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Date:         Sat, 24 Apr 2010 16:57:00 -0700
Reply-To:     Shawn Wright <vwdiesels@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Shawn Wright <vwdiesels@GMAIL.COM>
Subject:      Re: Front shock bushing questions
In-Reply-To:  <w2m1250b1e91004241526m159e3b0ctf18e5e5c8fb0bb6e@mail.gmail.com>
Content-Type: text/plain; charset=ISO-8859-1

On Sat, Apr 24, 2010 at 3:26 PM, Shawn Wright <vwdiesels@gmail.com> wrote:

> Hello all, > > Slowly getting around to my front shocks due to limited mobility for a few > days... I've pulled the old KYB out, and the top metal sleeve/bushing is > badly rusted, and looks to be slightly mushroomed, probably due to weak > shocks hammering at the weakened rusty metal. I can either order a new > bushing (rubber parts are fine), or make one. My questions are: > > 1. Is the OE bushing a tight fit where it goes through the hole in the > upper shock mount on the body? > 2. Van-cafe lists a kit with all the bits, but states "Please specify > below if you would like the kit with or without the shock collar" > (collar=bushing I am talking about). Under what circumstances would you not > want the collar? > > > http://www.van-cafe.com/home/van/page_1036_1354/front_shock_mounting_kit.html > > 3. Bentley states on 40.4 that two versions of the collar are used, but it > sounds like this change occurred around '82-83, and only applies if > installing a new bump stop on older van < VIN 25A 007 7959 (mine is 7JH 000 > 0000). So I assume I need the newer style, which is 28.5mm long according to > Bentley. Anyone have one handy they can measure the OD of a new one? > > Thanks > -- > Shawn Wright > '88 TD Westy >

After measuring all the pieces, here's what I've come up with:

hole in upper shock mount = 19mm old rusted bushing OD = ~15mm "tight" fit in upper rubber bushing = 16mm

So it appears that a 19mm OD steel collar/bushing would be a very tight fit through the upper rubber donut. It also appears that the lower rubber bump stop/dust shield is a tight fit into the shock mount area, effectively keeping the shock centred in the mount hole, preventing the loose steel collar/bushing from making contact with the shock mount hole (~2mm on each side clearance). This, combined with the picture here:

http://www.van-cafe.com/home/van/page_906_1354/front_shock_collar.html

leads me to believe the original collar is closer to an OD of 15-16mm than a 19mm (the length is 28.5mm, and the pic shows the OD is about 1/2 the length). Any idea why one end is knurled?

Also, on closer inspection, what I thought was "mushrooming" is more likely just corrosion on the more exposed part of the bushing eating away at the metal.

Still, I'd sure love for someone to confirm this... :-)

I'm going to leave it apart and move on to something else I think.

-- Shawn Wright


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