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Dant
Samba Member
Joined: November 15, 2007
Posts: 126
Location: T County, Ohio
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 Posted: Wed Aug 13, 2008 8:31 pm Post subject: Syncro Front End (PICS) |
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Thanks to all the Sambanites out there, here are pics of my Rusty Syncro project... I started with some cosmetic body work, then took the front end apart.
Don't let anyone tell you this is easy...
The "sleeve" stuck on the ball joint
should have done this in the first place
OFF! that WAS easy
This is where it goes - NOT!!! it goes on THE OTHER SIDE!!!
Getting somewhere...
I hope this makes some sense and could help out...
Again, don't let anyone tell you this is easy...OK go ahead, piece of cake right?
_________________
90 Carat
97 Jetta GLX
87 GL (nobody wanted it)
91 Syncro (Stripped,Plain Jane,fixed vent windows,no tach) also rusty. Hurray for me! |
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?Waldo?
Samba Member
Joined: February 22, 2006
Posts: 10012
Location: Where?
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| Posted: Wed Aug 13, 2008 10:05 pm Post subject: |
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The CV ball bearings should go back into their original races.
Andrew |
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doublez72
Samba Member
Joined: April 24, 2007
Posts: 37
Location: Bristol, VA
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| Posted: Thu Aug 14, 2008 5:35 am Post subject: For Sure its not |
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Wow,
I just did all of this myself too. Had to farm out the pressing and cv rebuilds. Also I went ahead and dropped the front transaxle and cleaned it up. I thought I got the parts needed for the rebuild and when I got it apart there were more bushings that needed replaced.
Anyway.....
Next I'm going to get everything sandblasted and POR15 things. I really dread putting it all back together.
If anyone else has some pointers on the assembly sequence let me know
Good Luck!!!
Joe
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1989 Vanagon Syncro |
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kayakwesty
Samba Member
Joined: February 15, 2007
Posts: 687
Location: East Tennessee
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| Posted: Thu Aug 14, 2008 7:48 am Post subject: |
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I'm jealous, you have a good looking shop and set-up...NICE WORK TOO
_________________
1984 Westy 2.0 Jetta ABA Motor/1.8 head converted to auto tranny, with 180,000 on body, 55K on engine and transmission
B.5.5 Passat Wagen with 30v V6-67000 Miles
DAS AUTO
CHANGE YOUR FUEL LINES!
A post without pictures is useless
http://www.kayakwesty.com
http://www.waldensridgewhitewater.com/ |
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iceracer
Samba Member
Joined: February 28, 2006
Posts: 981
Location: Milwaukee, Wisconsin
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| Posted: Thu Aug 14, 2008 8:14 am Post subject: |
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Hey guys, I am in the process of the same thing. Just picked up my newly installed front bearings and ball jts. They hit me up for $100 to press in. AND everything was cleaned and por15'd black. I am now ready to put everything back in the van. I wish I could figure out how to put pics up here. Will have to take the time to do it. I had the bottom of the van sandblasted and I have prepped and por15'd the entire bottom of the van, inch by inch. Been working on this since March.
Are you replacing the control arm bushings and upper A arm bushings? Those were a major PITA to get out but I did it and was able to press in the new ones myself with my bench vise.
I noticed your control arms look different than mine, Mine is an 86, you must have a newer model. Lots of fun, isn't it. 
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86 Syncro Wolfsburg edition
63 Beetle (The Iceracer) |
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rs4-380
Samba Member
Joined: August 13, 2006
Posts: 449
Location: Maine
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| Posted: Thu Aug 14, 2008 8:37 am Post subject: |
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| Andrew A. Libby wrote: |
The CV ball bearings should go back into their original races.
Andrew |
my observation as well
_________________
Dave
87 EJ25 Syncro GL |
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RicoS
Samba Member
Joined: December 02, 2006
Posts: 583
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| Posted: Thu Aug 14, 2008 9:26 am Post subject: Re: Syncro Front End (PICS) |
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| Dant wrote: |
Again, don't let anyone tell you this is easy...OK go ahead, piece of cake right? |
Time consuming, sure, difficult, not really . . . with the right tools.
The first time I renewed a Syncro front drivetrain/suspension, I tried to do the press work at a friend's shop. He's been doing aircooled work from day one and he has one of those Gawd-awful, Chinese presses. Whenever I put the grunt to it, the press flexed out of kilter so much that either it was going to destroy itself or else the workpiece was going to be bitch beyond reuse.
Once I wised up enough to stop what I was doing before disaster struck, I took the presswork to a shop that had a monstrous overarm press and a guy who had been stroking the thing for about 20 years. Bada-bing-buda-boom, the separated pieces were in my hands before I could light a smoke and for a cost of five bucks a pop. It felt so good that I went back for more on the other end of the rebuild.
Until that point, I had been ready to buy a press, but, I reasoned that I would never want to spend the price for a press worth having, only to have it taking up floor space for most of the time. For five bucks a hole every couple years, I'll let someone else take the depreciation on the capital investment.
No, it's not that difficult . . . if you do it everyday with equipment which is made to do it everyday.
Rich |
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Dant
Samba Member
Joined: November 15, 2007
Posts: 126
Location: T County, Ohio
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| Posted: Thu Aug 14, 2008 10:52 am Post subject: |
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| Quote: |
| Gawd-awful, Chinese presses |
I could appreciate a nice press, it works though. You get what you pay for.
I didn't do the control arm bushings. I am going to try and loosen up the camber adjuster before I get an alignment.
I also did not paint that stuff. Too much prep work this time.
About the only thing good to know is to unbolt the stabilizer links from the lower control arm before trying to remove the axles/CV's. If that was all you were doing.
After I had the wheel bearing carriers off the lower ball joint, a guy I work with told me you can hit the iron around the ball joint with a big hammer and "sometimes you have to watch out that the carrier doesn't fall on your fingers". Anyone else heard if that works? I kinda doubt it with that sleeve deal in there.....
I seemed to have a mixed up set of CV's, one inner boot was the kind you may not neet a clamp on, but the other one had clamps. Also I only had one "spacer" between the inner cv and the drive flange. The other side had a cv with space for a gasket. The spacer does show up in the Bentley...
Oh yea, After I had an outer cv apart, then I read to mark the housing, the cage, and the hub. I got it together though, a little tight, I think it will be ok. Just have to fix it if it breaks...
I kinda wonder about my SKF bearings that came out of a Febi box...from Pa., oh right....
Now all I need is my engine from Mass.!
_________________
90 Carat
97 Jetta GLX
87 GL (nobody wanted it)
91 Syncro (Stripped,Plain Jane,fixed vent windows,no tach) also rusty. Hurray for me! |
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iceracer
Samba Member
Joined: February 28, 2006
Posts: 981
Location: Milwaukee, Wisconsin
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| Posted: Thu Aug 14, 2008 8:41 pm Post subject: |
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Hey Dant, Just got finished installing my lower control arms and shocks and springs. Major pain to get those upper shock nuts on. Didn't use a spring compressor either but I got them in. I did this once before on my 86 sunroof. Anyway, next up are the radius arms and new rubber which I can see will be another real pain. And then some fancy use of chains and a come along thingy to get the bolts to line up. I have the 86 early style control arms. Just waiting on my local VW dealer to get the 6 nuts and bolts I need. ARGH 
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86 Syncro Wolfsburg edition
63 Beetle (The Iceracer) |
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Dant
Samba Member
Joined: November 15, 2007
Posts: 126
Location: T County, Ohio
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| Posted: Fri Aug 15, 2008 11:21 am Post subject: |
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After lower control arm bushings on the Carat, I ended up pulling my car strategically up beside it and jacked against the tire horizontally to line up holes. (if that makes any sense?) Keeping a close watch on the spring of course.
That was after many attempts with a floor jack only on the control arm.
_________________
90 Carat
97 Jetta GLX
87 GL (nobody wanted it)
91 Syncro (Stripped,Plain Jane,fixed vent windows,no tach) also rusty. Hurray for me! |
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iceracer
Samba Member
Joined: February 28, 2006
Posts: 981
Location: Milwaukee, Wisconsin
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| Posted: Fri Aug 15, 2008 12:14 pm Post subject: |
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Dant, now that is an idea I didn't think about. But this morning I got the radius rods on and correctly positioned with the control arms. Now if VW could just get me my bolts and nuts.
Check out my post on the steering rack today. Any thoughts???
_________________
86 Syncro Wolfsburg edition
63 Beetle (The Iceracer) |
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