Finale of the Trilogy – Shift boot replacement

Click here for larger image You can say that it's possibly one of my most-planned modification process, given the stages I planned and went through before ending so far. On the other than, it can be perceived as my typical Singapore kia-see-ism (n – state of afraiding to die) in act, wanting to make sure that everything is in order or validated before making the next move.

To be honest, I started just wanting to replace my peeling stock shift knob with a new one, and I accomplish that desire by replacing it with a Momo's automatic shift knob. Very soon, I realised it need not end there, as I can replace the entire chrome shift cover with something refreshing. But the process, through some IM (Instant messenging) correspondence with vwvortex's FEEL, seems complicated, and I want to be absolutely sure about my ability to execute it before embarking on the modification itself. Obviously, I am 'kia-see' as I don't wish my investment (of buying a replacement shift boot) to waste. But most importantly, I want to make sure I can do it myself, although I know that I can easily pay some shop and had it done professionally.

Hence, my assessment on the complexity of removing the shift console, prior to placing an order with hillsideimports for an Volkswagen OEM Sports edition shift boot (p/n: 1 J0 711 113 CD NEZ).

Before placing an order for the shift boot, one may be interested to know there exists a few variants of VW OEM shift boot that he can choose from. It's a matter of individual style preference, not so much of fitment choice :-

  • The 20th Anniversary shift boot has a brushed aluminium shift frame (or commonly known as ring ) and red-stitched black leather boot;
  • The R32 shift boot also has a brushed aluminium ring, and a white stiched black leather boot. (I believe you can opt for black-stitched one as well)
  • The Original Sports edition shift boot, has a chrome ring, with black-stitched black leather boot.

I chose the chrome variant one, not exactly because I love chrome trimming, but because the brushed aluminium style will be a mis-match to my current interior trimming.

STEP by STEP

1. Remove the gasket if you have not done. Follow the link for a reference of step-by-step on gasket removal how-to

Click here for larger image 2. If you have just removed your gasket, and have not put back the shift console, take the opportunity to remove the shift guider as indicated by the red arrow. If you manage to remove the guider, then you may skip step 6.

Next, focus on the shift boot.

Click here for larger image 3. Flip the boot, so that you see the bottom of the shift knob, with the ring bracket that holds the leather to the knob. Slip out the metal ring fastener.

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Removing the knob from the shift boot

4. With the help of a plier and exerting abit of force, pull out the ring bracket. The shift knob is now freed from the leather boot, and I can then proceed with putting my aftermarket knob to this leather boot.

Note Step 4 is unnecessary, if you prefer to cut off the leather boot around the edge of the shift knob. That is definitely the quickest and easiest way to remove the knob away from the boot, but I prefer to remove with minimal damage.

Click here for larger image 5. Slip the shift knob chrome ring and Momo's bottom chrome cap back into the boot, as shown. I used some adhesive tape to secure the ring to the boot, and as the chrome cap is “dropped” into the ring, I also used a strong adhesive tape to ensure it doesn't slip off from the ring easily.

Now, the next step is necessary if you choose not to remove the shift guide, just as I have not. If you have done, as per step 1, then skip step 6, and go straight to step 7.

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The underside of the shift frame, the left side is one with the tabs cut-off, the right is with the tabs intact

The diagram shows the bottom of the shift boot frame. There are clips on each side of the frame, in order to clip onto the shift console firmly. Notice that at the rear side of the shift boot, there are 3 tabs, at the position indicated by the red arrows. These tabs are meant to secure the shift boot to the frame. These tabs interfere with the shift guide, and prevents the frame from inserted completely into the shift console properly.

Click here for larger image 6. Use a cutter, and cut off these tabs. The picture on the left shows the trimed shift frame without the tabs. The cutting is pretty easy since the tabs are made of plastic[/i]). Cutting of the tabs does not compromise the fitment of the shift boot to the console. Neither does it result in loose leather boot on the frame. So cut it with a piece of mind!

If you have not cut the tabs as per described in step 6, and you have not removed the shift guider, you will find that your shift boot pops out alittle at the rear.

With the shift knob removed,

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Inserting the frame into the console

7. Slot the shift boot over the shift shaft, and slide in the shift frame forward, and under the shift console. Insert the frame completely by pushing it down into the console.

You may find difficulty in securing the frame properly into the console, as the frame might be still popping out alittle. Here's some tricks and tips for your reference.

  • Push the two sides (left & right) of the frame inwards so that that clips go underneath the console.
  • Push the rear side of the frame inwards so that the clips go underneath the console, and then pull it outwards so that the frame shifts back, allowing the bottom of the frame to have clearance off from the shift guide.

Click here for larger image 8. Put back the shift knob, tighten the allen nuts, and pull up the shift boot so that the chrome cap can be secured with the shift knob, as shown.

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Other resources

1. Part supplier – Hillsideimports
2. Information Source – Vwvortex

Protect your Investment: OEM Headlight protector

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You have read earlier on the extensive effort and money involved in upgrading bora headlight to OEM HID. With the investment made, it is prudent to invest alittle more on a set of headlight protector to protect the headlight lens from any stone chips and cracks while on the road.

But of course, if you would like to protect your normal halogen headlights, nothing can stop you, since every part of our car are precious assets that any damages, no matter how minor they are, are a heartache to us!

These high quality protector are actually parts from Australia VW dealers. Although I have purchased this from a US online VW accesories dealer, you can have your friends at Down Under to ask the dealer there on your behalf, and you may save some dollars, who knows!

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The protectors are made of high quality acryllic material, and are mounted by placing an attaching hook (on the top of cover) to the top of headlight. The cover is then secured by clipping two attaching clips (at the bottom of cover) to the bottom of headlight, in between the headlight and the bumper, as shown.

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How to – Removing shift console

Click here for larger image Following my successful attempt to remove the shift knob and the shift gate, I was so determined to go ahead and replace my chromy shift cover to a leather boot that's commonly found in the manual version of Bora and Golf. So I did more research, and have several correspondences with a fellow vwvortex's member, FEELER, who had attempted this mod awhile back. One of the important task is to remove the gasket that's secured beneath the shift console, so that any MK4 OEM shift boot can be fitted on the shift console perfectly without any further modification. To do so, I have to remove the shift console, and before placing an order from hillsideimportsp, I decided to try taking out the gasket first.

How-to step by step

the prerequisite of this how-to is to remove the shift knob, and optionally the shift gate. If you have not done so, just refer to the shift knob removal and shift gate removal articles.

Click here for larger image 1. First of all, using a torx screw #15 driver, remove the 2 torx screws, which are located at the front end of the shift console, just under the dash console, as shown.

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2. Next remove the cover as shown in the above picture on the left, and unscrew the torx screw. There are 2 torx screws on each front side of the shift console, which secured the shift console firmly to the ebrake console.

Click here for larger image 3. Remove the ash-tray component from the shift console. First slide open the ash-tray lid, and remove the ash-tray casing, and it will expose a torx screw at the bottom of the ash-try, as shown on the left. Unscrew the screw, and slowly slide the ash tray out by pushing the ash tray forward alittle before pulling up and away from the shift console.

If you have problem trying to move the ash tray, chances are the plastic tab at the bottom of the ash tray is clipping on the metal piece, as shown in the picture on the left (the two tabs are located on each side of the centre torx screw). Pry the tabs slightly so that the metal piece is off the tabs' hook, before sliding up the ash tray. In my case, it's very easy to take out the ash tray without even prying on the tabs.

Click here for larger image 4. When the ash tray is taken out, unplug the harness from the ash tray lighter, as shown in the diagram on the left

Click here for larger image 5. With the ash tray removed completely, you will be able to see a metal bracket as shown in the photo on the left. Pull out the left side of the bracket.

Click here for larger image 6. With all the screws and ash tray removed, you may start wiggle the shift console, pulling it up and backward.

First of all, pull up the shift console away from the bracket at the front, where you previously unscrew the 2 front torx screws. This free the front console, and then you can start to pull back the shift console.

Click here for larger image When you pull back the console, wiggle alittle so that the 2 finger-like plastic pegs on the shift console are out from the main console's bracket completely. When these plastic pegs are not cleared from the bracket, you will find it difficulting pulling out the shift console at all. Once the pegs are cleared, the console should be freed from any clips or brackets, and you can slowly pull it out, leaving the shifter as shown in the diagram on the left.

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7. Remove the shift guide & optic cover from the shifter, by unclipping the 2 tabs at each side of the cover, as shown above. Apparently, this is required for the OEM shift boot to be inserted into the shift console perfectly without any obstruction. Once my shift boot arrives, I will confirm if this step is required or not.

Click here for larger image 8. With the shift console taken out finally, the next step is where the real intent of removing the console is about. Flipping the shift console, you will see the gasket attached to the underneath of the console with 4 philip screws, as shown on the left photo.

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When the gasket is detached away from the shift console, you see that the rubber trimming around the chrome cover is also removed. The rubber trim is actually fitted onto the gasket, before tightening all 4 screws on the gasket to the console. With the gasket and hence the rubber trimming removed, it creates some gap around the shifter, presumeably for the OEM manual shift boot to be fitted on properly.

More information will be shared once I get hold of the shift boot and figure out how the shift boot will be attached to the shift console.

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In the meantime, I have ordered a shift boot from Hillsideimports, just couldn't wait for it to come. To be continue in 10 days time, hopefully!

How to – Removing the shift gate

Click here for larger imageFollowing the removal of my auto shift knob and replacing the stock shift knob with MOMO auto knob, I have been exploring options to “perfect” the look, hiding away the bare metal shaft like the picture on the left. One of the option is to remove the shift gate (from the layman point of view, the chrome cover seen in the photo on the left) and replace it with a manual shift boot. To do that, the first thing to do obviously is to figure out how the shift gate is secured on the console, and hence how to be removed without damaging the parts.

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1. First of all, remove the shift knob, regardless of whether it is a stock knob or aftermarket one. This will facilitate the removal of the shift gate, as you will see later on.

Click here for larger image2. Next, push the shift gate (the chrome cover) to the right with alittle force, you will be able to see some gap, like that on the right. The shift gate should be firmly secured at this point of time, so alittle force is required to open up the gap.

3. With the interior pryer tool, I try to fiddle with the shift gate edge and pry out. Becareful of prying to hard, otherwise, you may unknowingly broken the notch at the edge of the shift gate. With abit of trying and patience, I manage to have the notch out of internal slot, and when you do that, you will notice that the shift gate is starting to loosen on the left side as shown in the diagram below.

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When the left side of the shift gate's notch is out of the securing slot

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4. With the left side of the shift gate loosened, pull up the gate slightly and wiggle the shift gate to the left, so that the right side of the gate can be loosened as well. Becareful again not to wiggle or pull out the gate too hard, otherwise, the notch at the right edge of the gate may well give way and break.

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5. With sufficient patience and wiggling, I manage to loose the right side of the shift gate as well, and just carefully feel the touchpoints between the shift gate and the shift console so that you can free the shift gate completely from the console.

Click here for larger image6. Once the shift gate is loosened completely, just lift up the gate and away from the shift shaft. What remains is the whole shift guide in bare, with the optics that indicates the gear position.

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Done: when the shift gate is removed completely, this is what you will see

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The underside of the shift gate, to show you the structure of the gate that allows the latter to be mounted to the shift console.

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A closeup look of the 2 notches at one side of the shift gate. This is the part where the shift gate is most fragile at

what's next … ? A search for a nice OEM looking shift boot to replace the shift gate! and the search continues

Anatomization of Brakeswitch .. after a shift lock error!

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It happened out of sudden, out of nowhere. I was referring to the incident where my shift gear was stucked at Park position, as I was trying to drive off to pick up my parents in-law. Darn, I was mumbling to myself, “I hope this is not a sympton of aging car”, as my dear bora is reaching its 3rd year birthday in a month time.

As a car-idiot, and having hear alot of horror stories about auto transmission problems and overhaul, I was quite nervous, given that the first sympton of the problem (stuck shifter) had some relation to transmission. Is this a beginning to the mirror history of my old peugeot, where mechanical & electrical issues cropped up one after another every month, as if they were well planned for. And … my last car problem related incident was flat battery a month ago.

With alittle panicky, I rang Autospritze’s Dennis and Heng. It was Sunday morning, and I guessed it was a little early for them, after a long 6 days of hectic work. I rang up Raymond subsequently, and while he was also unsure about the cause of the problem, he accurately suggested non-stop stepping of the brake pedal to get the shift gear out of the Park position. While doing so for few minutes, Autospritze’s Heng responded to my earlier SOS call. He was in Malaysia, he too suggested the same thing, and true enough, after some preservance and patience, I felt the shift gear was finally unlocked momentarily when the brake pedal was stepped. Not wanting to miss this “momentary” opportunity, I quickly shift the gear to Drive position, as fast as I can, just like how the cowboys would draw their gun in split seconds in those cowboy show!

Not wanting to get myself in the stucked position again, I pulled up my e-brake whenever I want to stop my car while the gear is in D mode. At this moment, Autospritze’s Dennis had also just waken up from his beauty sleep, and he suggested that I bring the car to his workshop for repair the next day, and from the sympton of the problem and workaround, we all suspected that the brake switch is faulty.

The function of brake switch is two fold. When a brake pedal is depressed, it triggers two thing via the brake switch, which sense the depression and power the brake light. It also triggers a shift gear unlock signal, so that the shift gear can be unlocked from its current position. It’s a safety feature in all automatic-transmission based vehicles, whereby the gear must not be able to shift freely from “N” and “P” position to other mode.

True enough, a replacement of a new brake switch solved the problem.
A further check with VWvortex via its search engine, using “brake switch” as the search key words, return numerous threads that articulate the same problem as I had gone through, as well as the desire fix. A big thumb up for VWvortex, for its great knowledgebase, although I did not benefit from it directly in this particular incident problem (Now I would really appreciate accessing Vwvortex using my GPRS in the future!)

One particular thread in VWVortex actually threw in some insights with regards to the detail technical cause of the problem. Intrigued by the insights, I decided to do a full anatomization of the faulty brake switch, for the sake of knowledge gain, and of course the itch to tear out the parts!

The steps to anatomize the brake switch

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1. This step is optional, but it makes the subsequent steps alittle more easier. First of all, remove the pin cover, by prying the pin cover groove alittle (as shown by the red arrow) so that the the pin cover can be slotted out in the direction indicated by the green arrow.

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2. Push in the pin stopper as shown by the red arrow, and push it out in the direction by the green arrow. When the pin is pushed out alittle, use a pen knife or equivalent to push the edge of the pin as shown in the diagram on the right.

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3. Pull out the pin as shown in the diagram. The fault lies on the pin itself, so subsequently steps are not necessary, but it facilitate a better understanding of the what, why and how of the problem and resolutions.

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4. You will notice there’s two tiny stopper, one on each side of the cylinderical-shape part. One of them is at where the pen-knife is pushing, in the diagram on the left. When the stoppers are pushed in slightly, pry and push up the round cover as shown in the diagram below.

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5. When the cover is taken out, a spring will sprung out, remove the spring

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6. Push the thin rod at the other end of the cylindrical block, and that pushes out the plunger as shown in the diagram below

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At this point of time, all the sub parts of the brake switch are dis-assembled, and it’s time to diagnose the mechanical/electrical function of the brake switch, and its point of failure.

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Item 6, I called it plunger, and the plunger rod actually stays in contact with the brake pedal mechanism. When the brake pedal is depressed, it will push the thin rod.

Item 2, with the spring, it creates some tension as the brake rod is being pushed by the brake pedal mechanism. Once the brake pedal is released, it also release the tension of the spring, which will then pushes the “brake connector rod” (item 6) back to its original position.

Item 1, 5 and 4 are just covers, serve no working functionality.

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Item 3, is the brake switch pin that connect and complete a circuit for the brake light and shift lock. Upon further inspection of the pin, I noticed that the back of 4 pins are aligned perpendicular to with the 2 horizontal metal strips. There is 1 tiny stopper on the otherside of each of these 2 metal strips. The 1st 2 pins are in contact each of the 2 metal strips respectively, creating a close circuit. When there’s something that pushes either of the tiny stoppers, it will result in open circuit for the affected pin.

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One of the circuit indicates turning on of brake light and shift lock, while the other indicates a turn-off.

The diagram above simulates how the item 6 (brake connector rod) stays in contact with the tiny stoppers on the pin via a notch at the bottom of connector rod.

Now, there are two possible point of failure.

PoF #1 One is where the two pins are not staying in contact with the corresponding metal strip, when the tiny stopper is not pressed down. You can inspect this possible point of failure when you take out the pin. In my case, the construction of the pin is still in working condition, so this is unlikely the point of failure.

PoF #2 The other is where most of the Vwvortexers commonly faced. The contact point between the pin and the metal strip is bad due to oxidisation of the metal. In my case, I notice that the metal strips are badly oxidised already, hence, even if contact is made, there might not create a close circuit.

Solution ? either you clean the oxidised contact surface with alcohol, or you invest US$15 for a new brake switch.

Other references

1. Brake switch removal (from car)
2. JE’s Brake switch repair

Removing of shifter knob for 4-speed automatic transmission

Changing of automatic shift knob, to certain people in Vwvortex community, is a taboo, or in a certain VW modification cult group, is socially unacceptable. Well, I must emphasized that such mentality only prevails in a small group of vwvortex'ers, fortunately.

Perhaps, the strong feeling against the act, is based on the assumption that anybody who attempt the modification is trying to be manual-stick wannabe. That to drive an automatic-transmission vehicle is a joke of century, at least to this unique group of interesting earth inhabitants. In the true spirit of Veedub modification culture, I am sure this is a fallible thinking.

Anyhow, not withstanding such a dark force, I decided to go ahead with the modification, although I am still in search for a well-styled aftermarket automatic shift knob.


1. Turn on the engine, and shift the gear to Neutral. In many versions of How-to guide, the instruction said D or gear 3 or 2. For 4-speed automatic transmission vehicle, it has
been verified that either of the modes mentioned is okay. This might not be the case if your vehicle is tiptronic transmission, and should stick to gear 3 as most has suggested.

2. Pull down the chrome sleeve that covers the shift shaft as shown on the left. This will unlock the gear, and the knob button will be loose.

3. Then press the knob button and pull out the knob with some amount of force.

If you inspect the shift rod closely, you notice that the only movable mechanism is the plastic rod that's contained within the shift rod. When you press the shift knob button (with the stock knob intact), it actually depresses the plastic rod, and mechanically unlock the gear during "P" and "N" position. Hence, one can conclude that for 4-speed automatic transmission vehicle, one can replace its stock shift knob with any universal aftermarket shift knob, since it does not have any tiptronic plate or overdrive mechanism.


Upon looking at the internal of the knob, you notice that there isn't any complicated mechanism in the knob button. The knob button basically will keep in contact with the tip of plastic rod when the knob is plug on the shift rod. The plastic cylindrical clip within the knob is designed to held and clamp on the shift rod tightly.

Tips: I realised that if the car is parked under scorch hot sun for a few hours, it will be easier to take out the shift knob. This is possibly because that the plastic clip inside the knob has expanded due to the heat, and hence make it easier to plug out the shift knob.

With the stock knob removed, I begin to hunt for a nice aftermarket automatic shift knob to replace, as my stock knob surface is starting to peel. I wanted to make sure that the DIY removal of stock knob is possible before I commit myself with a new aftermarket shift knob.

The hunt for the new shift knob is not easy. There's little market for automatic shift knob, and alot of nice shift knobs made by Rapid, Momo and Sparco are mostly for manual shift stick. I bump across OEM automatic shift knobs like those for Audi and Porsche, but they cost an arm (more than US$150). My choice was thus limited to the Momo automatic shift knob, as shown below.


4. Insert in the chrome cover bottom as shown in the picture.


5. Screw 2 allen nuts to the Momo shift knob such that they are flushed to the inner wall of the knob. The Momo shift knob comes with allen key and nuts, and the knob itself has 3 holes at the edge of the thread (as shown on the left photo) for one to screw the allen nut so that the knob can be firmly secured on the shifter shaft rod.


6. With the allen nuts in the knob, slot the knob into the shifter rod as shown on the left. Do not over-screw the allen nuts, otherwise the knob can not be inserted down the shifter rod.


7. With the knob sits nicely on the plastic shift unlock rod, turn the knob so that wording "MOMO" is aligned, and depress the knob slightly (not all the way round), and begin to screw the 2 allen nuts tightly. The reason of depressing the knob before screwing the nuts, is to have the knob as low as possible.


Knob is secured by 2 nuts, the 3rd allen nut is not required as it'll prevent the bottom chrome cover not able to cover the knob.


8. Screw in the chrome cover bottom, as shown.

and voila, a new aftermarket shift knob for my automatic gear transmission BORA.

Passenger Door removal for Rattling fix â€¦

Click here for larger imageI must confess, that I am not an audiophile. In fact, my hearing history has never been that good, and it can be vouched from a general hearing test conducted by my primary school, when I was a primary-3 school kid. I failed that test, as I couldn't differentiate between a buzzing sound and a hissing sound (okay, I exaggerated here), and at times had difficulty identify the source of the noise (left or right)! Some doctor says this is a lazy-ear medical problem, all I know is it goes along with my personal character very well (or as a result of my personality), where I am at times stubborn and insistent of my way…

Anyhow, after a huge relief rattling fix at the front console, I thought I will be spared from any further rattling source. Perhaps its an indication of the car getting its age, or otherwise, few months later, an annoying rattling noise, albeit not as irritating as the previous ones, surfaced.

It has to do with the door panel, because each time the noise surfaced while the car is in motion, me or my wife will knock on the door panel a few times, and the noise goes away. But heck, that's not a way we should be enjoying our car ride, is it not?

So I have been wanting to dismantle the door panel for quite sometime, but was hesitant due to busy time schedule and fear of creating more problems as I try to fix one problem. But the urge to fix it DIY just could not resist, and couple the fact that fellow Vortexer VgRt6 did a very well write up on the how-to in removing the door panel. So with some guts and determination, I decided to fix the rattling once and for all, all by myself.

Click here for larger imageLooking back at the entire dismantling process, I have to say the removal of the door panel is very easy, except for the first step, which can be a PITA! The first step, mother of all steps, is to remove the door handle as shown in the diagram on the left. As I started to pry open the door handle, I notice the inner side of the handle has been abused by the distributors during the servicing & repair trips previously. Nevertheless, the trick is to use a soft flat pryer to insert behind the door handle, as indicated by the red arrow. When the handle is opened slightly by 5-10mm, start moving the pryer to the lower right side of the handle and slowly pry open the entire bottom of the handle. Once you have pryed the bottom of the handle by 0.5inch wide, pull out the handle with a jerk as it is snapped on by 2 clips shown in the diagram below, by the 2 green arrows.

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I use a tool (shown in the diagram on the left)
that is specially meant for interior panel opener,
it helps to pry open the door handle easier
without creating unnecessary dent or scratches

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the inner side of the handle,
which shows 2 clips indicated by the green arrow,
holds the outer side of the handle, shown in the picture
on the left

Click here for larger imageOnce the outer side of the handle is removed, the next step is to unscrew 3 torx screws at the bottom of the panel, and 1 philip screw at the right side of the panel, as shown in the diagram on the left. The 2 diagrams below give a closeup view of the torx screw and philips screw position respectively. Use a torx-15 to remove the 3 screws below, and a small philip screw driver to remove the screw, which is located just below the front tweeter speaker, due to the space constraint.

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removing the 4 screws at the bottom & right side of the door panel

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remove the 2 screws in the inner handle, so as to free the entire panel totally

Click here for larger imageAfterwhich, remove the 2 main philips screws that are found at the 2 end of the inner side of the door handle, as shown in the diagram above, pointed by the red arrows. Once the screws are removed, the door panel is basically secured by the 6 plastic door clips at each sides of the panel. To take out the panel completely, snap out the two sides of the panel, before lifting up the panel as the panel's top rubber lining is hooked onto the door edge. The diagram on the left shows the inner side of the panel when it is taken out. You see the position of the 6 door clips, where the clips (as shown in the closeup photo on the left) are at each side of the panel.

I have to be careful when snapping out the two sides of the panel, as the clips are very fragile, and can break easily if the door panel is pulled too hard. It is therefore better to buy extra clips as spare, so that you can replace them on the spot if you broke any of them.

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Closeup view of the door clips. The clip on the left is broken, while the one on the right is functional. It cost $2 each if you buy directly from the dealer.

Click here for larger imageAt this point of time, the panel is not completed detached from the door yet, as there are some wirings and cables that is stilled attached to the inner side of the door panel. Unplug the window lifter harness connector, as shown in the diagram on the left. Next, unhook the door lock cable, which is hooked to the door lock assembly, as shown in the diagram below (left). Unclip the retaining clip, and pull the cable forward (towards the front as indicated by the green arrow, and out of the catch as pointed by the red arrow) so
that the hook can be taken out. When that is done, unplug the door open light harness connector, as shown in the diagram below (right). Becareful the plug could be hot, due to the lighted bulbs.

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Unhook the cable from the dock lock assembly (left) and unplug the door opening light

Click here for larger imageWhen all these cables and hook are removed, the door panel is now hanging on the top edge of the door with its rubber lining. Lift up the door panel, focusing on the 3 arrows in the diagram on the left, and the door panel is now taken out completely.

With the door panel removed finally, now I can inspect the inner side of the door panel, as well as the door with various assemblies, to identify the source of the rattling.

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The inner side of the door panel, and the bare door body with the various assemblies. Those black patches on the door body are actually accumat material, a sound proofing material.

With some shaking and knocking, I deduce the following areas of possible rattling source.

Click here for larger imageDoor open light assembly, is made up of various plastic parts, which produce some low frequency rattling noise when it's shaked slighly.

Click here for larger imageOne of the door clips is loose, that may have not catch on the door hole properly, and loose clip might create some low rattling noise.

Click here for larger imageThe door unlock handle assembly is secured to the inside of the door panel with four clips and a philips screw. It's secured, but due to the rubbing of the plastic clips and the door assembly's plastic edge, I suspect there could be some rattling created as a result, if the car is rolling on an undulated road.

Click here for larger imageI notice the retaining clip is loose, that plastic piece might have rattled against the door panel or the hook catch.

Click here for larger imageWhile removing the panel, the speaker's rubber cap is loose. While this is not a source of rattingly (rubber is the least suspect in all rattling noise), it could create some distorted noise when the speaking is outputting loud music.

Click here for larger imageWith all these possible faults, I use some OWS liquid spray, which rubberised the sprayed surface to reduce unnecessary abrasion that causes rattling. This is the one of the products I used when I try to eliminate the rattling noise at the console area. This is not the best or ideal rattle elimination product, due to its stickness characteristic (that causes the sprayed area to be sticky while it is wet or lubricated). But it serves its purpose, and hence I have not considered those 3M sponge adhesive tape, which could be used in some of the fixes.

Once done, it's fixing back of the door panel time. The mounting of the panel is the reverse of the panel removal described above. Before placing and clipping the outer side of the door panel to the door panel, I drove the car around for a test drive, so that I do not need to remove the door handle again if I have to troubleshoot the rattling noise further.

All in all, it solved my rattling nightmare again, at least for now …

Aspiring to be a TT, with a TT pedal covers

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For the uninitiated, one of the beauty of Volkswagen and Audi cars is the fact that they are all built based on some common platforms, according to the model category. Possibly, at least 60% of the parts are common parts, with some part variants exists in one make / model based on the particular make product design and marketing requirements.

To cut the long story short, my Bora benefits from such 'leverage' program. In the case of foot pedals, Bora's stock rubber pedals can be easily removed and replaced by Audi TT's pedals, for both automatic and manual transmission models.

Original Audi TT parts from Audi Germany
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Comparison of Stock Bora rubber gas pedal, and Audi TT gas pedal.

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Wolfsburg edition Bora wannabe .. on a Wolfsburg-made Bora

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Wolfsburg, considered one of the greenest cities in Germany, is also the hometown of the automotive brand, Volkswagen. It's HQ is based there, and has a plant that's one of the largest and most advanced car factories in the world.

In VWVortex, Wolfsburg edition Germany is highly sort-after. In Singapore, all volkswagen BORA are assembled in Wolfsburg, short of being labelled as 'Wolfsburg edition'.

In EBay, there has been seller who had 'Wolfsburg edition' badges putting up for auctions. I could not resist the badges, and when I had my hand on the badges, I must admit I am impressed by its quality, regardless of its authencity.

Does it increase the value of my car, or gave my car some horse powers? Obviously not, but it certainly has given some character and personalisation to my ride.

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How to – Fix the damn console rattles

Click here for larger imageFor awhile, I have been getting irritating rattling and squeaky noise from the console and glovebox area whenever the car rolls on the road (yes as long as it rolls!). The dealer solution is they replaced the entire glovebox and console cage, so they have claimed. But the problem persists, and I was told I must gave allowance for the rubbing “movement”, which means I must live with the squeak 99% of the time I am in the car. It sure goes louder as I drive, and for a while, I was at the end of my wits, resorting to slotting a cloth between the left glovebox console and the gear console. Unsightly as it is, I decided to take out the glovebox with alittle adventurous, spray some OWS lubricants and vaseline petroleum jelly, and it works! At least the source is confirmed, whether the lubricant material is lasting, it left to be confirmed.

1. Open your glovebox lid

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2. Remove the side panel of the dashboard by carefully pry open from the edge. The panel is plugged into the side of dashboard by the 3 stud holes as indicated in the diagram above

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3. The glovebox is secured by 6 torx screws, of which 3 are at the top edges of the box, and the other 3 below (see diagram above)

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4. Use a torx-20 screw-driver to unscrew all the 6 screws.

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5. Once you have removed all the 6 screws, pull the glovebox outwards in the direction indicated by the diagram on the right. As the right side of glovebox is mounted on the console by studs and clips, in additional to the 6 screws (you get better idea from the next picture), you need to pull the glovebox out with a quick jerk. Tip: Hold on to the two side of the stowage compartment area, and pull out the glovebox.

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6. When you manage to pull out the glovebox, you will see that the side of glovebox is mounted securely on the console via 2 studs with metal clips and 2 plastic studs (red arrow). These studs rub against the stud holes when the glovebox is not firmly mounted, creating the irritating noise even when you drive on a slightly undulated road.

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7. I filled the studs and the stud holes with loads of petroleum jelly and OWS interior spray lubricant.

8. Push back the glovebox once I am done with the lubrication. The securing of the glovebox is the reverse of how one would take out the box.

To put an icing on the cake, I took out the headunit today, spray OWS lubricant at the loose headunit metal bracket, and now the metal rattling noise at the HU side is also gone! Now my car rides over humps and stripes with a tud-tud … rather than tud-tak-tek-tin-tak-tek-tud