Well, this is the second time I'm having a problem doing anything aftermarket with my 2013 S4. Apparently there are a few things just 'slightly' different with the 2013 that make certain things incompatible with the 2012.
After doing exhaustive research here I decided to go with spacers for my 18" factory wheels. I ordered 15mm for the front and 20mm for the rear. I ordered 20 pieces of the 50mm ball lug bolts all from Black Forest Industries (BFI). I ordered 50mm all around because they were listed on BFI's website as being compatible for the car both front and rear and I didn't want to use different length lugs on the front if I didn't have to . My worry was that if I ever got the car serviced and the tech accidentally got the lugs from the front on the back.
So everything arrives and I decide to wash the car and clean it before raising it up and doing the 'install'. Let me interject here that I made my living many moons ago as a mechanic and restored several cars in the intervening years. I have a scissor lift in my garage and a full suite of Snap-On tools. This ain't my first rodeo. The wheels come off and because I'm OCD I wash the insides while I can. Next I install the rear and front spacers, all with no problem.
Once the car is back down on the ground I torqued the wheels to 90 ft/lbs with a 3/4" hand torque wrench. Next I start the car to take it for a spin before re-torquing everything (the way I was taught 20 years ago and still do it). Here's where it gets ugly. The car won't move. Not in forward and not in reverse. I figure, 'What the hell?' and decide to turn off and re-start the car to make sure it isn't an ebrake problem. Nope, not it. So before doing anything else I call BFI.
I get a very nice (everyone has been nice so far) guy on the phone named 'Pete'. I explain that I am concerned that my 50mm front lugs may be too long and interfering with the front hub. Pete assures me that this is just not possible. He tells me that they have sold "dozens and dozens" of this set-up to S4 owners with never a complaint. I suggest that he explain to me why my wheels won't move and he tells me just to be safe I should take the spacers out and see if that fixes the problem.
Well, I can tell you that the front lugs did not want to come out. No way. Apparently, they were too long and stuck out through the rear of the hub and were bashing against the hub when I tried to drive the car (which was about 4 inches in each direction). The threads on the end of the lug bolts were shot. Now if you've ever worked on a front end before you know that you can't do anything with the wheel still on, so I slowly and carefully backed the lugs out, although I knew based on the super-human effort required that I was hurting the hub. Sure enough, a pile of metal shavings came out and the ends of the lug bolts were mangled.
I called Pete back and explained that I was basically screwed. He said that I should clean and re-tap the holes in the hub and I should be fine. Because I was a mechanic I happened to have the proper tap and thread chaser, so I went back and did just that, but only 4 holes on each front hub are even close to being acceptable and one on each side is totally wasted. I told Pete that I was going to need the front hubs replaced because I did not feel safe driving a 300+ hp all wheel drive sports sedan anywhere near it's capabilities with the hubs in the shape they are in.
All I'm getting now is silence. I have pictures of everything and I even took a screenshot of their website where they say that you can use their 50mm lugs with 15mm spacers. Shortly after I reported the problem they actually changed their website. I'm sure they did this to prevent it from happening to anyone else, but based on their silence I'm guessing that their next step is to say that they never recommended that set-up.
I'm posting here as a warning, and in the hopes that they wake the hell up and realize that my 700 mile car was damaged by their product and that nothing less than returning it to factory correct with new hubs is going to make me happy or even just be 'the right thing' to do. Sorry to rant, but I believe it's not how a company acts when everything is hunky-dory that counts, it's how they act when they screw up that shows who they are.
-Mike
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