Volkswagen Type II Transporter 1200 Series Shop Manual page 169

Front Axle
ltnd
Suspension-9
10. TORSION ARMS AND BALL
~JOINTS
(LATER MODELS.)
TO REMOVE
(1) Remove brake and drum assembly and steering
knuckle as previously described
under STEERING
KNUCKLE- TO REMOVE.
(2) Remove stabiliser bar as previously described under
ST ABlLISER - TO REMOVE.
(3) Remove the torsion arms by undoing the locking
nuts of the grub screws and unscrewing the grub screws
from the. torsion arms.
(4) Withdraw the torsion arms from their mounting in
the axle tubes.
TO CLEAN AND CHECK (TORSION ARM)
(1) Moisten some clean cloth with cleaning solvent and
wipe clean the torsion arms but do not apply to the ball
joint rubber seal. Use a clean dry cloth for the ball joints.
(2) From the tops of the ball joints remove the grease
nipple plugs and instal the tapered check pin of the special
tool, VW 282d.
(3) To mount the torsion arm on the special tool,
substitute the torsion arm inner bearing by fitting the bush
and for the o;uter bearing the spacer ring from the special .
tool, VW 282d.
(4) With the torsion arm mounted on the special tool,
push the arm down with the check pin below and see
whether the pin comes in contact with the appropriate
small boss on the face of the tool. If the check pin fails to
make contact with the small boss, discard the torsion arm
as it is obviously bent or distorted.
NOTE: Torsion arms and ball joints should be treated as
units and in the event of a torsion arm being discarded,
renew the complete unit.
(5) Remove the special check pin from the top of the
ball joint and refit original plug.
TO CHECK (BALL JOINTS)
(1) Having cleaned the ball joints, using a vernier gauge,
place one jaw on the plug at the top of the ball joint and
the other jaw on the bottom of the ball joint stud. With the
thumb and finger, move the stud in and out of the joint and
simultaneously take the reading on the vernier gauge. The
permitted axial play of a ball joint stud, new, is within the
limit of .0 12" and the permissible limit of wear is .080".
NOTE: Ball joints cannot be repaired and must be replaced
as a unit.
(2) In the event of the ball joint rubber seal being
damaged, dirt will have entered the joint, take off the seal
and at the top of the joint, repiace the plug with a grease
169
View of Left Himd Side Suspension and Steering Linkage.
nipple. Using a grease gun containing lithium grease,
thoroughly grease the joint, allowing the grease to remove
the dirt.
(3) To the lower end of the new dust seal, fit the small
metal retainer ring and reasonably fill the seal with lithium
grease.
( 4) Ensure that the lower ring groove is clean, then fit
the seal to the ball joint and secure with the lower retainer
ring. Using a special sleeve, press the upper retainer ring on
to the conical sleeve and then transfer it on to the seal.
(5) Remove the grease nipple from the top of the ball
joint and screw in a new plug. ·
TO REMOVE BALL JOINTS
(1)
Position the lower ball joint and torsion arm on a
press and, with the special tool, press the joint out of the
torsion arm mounting.
(2) In a similar manner, press out the upper ball joint
from the upper torsion arm.
NOTE: Ball joints which have been pressed out of the
torsion arms, should be discarded.
t3)
The eccentric bush on the upper ball joint stud can
also be pressed out with the same special tool on the press
but in this case a nut must be screwed on to the stud to
prevent the ball joint stud being suddenly dislodged.
TO INSTAL BALL JOINT
(1) Position the new lower ball joint in the top of the
·lower torsion arm mourlting, ensuring that the serrations in
the shoulder of the ball joint line up with the lugs on the
torsion arm mounting.