Both front shocks popped out

[duderanchero]

Hit a pothole at night, after which the drive was noticeably bouncier. Drove it home, found that both front shocks had busted through the lower mounting bolts (bolts were nowhere to be found, shocks were protruding visibly beyond lower control arm).

What pre-existing condition might have allowed this to happen?

Since I bought the van, there's been a fair amount of rattling looseness in the front passenger side suspension. The driver side was okay until now.

Thanks for any advice, links, anecdotes, predilections, transubstantiations, and permutations!
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'91 carat stick

[dart330]

I had this happen once before. The lower bolts weren't torqued correctly when the shocks were installed. That explains the noise you heard as they loosened up and why the bolts fell out. Tried using the same size hardware from a local store, but even the strongest they had weren't up to the task and they broke off after being installed.

You will need 3 parts to fix this correctly.
Front Lower Shock Bolt N.040.161.1
http://www.van-cafe.com/home/van/page_520_1354/front-lower-shock-bolt.html
Front Lower Shock Nut N.011.021.2
http://www.van-cafe.com/home/van/page_519_1354/front-lower-shock-nut.html
Tapered Ring for Front Shock Bolt VC.251.413.097
http://www.van-cafe.com/home/van/page_2153_1354/tapered_ring_for_front_shock_bolt.html

[spacecadet]

Original OEM Shocks? Ever swapped or changed?

If someone in the past had replaced the shocks and didn't put back the metal bushing that those lower shock bolts use to keep from bouncing around inside the lower control arm. The excessive play could lead to metal fatigue and eventually your situation.

Maybe someone can show a photo of this assembly?
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Daily Drivers Only
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1990 Volvo 740 Turbo(Sold)
1986 Mercedes 300 Coupe (Sold)
1954 Volvo PV544 (Sold)
1990 Dodge D250 Cummins (Totaled)
1990 Vanagon GL 2.1 Automatic (Sold)
1968 Ford F250(Current)

[MayorMcCheese]

Torque specs for those bolts is pretty high and they require the tapered spacer.
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wv2yb0252gg092706

[djkeev]

Sorry this happened but it begs to be asked......

If you had persistent "rattling" in the front suspension...... Why on earth did you continue to drive it?

There is little more important that the ability to steer......well......maybe brakes.

The Van was giving you fair warning but you didn't listen to it speaking to you.

You really need to listen to old vehicles, they talk constantly.
Ignore their conversations..... Crap happens.

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

[the joker]

You must learn every new and odd noise

It will head off a lot of headaches / $$$$

My son (15) is slowly learning the normal Humm of the engine
and the difference between road noise and problem's [/quote]

[[email protected]]

Sounds and smells should be payed attention to..
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2001 eurovn weekender 207k fresh batteries

[IdahoDoug]

Interesting timing. I have been chasing an annoying heavy rattle on my van for months. Periodically, I'd get worried enough to jack it up and examine everything with a flashlight and yank on things. Nothing. Had it aligned last month after putting in a new steering rack and tie rods for unrelated reasons (leak). Asked the tech to see if he could find anything while under it. Nope.

Finally, I decided my shocks must have failed internally and were the source. They did not wobble on the mounts and did not appear to be missing the rubber bushings.

In removing the front right shock I found the rattle. The lower mount is missing the little grommet like reducer that makes for a tight fit on the shock bolt. The shock bolt showed some wear from moving slightly.

So, I guess I'm defending him a bit if this was going to be my fate someday and I think you are exactly right in what happened with him. There was no way to know unless you finally got to the point I did and replaced the shocks suspecting the rattle was internal to them.

So to the OP - check and see if you are missing the metal grommets on the lower shock mounts. Should be one for each end of the shock bolt. If both are missing then your bolts were trashed and that's likely what caused it.

Doug
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1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader

[torchmonkey]

Are these required for pre 1985 vans? Yes I posted this question in two separate threads. Need answers ASAP.
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1983 1/2 Westfalia

[duderanchero]

Looks like spacecadet is today's winner--thank you! There are no grommets/spacers on either side. Each shock requires two?

dart330, thanks for the links--I'll keep the torque specs in mind when I reinstall.

IdahoDoug, I've looked/yanked around quite a bit under mine, too, trying to locate the rattle. I think I have an issue beyond the shock spacers, since both sides appear to have been missing those.
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'91 carat stick

[IdahoDoug]

Just FYI, you won't see these easily unless you have removed the lower bolts. The bolt heads cover them up and press them against the shock's lower eye, essentially creating a tubular sandwich under tension that the big shock bolt rides in and is held from vibrating. Cool design. When they are all together and tightened up, you'd need good eyes and a bright flashlight to see the faint edge of the tensioning washer that I am missing.

My rattle was fairly loud and not the lighter sound of an exhaust heat sheild or brake rotor dust shield. It was bordering on a rapid fire clank.

In 20/20 hindsight after I found the issue it was obvious the steel and iron worn off from the two parts (steel bolt/cast iron hole in lower arm) was responsible for the pattern of bright red rust powder trickling out of the lower arm. Did you pull the lower bolts off completely to check? Find empty holes where the grommet should be?
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1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader

[Vanagon Nut]

[j_dirge]

[Vanagon Nut]

Thanks. Helpful to know. I have the sleeves on order but those parts will be at least several days away. Want to do shocks now.
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1981 Westy DIY 15º ABA

1988 West DIY 50º ABA

VE7TBN

[j_dirge]

[Vanagon Nut]

Yes f course. Thanks. Easy to do later.
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1981 Westy DIY 15º ABA

1988 West DIY 50º ABA

VE7TBN