The rear suspension parts like PU bushings and dust caps are replaced. Pics to follow until end of this week.
I started to disassemble the complete rear suspension without going into the hub assembly because there is no need to do it.
First i removed the lower damper screw then the upper one, you can remove the fully extended complete damper unit without adjusting the spring height.
The supplied bushing kit has 8 tubes going through one pair of PU bushings.
These tubes are a bit too long and need to be turned down.
If not the step washer ( in case of the MK IV a cylindric thick washer)will sit borderline in the outer frame brackets and could jump out if the whole thing is stressed.
The dimension must be 46mm with a negative tolerance about 0.5 mm.
The rear upper a-arms, if fitted with the "inner" 2 PU bushings, have a very tight fit when you mount them back to the frame brackets.
After the a-arm was back in position I added the outer bushings with the inserted tubes, everything coated with petroleum jelly. The inserts can be placed in position through the step washer opening in the frame brackets.
With the long screws you can guide and press the inserts in position easily.
The dust cap for the ball joint was stretched with long needle hosed pliers. The caps are made from neoprene and are very flexible if heated up a bit.
I kept the metal bushings originally glued to the sides of the caps, cleaned them and held them in place by hand during assembly.
Before final assembly i put some moly grease in the caps.
Then the lower tie rods where disassembled, the damaged caps removed,the ball joints checked, cleaned and new caps with grease fitted as before to the upper a-arm.
The half shafts where removed, checked, cleaned, the seals checked and cleaned. The splines where greased, the shafts assembled and mounted back in position.
The uprights are checked for bearing play and wear, cleaned and put back in place.
The Konis are cleaned, checked for leaks and the piston rods checked for scratches or other damage.
They are fine, no leaks, no damages. After a short conversation with Koni they explained that in theire opinion there is no need for a rework until you don't have any leaks.
In case of a rework the dampers need to be sent to Koni for a close inspection, if the piston rod is scratched or damaged it is gainless and a replacement is less cost effective they explained.
Btw, the dampers are not longer available, I found one source in the US offering 2 NOS parts with the correct number for 427 rear suspension. They are are about USD for one!
To be continued....
