Syncro Schwenk springs and Fox shocks

[pbrown]

Hey All,

I need a favor. For those of you running Schwenk standard height springs and Fox shocks on your Syncro -- I would like to know your ride height. Measure from the fender lip to the wheel center.

I'm having an issue with the Fox shock rubbing on the axle. I like my ride height where it is. I will either have to adjust the shock higher to clear the axle or change to a stock Syncro spring. Stock springs are a little shorter.

Thanks in advance.

--Patrick
_________________
Patrick Brown

1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF

[Sodo]

Two possibilities:

Pray that its the UCAs upside down.

Other is even less fun.
You may have the left-side Foxshock on the right side.
_________________


'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[pbrown]

That's not is. At least I don't think so. I'll take a look. I have a ride height issue. The axle to shock body is okay. It's the adjustable spring cup. They need to be adjusted away from the axle a bit. I thought I had enough clearance but there are noticeable rub marks on the axle. It must be when turning or in compression.

I'm planning to pull out the spring compressor and adjust them up a couple of turns.

To make things worse, I had a local shop replace an axle and they put one on with a fatter hollow body axle. I need to get that out of there before there is additional damage.
_________________
Patrick Brown

1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF

[pbrown]

I just checked the UCA. They are mounted correctly. They are Burley control arms but that shouldn't matter.
_________________
Patrick Brown

1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF

[pbrown]

I adjusted the front shocks up about 1/8" to hopefully eliminate the axle rubbing.

I have a non-standard axle on the passenger side. It has a thicker axle than OEM and was rubbing. It was installed new by Peace Vans in Seattle. They should have known better. Lesson learned - do your own work.

I have a replacement axle coming from Van Cafe tomorrow. It has the NLA Lobro outer CV. I'm worried that it will have the same thicker axle issue as what I removed. I also have some new CVs coming from T3 that I can use to rebuild my old axle. There will be options.

I have a trip planned and need this done by the 22nd.
_________________
Patrick Brown

1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF

[pbrown]

I missed my deadline and cancelled the trip.

I started installing the stock springs from Christopher @ T3. It turns out that they have an inside diameter that is to small to fit the lower spring perch on the Fox shock.

IMG_3204 by Patrick Brown, on Flickr
The upper spring is the Schwenk and the lower is the replacement stock Syncro spring.

IMG_3205 by Patrick Brown, on Flickr
Schwenk spring

IMG_3206 by Patrick Brown, on Flickr
replacement sprint that is too small

I'm going to reinstall the Schwenk springs and change the ride height to clear the Fox shock's adjustment nuts.
_________________
Patrick Brown

1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF

[pbrown]

Here is the problem. The axle has been rubbing.

IMG_3202 by Patrick Brown, on Flickr

And I had an axle fail. It's unclear if it was from the rubbing or other. I think it was self inflicted. I have a sport VC and think I broke the axle when turning too tight and too high speed.

IMG_3201 by Patrick Brown, on Flickr

I have some original rebuildable axles. I'm working on rebuilding now. Those outer CV joints are a PITA to remove.
_________________
Patrick Brown

1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF

[ALIKA T3]

I don't understand how the splines can only be damaged at the tip...
_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget

[pbrown]

The axle came out of the cv joint while still on the van. Possibly the clip was not completely engaged when last rebuilt.
_________________
Patrick Brown

1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF

[pbrown]

I have a couple of core axle assemblies. I was able to get one stripped down. That outer CV is a PITA. An angle grinder was involved.

This photo shows the old and the replacement. The red one is the old. It doesn't seem so bad after seeing them side by side.

Syncro Front Axles by Patrick Brown
_________________
Patrick Brown

1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF

[pbrown]

I spent some time with a small file cleaning up the replacement axle.

Syncro axle cleaned up by Patrick Brown, on Flickr


I'll take it to the powder coating shop on Monday.
_________________
Patrick Brown

1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF

[4Gears4Tires]

I'd throw chinese ebay axles in there before I ran that.
_________________
'87 Syncro Ferric Oxyhydroxide Superleggera Edition
'85 Westy Sciuridae Domus Edition

[pbrown]

I finally found a good axle.

Good Used Axle - Syncro Front

I'll repaint tonight and assemble tomorrow.

I perfected my process for removing the outer CV. I no longer fear this task. Here's the secret.

Build a small slide hammer from a 1 1/4" x 10" steel pipe. Use an angle grinder to cut a notch as seen in the photo below. The notch provides a place for the snap ring tool.

CV Removal Tool

This is the snap ring tool I used.

Snap Ring Tool 1

https://www.amazon.com/dp/B00209ETSS?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1

Pull the inner CV first. Slide the tool over the axle with the notch facing the outer CV. Clamp axle in vise close to the inner end but not on the splines. Hold the snap ring open while slamming the pipe against the CV joint. The first hit should get past the groove so that the snap ring tool can be set aside. A few more wacks and the joint pops off.
_________________
Patrick Brown

1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF

[pjn_wyo]

I still think sodo is right

[pbrown]

[pbrown]

Upper Control Arm. I'm pretty sure it's mounted correctly. Please advise if I'm mistaken.

Upper Control Arm Mounted Correctly


Freshly rebuilt axle. New CVs from T3. Replacement axle shaft from Burley.

Freshly Rebuilt Syncro Axle

Now it's time to get this axle in the van and get my ride height set.
_________________
Patrick Brown

1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF

[pbrown]

And the axle is back in the van. I haven't torqued anything yet. You can see the tight clearance to the Fox shock. One should stick with OEM size axle shafts if running these.

Axle installed again

The new 12pt 8mm head CV bolts from T3 have two piece Nordloc washers. I've not seen these before.

Two layer washer for CV
_________________
Patrick Brown

1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF

[pbrown]

It's back together and the axle nut is torqued to 258 ft-lbs.

Big torque wrench

I took it for a drive and found a flat place to spot and measure ride height.

Front Right - 19 1/2"
Front Left - 19"
Rear Right - 19 1/4"
Rear Left - 18 1/2"

I bought some rear spacers from T3. I'll start at the Rear left and add a 1/2" spacer to start and remeasure. My target will be 19 1/2" at all wheels.
_________________
Patrick Brown

1986 Westy Syncro EJ25
Flickr --> https://flic.kr/s/aHsmQNUXEF