Date:         Tue, 11 Jul 2000 12:40:01 -0700
Reply-To:     Daniel Schmitz <djs@gene.com>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Daniel Schmitz <djs@gene.com>
Organization: Genentech, Inc.
Subject:      Strange noise after being parked/interesting C/arm problem...
Content-Type: text/plain; charset=us-ascii

Since the real list is apparently back in service, I feel pressure to
post a plethora of pent-up problems.

1) After not driving my '87 Westfalia for about a week, I started it up
and noticed that it makes a sound similar to tappet noise. The van has
been parked in a slightly sloping driveway, so I'm wondering if a lifter
has bled down.. I didn't drive the vehicle or let it warm up, just ran
it for a minute or so. Can anyone tell me if WBX lifters occasionally
bleed down, or is this more likely an exhaust leak? The van sounded fine
last time I drove it, so this noise seems to have developed since that
time, if that's possible.

The motor is a VW factory rebuilt unit (according to receipts that came
with the van) with less than 20K on it, and the exhaust system is an
after market header and muffler. I recently installed a new converter
and noticed that there was a slight misalignment between the exhaust
pipe and aftermarket muffler. Could bolting everything up tight have
opened an exhaust leak somewhere? The noise doesn't really sound like an
exhaust leak, but I'm open to all possibilities.

2) I installed new KYB GR2 shocks in the front of my van last weekend.
The rears are next, but I thought I'd get the harder-to-install pair out
of the way first. Anyway, on the driver's side, I noticed that the lower
control arm had a conical, split metal expansion "bushing" installed
where the shock bolt goes through. It looked like a repair piece for a
worn out bolt hole that had been drilled out. (?)

As the shock bolt had rusted onto the old shock, I had a hell of a time
getting it out because of this odd "feature" as the I couldn't tap the
bolt out from the other side like you would normally do. Has anyone run
across this repair piece before? It seems to work great as a way to
salvage the lower control arm, but I haven't seen this before.

Also, as noted by other posters, the new, top rubber bushing and
retainer that comes with the KYB's is kind of flimsy looking compared to
the stock VW pieces. I re-used my factory bushing and larger, beefier
retainer, as they looked fine. I would recommend this to others that go
with the KYB's.

--
Dan
__________________________________________________
Dan Schmitz - Genentech Automation Engineering
djs@gene.com (650) 225-6119
__________________________________________________

"I'll so offend to make offense a skill
Redeeming time when men least think I will"

W. Shakespeare
Henry IV, Part 1