88 Westfalia suspension rebuild

[zoti]

The disassembly of the other side went fast. No stuck bolts.

Had to address the sticky shifter bushing.

And install a new front parking brake cable. Done it without removing the gas tank.

Took it for an alignment today and it came back perfect. All in the green.

The beast is finished.

[Howesight]

Thanks for all the great photography! The Bentley diagrams don't give the details that those great pics do.

By the way, if you could do a pictorial of rebuilding a Syncro transaxle and adding pressurized oiling, I know a few people who would be very pleased.
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'86 Syncro Westy SVX

[zoti]

Started taking apart the second side. 34 yo grease?

[zoti]

[zoti]

[PDXWesty]

Nice work. I've rebuilt my front end but didn't have the time or patience to paint everything. Maybe next time. Looks great!
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89 Westy 2.1 Auto

[zoti]

Waiting on some parts (cv boots, e brake cable etc) so in the meantime the rear training arm went back in and the brake lines were attached.

[zoti]

34 year old brake lines are always fun but it did open. Replaced the flex line and cleaned then painted the area.

The bushings took an unreasonable long time to get in. Just annoying and hard but finally got them in.

New bearings and seals in the bearing housing and stub axle installed. Don't forget the big C lip for the bigger bearing or you will have to take it apart again.

[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

[zoti]

[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]

And start driver rear

[zoti]

Finishing the front

[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]

[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

[WestiT3_1986]

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

[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.

[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)

[zoti]