Date:         Sun, 25 Jun 2006 15:03:00 -0700
Reply-To:     James V <tornadored@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         James V <tornadored@GMAIL.COM>
Subject:      Front Shock Installation - Upper Spacer Sleeve?
In-Reply-To:  <cf4df96f0606251239w247be653xe2a98e28241fbee8@mail.gmail.com>
Content-type: text/plain; charset="US-ASCII"

I'm in the process of replacing all four Bilstein Touring shocks installed
by the PO, with new Bilstein HD shocks on my 88 Westy.  I did the rears, no
problem.  But, I'm a bit uncertain about a particular spacer in the fronts.

The new Bilsteins include a short (~3/8") spacer bushing w/ a "stepped"
inner surface that sits atop the "step" below the threading on the shock
shaft:

http://three91.com/vanagon/bilsteinShocks/newBilstein.jpg

My old Bilsteins were installed as follows: dust shield, (upper control
arm), 3/8" stepped bushing (same as the one included w/ the new Bilstein)
inside of rubber donut bushing, large flat washer, then the retaining nut:

http://three91.com/vanagon/bilsteinShocks/oldBilstein.jpg

When installed, the 3/8" stepped bushing is "swallowed" by the rubber donut
bushing, and the top of the dust shield is pressed directly against the
control arm:

http://three91.com/vanagon/bilsteinShocks/oldBilsteinInstalled.jpg

Instead of the 3/8" spacer bushing, Bentley shows a longer (1.12")
(non-stepped?) spacer sleeve that slides over the shock shaft on top of the
dust shield and seems to extend through the control arm and donut bushing.
The dust shield looks like it has its own stepped bushing inside, that
allows it to sit atop the step on the shock shaft, as well as receive the
factory spacer sleeve from above.

So, my guess is that the 3/8" bushing included w/ the Bilstein shock is used
only if the factory dust shield is not...?  And it looks like, then, that
the PO mistakenly replaced the longer factory spacer sleeve with the shorter
one included w/ the Bilsteins...?

It makes more sense to me to discard the 3/8" bushing included w/ the
Bilsteins, and use the longer factory spacer sleeve.  This way, the when the
nut is tightened, it bottoms out on the spacer sleeve, providing a specific
compression for the donut bushing...  Is this correct?

If so, then I need to get new spacer sleeves and Bentley calls for part
251-413-439A (28.5mm).  However, a quick search on Bus Depot only came up w/
251-413-439C.  Is this a suitable replacement?

Thanks for your help.  (Sorry for the lengthy explanation - Let me know if
clarification is needed anywhere.)

James V
88 Westy