That's a wrap for today.
I started around 11:15, and took about an hour to get the pinch bolt out. It wasn't stuck, just slow going with a measly 135 psi. mini-compressor and a ratchet. Then I got the axle bolt out with little more than a good tug on my 18" breaker bar (I don't know what all the fuss was about!), and then, the ONE thing I NEVER read about being an issue - the upper control arms won't come out!!! After I sat around for 4 hours twiddling my thumbs waiting for my wife to get home so I could take her car to buy tools, all I could come up with was a pickle fork! NO ONE in my area sells or rents ball joint separators! THe front is finally out with the help of the fork and a chisel and 4 lb. sledge. I've PB blasted it, pried it, smashed it, etc. from every which angle and it won't even BEGIN to give! The boot is destroyed, so apparently I'll need new arms anyway, but I don't want to mangle them to get them out, as I need to be back on the road by Tuesday, whether I keep trying to get it out or just bolt it all back together and pay somebody else to do it Saturday will be a wash as I'll be at an event all day long.
So I figure my options are:
1. Try to track down and attempt to use a traditional ball joint separator;
2. Try MAPP gas on the upright with my pickle fork or separator if I find one.
3. PB Blast it occasionally from now until Sunday and just try the pickle fork again.
4. Put it all back together again and pay someone else to do what I was too incompetent to do myself

Anyone have any other helpful idea's? (I don't have an air chisel by the way)

 

You may be able to get new boots for some of the Audi control arms and tie rods from www.blauparts.com .
As, I don't have a 2004 A6 2.7L, I am not sure as to which tools you need. This information is in the BentleyPublishers.com Audi shop manual. My CD does not cover your year of car.
A pickle fork is only good if you don't reuse the parts.
OTC makes very good tools, however they are usually special order from auto stores.
You may find tools by googleing "Audi tools".

 

That makes perfect sense after witnessing the carnage that it unleashes on my boots...

 

I checked blauparts. Close, but no cigar... They only have them for the lower, and not for my year. Thanks for trying though!
At this point, even if I buy new uppers, if I can't get it out of the knuckle, I'm gonna have to pay someone to do it for me!

 

You couldn't get the upper links out? You need yourself a small sledge hammer and some weights to work out with 3X a week LOL. Seriously, you just have to bang it out from the bottom at hard as you can. Sometimes you have to try hitting it from different angles when turning the wheel back and forth by manipulating the brake rotor.

 

Just goes to show you... I have a 4 pound sledge and have been a personal trainer and bodybuiler for 7 years now. Lack of strength is the LEAST of my worries
That sucker is STUCK. I've spent hours pounding on it on and off. No give.
I'll probably try the lower arm method today.

 

First, unload the upper control arms by jacking up the knuckle. Next, put a chisel in the slot and make sure to expand the slot. Now, put a c-clamp on and compress. Yes, compress!!! Make it move, then make it move the right way! Finally, back to the hammer but by now it will be much mre willing to come out. Don't be afraid to hammer the knuckle outside of the stuck stud to help deform the hole and jar the stud loose.

Good luck!

Bob