Frank Condelli & Associates

RR #2, Almonte, Ontario, Canada, K0A 1A0

Phone: (613) 256-6763 E-Mail: Fkc43@aol.com

Vanagon Westy Suspension, Steering, Brake Overhaul

Below are photos taken of the complete suspension, steering and brake overhaul done on my personal 1987 Vanagon Westfalia. This vehicle has approximately 500,00 kms on the clock at the time this work was performed in January 2007. The last picture is of the rear bearing hubs and shows the addition of grease fittings to allow greasing of the rear wheel bearings. Following the photos is a list of parts that were changed, their cost price and a work list. Ride height seems to have remained about the same. Unfortunately, I did not take a measurement before however the measurements I have now are as follows, taken from the bottom middle edge of each wheel well to the cenre of the axel: Front: LH - 16", RH - 16-1/2", Rear: LH - 16-1/8", RH - 16-3/8" I cannot at this time account for the measurements being different from the right and left sides. I have put up a webpage survey of Vanagon ride heights that I will add to as information is gathered by myself and those who send it.

1 Spring set, front, BOGE, Bus Depot, 251 411 105 A 952, BD - 120.00

1 Spring set, rear, BOGE, Bus Depot, 251 411 105 952 - 120.00

2 Shock absorber, rear, oil, AL-KO (Spain), 5528, 251 513 031G - 101.00

2 Shock absorber, front, oil, AL-KO (Spain), 4528, 251 413 031J - 111.10

1 Calliper, '86 ~ '91, front brake, RH, Girling, rebuilt NAPA, 251 615 124 D - 78.69

1 Calliper, '86 ~ '91, front brake, LH, Girling, rebuilt NAPA, 251 615 123 D - 78.69

2 Boot kit, front brake calliper carrier, 443 698 470 - 34.64

2 Brake hose, front, '86 ~'91, 460mm, 6699, 251 611 775 B - 22.00

2 Brake cable, rear, 2 WD, 6165, 251 609 701C - 25.00

4 Plug, rear brake backing plate, brake adjust & brake check holes, 113 609 163 - 6.52

2 Bearing kit, rear wheel, 5994, 211 598 625 - 72.72

2 Tie rod with ball joint, 4794, 251 419 803 - 80.80

2 Ball joint, upper, 4216, 251 407 361 - 36.00

2 Ball joint, lower, 4217, 251 407 187 - 36.00

4 Bushing, upper control arm, 4200, 251 407 077 - 56.00

2 Rubb mount, lower control arm, 251 407 183 - 45.56

2 Bolt, lower control arm rubb mount, N 010 167 5 - 5.52

2 Washer, lower control arm bolt, N 012 232 3 - 0.66

2 Nut, lower control arm bolt, N 011 020 7 - 1.34

2 Mounting, radius rod, 251 407 175 - 25.88

2 Mounting, radius rod, 251 407 179 - 35.08

2 Sleeve, radius rod mounting, 251 407 097 - 33.12

4 Damp ring, stabilizer rod to lower control arm, 411 513 121 - 10.96

2 Sleeve, damp ring stabilizer rod, 251 411 047 - 22.24

2 Damp ring, top front shock mount, 701 513 121 - 5.30

2 Bushing, top front shock mount, 251 413 439 C - 13.36

2 Cap, top front shock mount, 251 413 437 - 1.02

2 Mounting, stabilizer bar to body, 251 411 041C - 22.24

2 Nut, front axle, 251 407 671 - 13.44

2 Ring, front rotor bearing seal, 251 407 631 - 22.62

1 Cap, front wheel bearing, LH w/square hole - 50.54

2 Seal, front wheel bearing, 4413, 251 407 641 A - 2.72

1 Speedo cable assembly, 251 957 803 E - 53.69

4 Brake fluid, Kleen-Flo, dot 4, 532 - 32.40

Shop material: Cleaning, POR-15, undercoat, Krown Oil, anti-seize, wheel bearing grease, misc. - 100.00

Sandblast parts - Blast All - 50.00

Alignment - Frizby Tire - 96.85

Total wholesale cost of parts and sublets - 1623.70

1/3/07 430,014 km Start repairs to front suspension, steering & brakes. Clean, prep & POR-15 new springs, brake callipers, brake calliper carriers.

1/4/07 Disassemble RH wheel, brake and suspension components.

1/5/07 Disassemble LH wheel, brake and suspension components. Remove all bushings and joints, clean all parts and prep for sand blasting, make list of parts needed.

1/6/07 Remove tie rods, torsion bar, scrape & clean rust spots on van. Straighten & weld repair damaged areas. Gunk & pressure wash all areas.

1/8/07 Clean & prep all areas for POR-15. Wire brush clean all pieces to be POR-15ed. Bring parts to sandblaster. Weld repair radius rod. Order parts.

1/9/07 POR-15 & undercoat front end undercarriage. Prep & POR-15 parts for front end rebuild.

1/10/07 Assemble pipes & hoses to brake callipers and POR-15 parts. Remove LH front brake line, make new one and install. Install new speedo cable, Install new tie rods. Undercoat as needed.

1/11/07 Disassemble rear wheels, brakes, shocks & bearing hubs. Inspect, clean & remove rust from all parts to be POR-15ed.

1/12/07 Prep & POR-15 rear brake, bearing carrier, & swing arm parts. Clean & remove rust from hardware parts. Undercoat rear swing arm assemblies. Remove old rear brake cables, repair frame carriers, install new brake cables.

1/13/07 Install new bearing & seal kits in rear wheel bearing carriers. Assemble LH rear suspension, bearing & brake assembly, new bearings, new spring, new shock & old brake parts.

1/15/07 Clean, prep, & POR-15 rear drums. Install new bearing & seal kits in rear wheel bearing carriers. Assemble RH rear suspension, bearing & brake assembly, new bearings, new spring, new shock & old brake parts.

1/16/07 Clean rear drums, install and adjust brakes. Torque rear axle nuts. Install wheels

1/20/07 Parts from sandblaster back. Install seal rings, lower ball joints & swing arm bushings. Prep & POR-15 all parts.

1/22/07 Install new seals in rotors, clean and pack bearings. Install rotors, brake calliper carriers, brake callipers, connect hoses, bleed brakes. POR-15 mounting hardware. Install front wheels and adjust front wheel bearings.

1/24/07 Bring van to Frizby Tire for alignment.

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This page was last updated on May 29, 2010

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