MonroeS4

I'm sure you used a penetrating product, but if not I always get good results for the non-aersol L/W. The pinch bolts on my 2000 S4 were no problem using this method. I can't remember for certain which ones but some of the bolts have a "D" shaped head. It won't spin until its backed out from the recess it sits within. Anyway there are NO threads inside the CAs the bolt and nut just pinch the split closed, so you can drill it out with no worry. Due to the reaction of the steel bolt and aluminum arms I use Antiseize to reduce this problem.

Indyxtype

After trying a few things on the same bolt, I managed to snap off the other end where the nut goes on the threads. So, I guess my options are kind of limited at this point and I will be looking to drill it out after all. As for the other side, I found an interesting method on passatworld (link below), where someone used a dremel to cut half way through the bolt at the slit on the knuckle. Then after you get it to snap, you can use a wrench/impact and anything else in your arsenal: PB blaster, heat, punch, to work each half out one at a time. Seems like a good idea and better than trying to battle with the whole seized up mess at once. Anyway thanks to everyone who chimed in and I'll keep my fingers crossed that the next side and my axle bolts give me better luck than this first one did. By the way, WTF was Audi thinking, in all of their engineering prowess, using this kind of system to secure the CA's?!? AOA should be required to offer PTSD counseling to all of their techs in the North East who have to work on these things all day.

http://www.passatworld.com/forums/sh...d.php?t=233225

jibberjive

Yeah, that's actually the one I was thinking of where it used the threads to zip it out. Sorry, I thought it was on AW, maybe it was just the link that was on AW. Looks like a good approach though!

complacentsee

It comes out extremly easy if you load the hell out of it with good antiseize. I guess they could have repeated what they did with the lower side but it is a decent system.