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Hello Sam here with JBugs.com. Disassembling
and reassembling king and link pin spindles can be a difficult task. Removing
bushings out and installing new bushings requires an extreme amount of force. The
use of the correct tools will make things much easier but with some stand-ins, the
job can be done in your garage at home.
The only tool that we consider to be
a necessity for installing new kingpins is a VW king pin reamer. A .710 inch
reamer could be used but will not guarantee that the two bushings are aligned
vertically. A press and proper sized dies are ideal for removing and installing
new bushings. The next alternative would be a proper set of punches, a brass
hammer and a bench vise. In keeping with the theme of "Common tools found
in your garage at home", we use a framing hammer, some extensions and
sockets as opposed to punches and a proper hammer. Our method was not the best
we'll admit but it was effective and it got the job done.
With our original spindles cleaned
and degreased, the first spindle is securely clamped into its vise. So the
horizontal link pin bushings can be knocked out of the spindle carrier. Extensions
[and] a socket are used along with a hammer to tap the upper and lower bushings
through the spindle carrier. The link pin bushings are usually simple to remove
with a few forceful strikes of the hammer. With the link pin bushings removed,
the grease in the carrier is cleaned out of both ends.
Then the spindle is clamped upside
down in the vise so the king pin can be driven out the top. A six inch
extension, a closed end wrench to act as a guide and a hammer are used to
deliver numerous powerful strikes to the king pin. Note: our extension has
started to mushroom out as a reminder of how much force will be needed. Eventually
the pin is driven through, and with the pin almost out, a 12" extension is
used to drive the pin out completely.
The spindle can be slid or tapped
out of the carrier in the direction of the grooves on the carrier. The dust
cap, nylon bushing, alignment washer and spindle all come out together. Save
the washer and the spindle, if you're reusing it. The cap and the bushing are
not reused.
With the spindle carrier still in
the vice, a small extension and socket are used to tap out the upper and lower
king pin bushings. The other spindle assembly is disassembled using the same
method and both spindle carriers are cleaned up a bit more and readied for
reassembly.
The cleaned up spindle carrier is clamped back in the bench vise vertically with the bottom side up. A new king pin bushing is dropped into place. The bushing is tapped into place using the same extension and socket that we used to remove the old bushings. The bushing is tapped through the carrier and just slightly past the bottom edge. The spindle carrier is flipped over and a flat file is used to file the bushing flat with the carrier. Do not file down the steel carrier. Once you see marks into the carrier stop. The top bushing is dropped in and installed in the same manner.
Then the spindle is flipped over
again and the flat file is used to file the bushing flat with the carrier. Then
the narrow end of the flat file is used to notch the bushing to match the
carrier. Now our one specialty tool, the VW 224 king pin reamer tool, is slid
through the upper bushing and aligned with the lower bushing. We spin the
reamer with a crescent wrench and light pressure through the upper and lower
bushings. The shavings are all thoroughly cleaned from the spindle carrier and
then it is clamped upright in the vise.
We use a socket below it to keep it
from sliding through the vise. The original alignment washer is tapped into
place over the pin, on the new disc brake drop spindle followed by a new
greased nylon bushing and a new dust cap. The angle on the brace for the
carrier has a flat side and an angled side. The flat side sits toward the
chassis. Then angled side sits toward the spindle.
With the steering arm for the
spindle at the opposite side of the carrier brace. Grease is applied to the
upper and lower bushings. Then the spindle is slid into the carrier following
the notches in the carrier. A new greased king pin is dropped through the top
hole of the carrier. With the spindle straight in the carrier, the grease ports
are aligned with the holes pointing forward. The pin is tapped with a good
amount of force into place through the upper carrier, into the spindle and the
lower carrier. It is tapped down until it is roughly flushed with the upper
king pin bushing.
The assembly is removed from the
vise and clamped back in on its side. So the link pin bushings can be tapped
into place. With drop spindles, installing the lower bushing is simple as there
is plenty of clearance for an extension and socket. Make sure the grease hole
in the bushing is pointing towards the king pin to ensure that the grease can
enter the bushing. We start with a similar sized socket and tap the new greased
bushing almost flushed with the carrier. We switch to a slightly larger socket
to ensure the bushing is installed flush with the carrier and tapped all the
way in.
There is less clearance for the top
bushing as the drop spindle sits higher to lower the car. So the spindle is
braced by hand against the bench vise. While carefully tapping the greased
bushing into place as squarely as possible, again make sure the grease hole
points toward the king pin. We use the same small socket first, then a large
socket is again used to make sure the bushing is flat with the carrier. The
reamer can be used to make sure the bushings are not deformed and will accept
the link pins smoothly. Both the king pins and the link pins are reamed to the
same size. The opposite spindle is assembled in the same manner and because we
installed aftermarket spindles, we double check that both spindles rotate in
the spindle and stop against the steering stop at the front of the carrier.
Our right spindle was clear but the
left side spindle needed some clearance which we did with an angle grinder
before it hit the steering stop. This can be caused by manufacturer variances
in the casting or milling so double check the operation before installing the
spindles on the car. With the spindles completely assembled they will be
painted and once dry, they will be ready to install on the trailing arms. That
will be covered in our next video so stay tuned. In the meantime stop by
JBugs.com for all your vintage Volkswagen parts and accessories.
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