Failed Steering Coupling Disc

Fritz · Last edited by Fritz on Mon Dec 31, 2012 10:56 am; edited 1 time in total

Have a '85 Vanagon Westy 2wd with power steering. Removed my radiator yesterday and was looking around the area and found that the steering coupling disk has cracked and on the verge of failing. Could have been really really bad if I had been going down the road when it finished coming apart. Crying or Very sad

Image may have been reduced in size. Click image to view fullscreen.

Looking at the coupling disk installed. This is the disk between the connecting shaft and the transfer gear. (Bentley page 48.4)

Cracks all the way through around every bolt hole.

Sorry for the terrible photos but Santa didn't bring the new camera for Christmas.

insyncro · Posted: Mon Dec 31, 2012 9:34 am Post subject:

Yes Sir,
One of many of the rubber parts I replace on vans that come to me for service.
Once replaced, you feel the difference immediately.

cellerdoor · Posted: Mon Dec 31, 2012 9:42 am Post subject:

walking toward garage now....
_________________
1986 Westy

Love My Westy · Samba Member Joined: August 08, 2007 Posts: 1837

I replaced mine last spring. I didn't notice any cracks in the old one.

Vanagon Nut · Posted: Mon Dec 31, 2012 10:11 am Post subject:

On a manual steering Vanagon, there's 3 of those couplers. Don't know about the PS equipped Vanagons.

I too had cracked couplers. Use the right nuts ("Always replace" nuts. aka "stover" nuts)

Here's a page I did on that job.

https://sites.google.com/site/tubaneil2/steeringcouplingdiscfrom%2781

image of one (not mine) that totally failed:

_________________
1981 Westy DIY 15º ABA

1988 West DIY 50º ABA

VE7TBN

t3 kopf · Posted: Mon Dec 15, 2014 11:02 am Post subject:

Where can the hardware for this job be had?
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'90 Carat w/ '95 phase 1 EJ22 OBD2 conversion

Jake de Villiers · Posted: Mon Dec 15, 2014 11:08 am Post subject:

MarkWard · Posted: Mon Dec 15, 2014 11:31 am Post subject:

t3 kopf · Posted: Mon Dec 15, 2014 12:33 pm Post subject:

Thank you. I can get those bolts. I was under the impression after reading this that I needed a special nut. Are the "stover" or "jet" nuts just lock nuts?
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'90 Carat w/ '95 phase 1 EJ22 OBD2 conversion

ALIKA T3 · Posted: Tue Dec 16, 2014 12:13 am Post subject:

You can mount urethane discs from a Ghia and all Wink

Yes M8 bolts.
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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

82WestyMan · Posted: Tue Dec 16, 2014 3:01 am Post subject:

"urethane discs from a Ghia"

I recently replaced mine with the stock rubber units
But would much rather have urethane.... where to you find those?
_________________
"The floggings will continue until morale improves"
"I never did give anybody hell. I just told the truth and they thought it was hell" - Harry S. Truman
82 Westfalia - w/ a Raby 'Camper Special' engine

MarkWard · Posted: Tue Dec 16, 2014 10:27 am Post subject:

I like the Jet nuts because they have a washer forged into them, do lock, and have a smaller hex for tight areas, like the U joint flange on a Vanagon.
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insyncro · Posted: Tue Dec 16, 2014 10:30 am Post subject:

kalispell365 · Posted: Tue Dec 16, 2014 11:25 am Post subject:

It looks like others in the air cooled arena don't seem to like the urethane too much, claiming it is not reinforced and can crack (I assume?).

http://www.shoptalkforums.com/viewtopic.php?f=51&t=139154
_________________
1983 Diesel Vanagon Westfalia chassis with Subaru 2.2l

MarkWard · Posted: Tue Dec 16, 2014 11:58 am Post subject:

Are the operating angles so poor on the Vanagon it needs this flex joint, is it a mandated safety solution, or could it be replaced with an aluminum disk?
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t3 kopf · Posted: Tue Dec 16, 2014 3:29 pm Post subject:

Since the original design took 30 years to crack, I ordered three new oe discs from van cafe.
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'90 Carat w/ '95 phase 1 EJ22 OBD2 conversion

t3 kopf · Posted: Fri Dec 26, 2014 1:34 pm Post subject:

I finished replacing all three steering couplings today and what a PAIN that was. I also removed the steering shaft and wire wheeled, primed and painted it. The best advice i can give on doing this job on a manual is to attach the disc to the forward end of the shaft and on the coupling side of the steering rack. Put the forward side on first and torque it, then flex the other coupling slightly with a screwdriver through the bolt hole, put the aft end of the shaft in position and tap it in place with a rubber mallet. Then torque the other bolts and nuts. The ones under the steering wheel are not too hard. I used 10.9 grade m8 bolts and solid lock nuts.

Heres the old ones.

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'90 Carat w/ '95 phase 1 EJ22 OBD2 conversion

levi · Posted: Sun Apr 12, 2015 4:18 pm Post subject:

Worth posting this again.

Lift up the carpet a little bit.

Pull up the boot

Amazing how flimsy this was, can't believe I was driving around on this thing.

_________________
One of these days I'm gonna settle down,
but till I do I won't be hangin round.
Going down that long lonesome highway,
gonna see life my way

https://youtu.be/cSrL0BXsO40

levi · Posted: Sun Apr 12, 2015 4:20 pm Post subject:

Apparently some vans have 2 of these, some have 3.

Mine has 2 and they were both shot.

Embarassed

btw, you can see in that last pic that there are no bolts, but 4 rivets.

With the rivets you have to drill them out.
Not a lot of fun to be had in that job.
For any of you that have to drill out the 4, my sympathy.
Looks like my undercarriage is next for the drilling.
Access there looks even worse.
That's all.
Have a good day.
_________________
One of these days I'm gonna settle down,
but till I do I won't be hangin round.
Going down that long lonesome highway,
gonna see life my way

https://youtu.be/cSrL0BXsO40

insyncro · Posted: Sun Apr 12, 2015 5:31 pm Post subject:

http://www.ebay.com/itm/161081491317?_trksid=p2060353.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Some are into these, some not.
I have had great luck with them.


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