Aircooled VW South Africa

Hi all

I have just completed a successful removal and refitting of all 4 ball joints on a 73 baywindow - first change as the orgional joints were still in.
I did this on the vehicle without removing the arms or grinding or hammering.

I did this with a a copy i made of the VW removal tool with a modification of mine to reseat the new joints. I used a C clamp press i bought from Ardendorfs and my big 1 inch drive ratchet spanner bought years ago for R30 to stop shearing off the 3/4 drive when tightening beetle crank bolts.

after all the horror stories i was told and heard about needing a 10 ton press - this job was actually pretty easy with the correct tools.
I did have to fiddle around getting the ball joint tools 100% _ made them from mild steel not tool steel. i now have a good template for a tool and die maker to use to make them.

If any one is going to do this job - it can be done on the vehicle without stripping much.

Good job!

Some pictures would be nice.

well done, yes always better to made your own tools then you always have them.

Photos please

Herman

I tried to copy the VW tools and thought I did a good job, but they just ended up bending. I've been meaning to make another beefier version but I havent gotten to it yet.
Also, sometimes the G-clamp bends quite a bit and I've had to resort to other methods. Mine is a proper balljoint G-clamp, not a small woodworking one.

Glad you came right. It is a really crap job if the balljoints dont shift

Have always found it easy to use heat to expand the socket side ,

as even it you roast the ball joint, you going to turf it away anyway.

Herman

extraction tools


reseating tool


ardendorf C clamp - about R700


assembled extraction tool


new ball joints in

stub axle back on

I copied the tools from pics of the VW tools found on the internet.


mild steel cost about R200 for the bits and pieces - i used a new balljoint as a template
plug welded etc together with a 50year arc welder with 3 settings so welds strong but not pretty
some modifications and reweld of the two pins (they compressed slightly on second joint as it the arm had lost a corner of the pushing area. weld made it stronger (heat treatment)
I tried to heat treat the tools - heated up in my anthracite stove and plunged in oil.

to use continually they really need to be made out of toolsteel. sadly i dont have a workshop or the equipment to do this.
the thinner tubes were used to press the new joints back in using the base of the extraction tool.

the Clamp worked perfectly - if you can bend that doing this I will eat it.
i compressed the ball bearing inside the shaft - so i can see the pressure I applied.
no heating required - the second side i pulled and replaced ball joints in about 1 1/2 hours - no rush.
i had to pull the upper ball joints with the camber adjuster on - would not move but there was enough clearance inside the tool to not damage the camber adjusters - removed afterwards and reused

this is a 1973 one owner bus - the joints removed were origional.
i used a punch to seat the top edges of the ball joint - didnt get to make the tool per VW
Ardendorf press cost about R700
steel cost me about R200
welding time and a few rods
a fair amount of time scratching my head and think about the whole process
I found 4 ball joints a while back marked ECO and with OE dust covers on them - possibly VW origionals? paid R1200

Thanks Jonathan. This will be a good reference when I tackle this job on my Bay Window.