is less that a few years old. You can also use a previous VIN that has worked in the past. This will allow you to choose the dealer you are submitting your Mercedes Benz TRP D1 form to.

Once that dealer is selected, you can now change the VIN back to the one you are submitting. Personally, I did not click on the ‘Decode’ button and made sure all of the info in the vehicle selection boxes were the same. It may still populate ok, I didn’t want to have to go though this all again if it didn’t work.

From time to time customers ask us if we accept Aftermarket Auto Warranties for their vehicle.  Unfortunately, we do not work with these companies. We use to work with them quite a bit. However, over the years, these companies have been difficult to work with.  Here is a comprehensive guide on all the ins and outs on how these companies work, what to expect and what you need to know when planning on purchasing one.

What are Aftermarket Auto Warranties?

The first question you might be asking is, what are Aftermarket Auto Warranties? When purchasing a used car from either the dealership or used car lot, they may offer you a warranty for an additional fee. Most used cars are ‘As Is’ with no warranty. This is where these warranties comes in.  Sometimes dealerships such as Mercedes-Benz, BMW, or Audi will sell certified pre-owned vehicles. If they are still within the factory warranty timeline, they will still retain a factory warranty. If they are out of that factory warranty they defer to an aftermarket. So, please make perfectly clear with your sales rap, before purchasing a used vehicle.

Companies, such as CarMax, use a third party company called Assurance. Other dealers use different companies as well. The reason being, they would have to classify their businesses as an insurance company which separates the two entities. For example, other third party Aftermarket Auto Warranty companies are Complete Car Warranty, and Concord Auto Protect, just to name a few. Even the commercials you see on T.V., with Ice-Cube promoting CarSheild uses a third party entity. This is a completely different entity called American Auto Shield.

The aftermarket warranties are not the same as manufacturer’s warranty. They are third party, private companies that are in business to be profitable. America’s free market dictates that they can conduct business to be profitable, which we fully support. However, the way in which they conduct business is questionable at best. They are in business to pay the least amount possible, so they can be as profitable. This rolls in into our next topic.

How Aftermarket Auto Warranties are Presented & Sold

Some dealership that sell these, use tactics that are borderline fraudulent. A sales rep may tell customer that you are buying the “The Best” or “The Platinum” policy. They may say that it covers everything. This is often not the case. These plans have many options. Some include, ‘Internal Engine Only’, ‘Engine & Drivetrain’, and/or Fully Vehicle Coverage’ plans. Each company has their own legal terms and agreements, so these will all vary. The better the plan, the more they cost. Rarely, some plans also include maintenance plans. These cover oil changes, flushes and wear items such as belts, Bushings, and timing chains . Make sure you know exactly what you are purchasing before you agree to pay. Most premium warranties are around $3000-$4000 depending on coverage.

For Example

One of our Meister Werks employees recently purchased a used Mercedes. The sales rep tried to sell them one of these plans. It was almost $8,000 on top of the vehicle cost. They declined it, but it was insanely expensive. Most of the time the sales rep will markup the price on the warranty and will take the rest of the money for themselves. So, if you decide to purchase one, don’t pay too much.

It is our opinion (and much less money) to open a savings account and have $50-100 transferred to that account every two weeks. IF you can find a savings account that compounds interest, you will actually make money on your deposits. If you deposit $100 every two months, in a year, you will have around $2600. This is the average yearly cost to maintain and repair a standard European vehicle. If you don’t need to use the money, just let it keep growing. A used car will eventually need a large repair.

Keep reading and we’ll explain why this is a better option.

Your car breaks down & it’s time to use the warranty…

If you have purchased a warranty and your car just broken down. Here is how it all works.

  1. Firstly – The Breakdown

    You bring your car in and the repair facility diagnoses the problem.

  2. Secondly – Diagnostics

    The shop will write a quote based off the findings.

  3. Thirdly – How it really works

    The repair shop contacts the warranty company, typically on a 1-800 number. Some companies use a website, which is much easier and faster. Here is what happens:

    1. How Our Last Warranty Went

      I personally did for a customer, I was on the phone for 2-1/2 hours, most of this was waiting on hold. I had to give them every minor detail about the diagnostics, methods, and techniques on how we found the problems. Which is fine, and I understand why. However, this also included submitting very detailed photos of the leaks, VIN number and odometer reading. THEN, we had to call them back after these were submitted. When I got another rep on the phone, they told us why they were not going to pay the claim. The main reason was because we could not show them a leak that was deep inside the engine. As you know, most modern engines can be impossible to see where leaks are coming from. Furthermore, if we take the engine apart – we are not guaranteed and kind of approval from the warranty company or the customer. For which, we may not get paid for the service we just provided.

    2. Approval & Labor Rates

      The items they did approve, were based off a Meister Werks old hourly rate that was posted on some obscure website. This was posted over 6 years ago. On top of that, they said, if they were going to pay our currently hourly rate which was 25% less. Also, they said if they were to pay that out, ‘WE’ would have to call the questionable website and have them to change our hourly rate. This was absolutely absurde.

    3. Labor Times Pricing Payouts

      The labor times most repair facilities use are list by the manufacturer via special software. Many labor times do not include other procedures to access the part or remove components. These warranty companies do not read though the instructions and will just pull the labor time for that listing. Most of the time, these instructions list prerequisites before starting the actual repair. For example, to replace the turbo oil lines on a 2013 Mercedes C240, the instructions say First – remove drive belt. Then – remove alternator. This was an additional 1.75 hours for both. This labor time is not included in the repair of the turbo oil lines, which was listed at 0.6 hours. This give us no choice but to either eat the labor time or charge the customer the additional labor time to perform this repair. Almost every warranty job we performed required us to charge additional fees to the customer to make up for labor time that the warranty company would not pay for.

    4. Part Numbers

      To add to the insane policies of this company, they had to have every Mercedes part number, even though some of the parts were OES from the OE manufacturer. Such as Bosch, Hella, Continental, and Bilstein, just to name a few. These parts do not necessarily use the same part numbers as the manufacturer. Nevertheless, we still had to look up every single part number.

    5. How They Get Part Pricing

      The warranty company will only pay the list price. The adjuster said he was basing this off internet pricing and was actively looking for prices online. Furthermore, the prices were the cheapest aftermarket parts he could find. This is another reason we stopped doing warranty work. The prices they are finding are sometime less than what we buy the parts from wholesale and the lowest grade possible.

  4. Fourth – The Catch

    After the warranty company has complied all the parts needed, they will check all the labor times.Labor times are all based off what the industry calls ‘Book Time’. The problem with book time is it sometimes does not include all the information to complete certain repairs. For the example on the repair we were performing, we had to replace all of the turbo line seals. The book time to complete this was 2.1 hours. However to access this area, we had to remove the alternator. The book time on the alternator was 1.6 hours. These times are never calculated together and the warranty company do not read the instructions. If there are any additional times that need added, they will not do this and only cover the actual book time repair.

  5. Last – Customer Still Pays

    This leaves customer to pay for the additional work to complete the repair that should be included, but is not. In order try and get them to pay, we would have to argue with the adjuster and tell them how the repair is completed. Most of the time they believe they know more than us and will still not pay. This is just another reason why we do not do warranty work. The customer always had to pay for something and the companies would only pay a fraction of what they should.

In Conclusion

We will do Aftermarket Auto Warranties repair work under these circumstances. The customer pays everything up front, then has to submit the invoice to the warranty company after the repair are complete. We will not call these companies or get approvals. This will be the obligation of the customer and to find out if they can do this with their policy. This is so we do not have to charge the customer for additional paperwork. Also, this is so we do not have to tell the customer that it is not approved on their plan. If there are any disputes, we do not want to be the ‘Bad Guy’ telling you that they will not cover the work. Most of the time they will not cover everything and/or will not pay the hourly rate it takes to complete the job correctly. Not every company does it the same way so you will have to contact them and ask if you may submit the invoice after the work is completed.

1998 Jaguar XJR Cooling Fan Conversion

The other day we started on a 3d printing project for a customer’s 1998 Jaguar XJR Cooling Fan Conversion. One of the customer’s radiator cooling fans stopped working and the engine started to overheat. The fan assembly from Jaguar were quoted between $1100 and $1400 (for 2 fans and the shroud) We told the customer that there was a second option. The other option was to convert the fans over to brushless slimline style cooling fans.

The Process

I took about 20 measurements and traced the mounting holes. Then I scanned the tracings on my flatbed scanner. After that, I digitized the files and imported them into Fusion 360. After a few hours, the CAD files were done and it was ready to print. I stayed up until about 3am, making sure the first bracket was printing ok. It wasn’t. Some of the settings needed tweaked. I changed the settings and hit print again, praying that when I woke up the print would be good.

When I woke up 3 hours later the print was almost done and looked really nice. When that was done I removed it from the build plate. Then, I hit print again. I went into the shop to start modifying the shroud.

One of my techs ended up taking the motor apart and we extracted the OEM harness connectors. I wired and loomed that electrical connector to the fan harness. Furthermore, this made for a really nice, cohesive OEM looking connection.

Fitment

This bracket will fit the following Jaguars:

  • Vanden Plas – 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, & 2003
  • XJ6 – 1993, 1994, 1995, 1996, & 1997
  • XJ8 – 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, & 2003
  • XJR – 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, & 2003

How was it made?

The XJR Cooling Fan Conversion is printed on a highly modified AnyCubic Kobra Max 3d printer with Priline Polycarbonate CF. For example, here are the A-Z photos of how it was done, and how it all turned out.

Gallery

Question / Contact Meister Werks

For more information on how to get your XJR Cooling Fan Conversion installed, please call 425-254-0627. You can also contact us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and on the westside of the Paccar / Kenworth plant.

HVAC Fan Motor Resistors

HVAC Fan Motor resistors are responsible for controlling the blower motor speed. They do this by varying the voltage supplied to the blower motor. They are prone to shorts, corrosion, and overheating. When the resistor fails, typically, the highest setting is the only option that still functions. 

When replacing your heat, A/C, & ventilation blower fan motor or HVAC van motor, we always replace the resistor. We do this due to the potential that the old resistor may damage the new motor. We also replace the inexpensive relay just to ensure that you HVAC motor will not prematurely fail and that you’ll always have air flow though your HVAC system.

Another reason your fan motor might not be working is the switch on your dash. Although very unlikely, we have seen these fail on some cars. Vehicles with more modern digital temperature controls are a little more complex. These digital controllers are also known to fail, however diagnosing the problem is sometimes a little easier. Using a OBDII factory scan tool, we are able to scan the entire vehicle for fault codes. The HVAC system will typically tell us what to look at, although it never says, “replace this part”. We would have to manually inspect the components related to the fault codes and identity the exact problem.

Sometimes performing a service on your air conditioning system will fix the problem. Systems that have leaks and are low on refrigerant will not function. Other times too much pressure will cause it not to work as well. One thing we see a lot of is people trying to charge their own A/C systems with a over the counter bottle. This is by far the best way to damage your A/C system. We see more damage to A/C systems cause from owners thinking they can fix it with a bottle for $25. In the long run you might pay hundreds, if not thousands of dollars to repair this. Over pressurizing the system will damage sensors, pumps and expansion valves. Bring it to the professional with the correct A/C service machine and avoid costly repairs in the future.

For more information on how to get your European cars HVAC, A/C or Fan motor repaired in Renton, call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and on the westside of the Paccar / Kenworth plant.

Digifiz Manual for Volkswagen Mk2 Digifiz

This is the link for the factory Volkswagen Mk2 Digifiz Manual study guide. Also has the wiring harness diagram and explanation of how the digifiz works. Feel free to post this link. In exchange, all we ask is to leave us a 5 star review on Google, click here.

Manual as of July 1987
PN: 700 2809 04 20 / 700.2809.04.20

• Digifiz Factory Manual – Click Here

• Digifiz Owners Manual Insert – (Deutsche/German) – Click Here

 

Complete Kit – Everything you need

(For Reference Only – Please do not contact us
about buying this, we no longer have this)

Project 1991 Mercedes-Benz 560sec

It’s been a long road to completion but we finally got Project 1991 Mercedes-Benz 560sec finished today. Our customer came in about 6 months ago wanting to do a air suspension install on his 1991 Mercedes-Benz 560sec. We wrote him a quote based off his needs and some suggestions from Meister Werks. After approving the quote we ordered all the parts necessary to install his custom setup. The customer also wanted us to have the bumpers, side mouldings, mirrors and door handles painted white to match the body. We contacted our friends at Automotive Solutions to come out and do all the body work, prep and paint.

Fast forward a few weeks later, Covid-19 / Coronavirus hit the Seattle area and thus started the parts delays. It took a few months of waiting to get all the parts in. A few months later in March, we finally received everything and the install started very soon after.

Install Begins

We began the install by removing the bumpers, side mouldings, mirrors and door handles. While these parts were out, we started polishing the OEM stainless steel trim. After all the parts went into paint, we began the air suspension portion. We started the air system by disassembling the custom stereo setup in the trunk. The car stereo installer had fabricated a custom enclosure to house the rose gold plated air tank, Air Zenith air compressors and Airlift 3p manifold. We bent custom hard lines, powder coated them white (to match the body) and affixed all the fittings to the components. After we did this, we install them into the custom build enclosure. After that, we wired the Air Zenith OB2 compressors with 4 gauge wires and 80 amp fuses. We also ran the harness to the Airlift 3p manifold, connected the remote wire to the ignition on circuit and installed the 3p controller in the Mercedes-Benz 560sec center console. 

We had many issues with the custom air bags we purchased from a company in Germany. The bags were rubbing on the body and the upper bag mount did not line up with the control arms. Countless hours corresponding, assembly, disassembly, reassembly, photos and diagrams were sent to the manufacturers. After weeks of communications, we

finally got results and newly machined parts were shipped from Germany. After 3 additional weeks, we received new parts. Unfortunately the parts still did not work right. So we decided to machine the new parts in house to get them to work. What we machined was perfection and will be able to replicate this on any future projects. The Mercedes-Benz is now able to air up properly, lay frame and not rub on the body. These additional modifications to the air suspension was much better than the original kit.

More Custom

We also had to delete the Mercedes-Benz factory hydraulic suspension. To do this we removed the rear shocks, removed the hydraulic pump on the engine and machined a custom block off plate. We used 6061 T6 aluminum to machine this part in our inhouse machine shop. We also made a custom gasket on our CNC cutter. Everything installed perfect, with no leaks or issues.

The components now installed, we attach the air lines using OEM brake line clips to secure the air lines in place. While all the the work was being done, we assembled and sealed the custom rose gold plated AMG wheels and mounted and balanced the tires. After test fitting the wheels, we knew we needed spacers on the front to give this beautiful Mercedes-Benz 560sec a flush fit when rolling down the road.

After all this hard work, we finally were able to test the system for air leaks, button up the trunk and make sure all the small details were handled.

Project 1991 Mercedes-Benz 560sec Build List

  • Airlift Performance 3p management
  • OB2 dual air compressors
  • 4 Gallon Specialty Suspension seamless air tank – plated rose gold*
  • Custom hard lines at Meister Werks
  • Air suspension install at Meister Werks
  • Front bags & hydraulic pump block off plate custom machined at Meister Werks
  •  Rose gold plated* AMG wheels & OZ lips & barrels assembled and sealed at Meister Werks
  • Bumpers, mirrors, door handles, moldings, body work & paint at Meister Werks by Automotive Solutions
    * All custom rose gold plating done at the customer’s shop in California.

To make an appointment for your custom air ride, stop by or call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from The Boeing Store and on the westside of the Paccar / Kenworth plant.

Coding, Updating & Programming Control Modules

Meister Werks now has the ability to code, update & program control modules. We can fully scan your BMW, VW or Audi and verify that the control modules are up to date.

The manufacturers regularly update software that is necessary for a efficiently running vehicle. When cars are first manufactured, the parameters are written for very tight tolerances. As the cars age and parts start to break in, some parameters can slightly shift out. This can cause check engine lights or components to no longer function. Often, this does not mean than the part is faulty, the software just needs updated. Just like your laptop computer or smart phone.

2006 BMW M6 V10

In the case of this 2006 BMW M6 V10, there were many modules that would not function even after we replaced the faulty components. The communication between modules would no longer talk to each other. After scanning this BMW with our new software, we found many modules were out of date. After performing an update, the car ran and sounded much better. The steering column switch that failed, now is functional. The software will also tell us if there is a faulty component, a wire short and where the location of that is. This makes diagnosing you vehicle much quicker and the result is a potentially smaller repair bill.

In this instance, the screen shot shows the version ID from BMW’s plant in Munich, Germany (outlined in red) is much older than the software on the vehicle. Our software connects directly to the manufacturer, insuring the most up to date software is loaded onto your vehicle. This will update everything from engine control modules and transmission control modules to the radio, battery control modules and even the instrument cluster.

More Info

If you have any questions about this service, feel free to contact us any time for a estimate or an appointment. To make an appointment for your vehicle’s coding, updating & programming control modules, call 425-254-0627 or email us. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from The Boeing Store and on west side of the Paccar / Kenworth plant.

 

Porsche 911 / 996 Headlight Refurbishing

Our customer brought in his set of Porsche 911 / 996 Turbo for headlight refurbishing. The lens were oxidized and dull when they arrived. This is cause from the sun light’s UV breaking down the surface of the lens. We wet sand all the contaminants out, clean and spray with our special clearcoat. This clearcoat is the same acrylic makeup as the lens which bonds with it down to the molecular structure. Not only that, but the clear coat adds a layer of protection against fading or oxidation. The clear coat also dries very glossy and there is no need for wet sanding or buffing after the clear coat dries. However, we can do this and is an additional option if you upon request.

Note: Some imperfections are within the inside of the lens area and are unable to be removed. New housing would be an alternative to getting brand new headlights.