88 Westfalia suspension rebuild

[zoti]

Lots of pictures. Doing every bushing and ball joint. Everything is original to the van and most is in really good condition for the age.

[zoti]

[zoti]

[zoti]

[zoti]

[VicVan]

Nice !

What paint did you use? What springs, what shocks?

Have fun installing the new parts!
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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH)

[zoti]

[Robsmaze]

I spent Saturday (9am to 7pm) doing the radius arm and sway bar bushings and it felt like a massive endeavor. I’m so impressed with the scope of this suspension rebuild. Mighty fine work.
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‘87 2WD 2.1L Westy
‘87 2WD 1.7L Diesel Doka (euro spec)

[zoti]

[Robsmaze]

About 3 hours were spent getting the radius rods loose. Heat, penetrant, heat, penetrant. Some bad experiences with breaking bolts has gotten me cautious. I finally just stood on the 27mm wrench on the passenger side and it came loose. My van also has this wonderful rubbery, tarish underbody coating that was done sloppily 30 years ago, so several hours were spent cleaning with a wire brush and repainting everything. Then, I overlubed the drop link bushings and had a hell of a time getting them on the sway bar. Finally a team effort of my girlfriend using a quick clamp while I held it in place popped them both on in 3 minutes, after I tried to do it myself for an hour and a half. There is a lesson there about asking for help that I’m sure I didn’t learn.
And (despite warnings) I got bushing lube in my hair. had to wash it twice - lol.

I still have the upper and lower control arm bushings to do in a couple weekends. We’ll see if that goes more smoothly!
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‘87 2WD 2.1L Westy
‘87 2WD 1.7L Diesel Doka (euro spec)

[1988M5]

Great documentation Zodi. Simple photo progress of tackling a large job is inspiration for others to "just do it". And don't you just love that refreshing feeling when it's all buttoned up and the work is behind you? Giant "to-do list" check mark with pride!

Cheers,
BK
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1991 tin top GL
2002 Winnebago Vista. VW VR6 24V Eurovan front clip powered class C 21' RV.
Some BMWs.

[WestiT3_1986]

Very nice job! May I ask, what kind of de-ruster you used on the lower controlarms? Seems like a jelly consistence?

[djkeev]

Nice job,
Thanks for all of the photos
I put this in the FAQ's because of the good photos and the tricks you used to install the parts.

I need to do this exact thing on my 90 but don't want to use the inferior ball joints on the market today.

I've been patiently waiting for T3's ship to come in with his lower joints.
I already have his uppers (if I can find them 😂 it's been months) while I wait for his lowers.

My front right is bad and not improving........

Dave
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Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[zoti]

[zoti]

When I cut the bolt of the pass side lower control arm it messed up the mount so this morning I used my crappy welder to fill it and sand, fill and sand until I was happy enough with it.

I'm not a welder but this is good enough for me.

[zoti]

Finishing the front

[zoti]

And start driver rear

[zoti]

I thought I was being smart trying to use a condom to prevent the brake build from draining. Apparently, brake fluid is not a good lube. The condom broke from the fumes. lol. Ended up putting a plastic bag and rubber bands.

[zoti]

[DanHoug]

thanks for all the documentation! great help!
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-dan
60% of what you find on the internet is wrong, including this post.

'87 Westy & '89 Westy both 2.1 4spd

Past projects can be found at--
www.thefixitworkshop.com