Been there done that.  The only = tool that is needed other than a few wrenches and a hammer is a press.  I = looked at what was in the manuals, but they make it too difficult.  To start = with, you need to remove the wheel, and rotor.  to remove the rotor, you = will have to remove the brake caliper.  Remove the bolt on the lower = half of the upper ball joint, the two bolts on the back side of the brake caliper = and remove the caliper (no need to disconnect the brake line).  Take rotor off = as per manual.  Unbolt the lower ball joint and tie rod end.  Loosen = the adjusting bolt on the tie rod end.  Now here is the part that may = have everyone screaming, but it worked for me.  Break out a good heavy = hammer, though not too heavy don't want to accidentally break anything.  = Start tapping the bottom side of the tie rod end until it is loose then remove = it.  now do the same with the upper ball joint and lower ball joint = except tap the lower ball joint from the top, the bottom will come later.  = That should have gotten the steering knuckle off for you.  Now since you = are at this point, I did a few "might as wells"  I replaced the = upper control arm bushings and did the brakes.  Figured it couldn't = hurt.  Now that you have the steering nuckel off lay it on the floor and start hammering on the bottom of the lower ball jont until it comes out (which = was rather easy for me).  Now it is time to put everything back = together.  This is where you need a press, but you can take the lower ball joint = and the steering nuckle to a shop and pay for that part, you are sill saving a = lot of money still.  If you have access to a press then take a pipe or = something that will fit over the top of the lower ball joint (no need for = expensive VW tools here!! :>)  I used a large deepwell socket! now press the = lower balljoint home.  Everything now bolts together the opposite way it = was removed.  The only difficulty I had here was torquing the ball = joint bolts, couldn't get the torque wrench to fit, but I am sure that there are = special expensive addapters that will fit.  What  I did was tighten = the life out of the bolts.. they are probably large enough to handle alot.  = Even if they were a little loose, the way they are set up, your front end won't = fall off.  Now if you get the new alignment and it doesn't drive = straight, look at the sheet the shop gives you and make sure they did all of the adjustment.  Don't let the service people tell you that a part = wasn't adjustable because they all are (Camber, caster and toe).  Better = yet, have them check the alignment machine before the service and get a print out = of your van to see if the machine has the updated informaton including all of = the ajustments and how they are done.  I took mine to Sears and they = did that for me.  The printout had pictures of all of the adjustment points = and how to adjust them.  Only one of their alignment machines had the = information correct for the vanagon so make sure to check if you want it done = right.  If you still can't drive straight after all that, check your tires, mine = were out of alignment so long that they decided where they wanted to go!!
 
Tools required to change ball joints:
1 common hammer
open end wrenches 13, 15, 19, and a few larger? = can't remember.  I did have to use 2 together to get some extra torque
pliers for cotter pins
press (could probably use a large bench = vise)
Torque wrench
something stable to hold front end up (you gotta get = underneath and dont wanna get squished)
Bentley manual (gotta pray every once n = awhile)
Big screwdriver to hold up brake = caliper
NO VW TOOLS REQUIRED!!!!
 
This job is not too difficult but rather time = consuming.  I paid about $200 for all of the parts including the upper control arm = bushings and brake pads.  Bought all of it from Ron at The Bus Depot except = for the pads.
 
Let me know if you have any more = questions.
 
Pete
peterz@gte.net
83.5 = Vanagon
 
-----Original = Message-----
From: gerry rafferty <gerryr@DIRECT.CA>
To: = Vanagon@VANAGON.COM <Vanagon@VANAGON.COM>
Dat= e: Saturday, August 22, 1998 10:33 PM
Subject: Re: Ball = joints replacement

Took my van in for a wheel alignment-requires upper and lower ball joints and tie rod ends.
Tried getting info from archives = but it times out.
So has anyone tried changing = above items?
Is it worth trying to do myself = or let a VW mechanic do the job?
I have the Haynes and Bentley = manuals-the upper ball joints and tie rod replacement I think I can do but the = lower ball joints look difficult in the VW tools required.
Does anyone have exact location = in archives(Month,Year) of above info?
Any opinions/suggestions welcomed.
Thanks
GerryR