Volkswagen Type II Transporter 1200 Series Shop Manual page 171

Front Axle and Suspension-11
laminated Type Torsion Bar.
( 4) Check the torsion bars to ensure that they have
been correctly assembled and the recess for the grub screws
will line up with the screws when installed. Tape the
forward end of the torsion bar and instal in position and
secure by tightening the grub screw.
(5} Connect the front gearshift rod to shift rod
coupling.
( 6) Instal the torsion arms in the axle tubes, lubricate
bearings and secure the grub screw lock nut.
(7) Instal the shock absorbers.
(8) Instal the ball joints in their mountings on the
steering knuckle.
{9) Instal the road wheel and secure· with mounting
bolts.
(10) Lower the vehicle to the floor.
12. TORSION ARM NEEDLE BEARINGS AND INNER BUSHES
TO REMOVE
The torsion arm is mounted within the axle tube on
two bearings, the inner being a metal bush with a plastic
bearing seat and the outer is a needle roller bearing. The
wear on the inner metal bushes is very slight and renewal
should only become necessary when the contact point on
the torsion bar shows signs of excessive wear. ·
(I) Raise the vehicle and support on stands.
(2) Remove the outer hub cap, wheel mounting bolts
and withdraw both road wheels.
(3) Disconnect the brake hose pipes and plug the ends.
( 4) Extract the split pin from the speedometer cable
and remove inner hub cap.
(5) Undo the locking screw, remove the clamp nut and
withdraw the hub and drum assembly.
(6) Disconnect the front gear shift rod at the rod
coupling.
(7) Remove the shock absorber.
(8) Disconnect the ball joint and remove torsion arms
from axle tubes.
(9) Undo the axle tube grub screws and remove the
torsion bars. ·
(10) Using a suitable gauge, measure the inner metal
bushes in the lower and upper axle tubes. If wear limit
registers more than 1.692" renew metal bushes.
(11) Using a special tool, extract the needle bearings
from the axle tubes.
( 12) Using a special tool, extract the metal bushes from
both axle tubes.
TO INSTAL
(1) Before installing the needle roller bearings and
metal bushes thoroughly clean out the axle tubes.
(2) Using a suitable internal gauge, measure the. bores
of the needle roller bearing seats in the axle tubes arid also
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check their condition. The diameter of the seat of needle
roller bearings in both axle tubes should be 2.244" and
bearings should be 2.243".
NOTE: If the bearing seats, in the axle tubes show excessive
wear, and as it is rzot possible to rectify the wear, the axle
tubes must be replaced.
(3) Clean the needle roller bearings and check very
carefully for any signs of wear or damage. If not in good
condition, renew.
(4) Apply a light smear of lithium grease to the needle
roller bearing seats and using a special drift, drive the
bearing into the tube, with bearing shoulder marking on the
outside. The bearing is correctly seated when the shoulder
of the drift is up against the axle tube end.
(5) Using a special tool, drive the metal bushes through
the needle roller bearings, using the bearing to serve as a
pilot for the drift. The bush should be driven in until the
shoulder of the drift is in contact with the tube.
(6) Instal the seal retainers in the tubes with the lugs in
the vertical position. ·
(7) Instal the torsion bars as previously described and
lubricate the grease nipples.
(8) Position the seal on the torsion arm and instal the
arm and secure the. grub screws and lock nuts and lubricate
the grease nipples. .
(9) Connect the front gearshift rod to rod coupling.
(1 0) Instal the shock absorbers.
(11) Instal the ball joints on the steering knuckle and
lubricate the joints.
(12) Mount the tie-rod on the steering anti.
(13) Instal the hub and drum assembly, adjust wheel
bearings and secure clamp nut pinch bolt.
(14) Connect the brake hose and bleed system.
(15) Fit inner hub cap.
(16) Instal the speedometer cable and insert split pin.
(17) Instal road wheel and secure with mounting bolts.
. (18) Lower vehicle to the floor.