Suspension

[Hazzobongo]

Hi folks

Just had one side of the front suspension spew its oil out and have bought both units and droplinks to do the job for going away in Sept from mazdabongo.com which lists the dampers as for all models including my 2.5 diesel, having had a quick look at the originals in place I noticed there appears to be two springs in place, the large main spring and a wrap around type spring around the damper leg inside of the large outer spring, my questions are is this normal on other Bongos and can I re-use those springs as there appears to be nothing at all wrong with any of the springs. Hazzo

[g8dhe]

The diagrams only show one spring, there is a rubber dust boot that might be mistaken for a spring perhaps ? see here https://www.lushprojects.com/bongoparts ... o=.html#10

[Hazzobongo]

Thanks Geoff just went and had another look and as you say its the dust boot/gaiter when I pushed a finger against it. The springs themselves look to be in good order as does the dust boot and rubber at the top so I'll reuse those to save on the expense.

The van running doesn't appear to be affected by the blown seal on the damper though I'm trying to avoid all potholes and speed bumps as don't want to have a busted spring too.

[Hazzobongo]

Well we got the old suspension unit out and stripped with great difficulty in removing the two large bolts which hold the unit to the suspension arm at the bottom, these were either just super tight or the 30 years they had been in place caused them to think they were all one part, I actually broke 2 of my three 1/2 inch drive socket extension bars trying to crack those two bolts even after spraying with release agent and two goes using a gas torch to heat up the nuts.

Anyway other than that the springs have only surface rust at the bottoms with paint still looking fresh at the top half but they are the only component going back in.
The top shock mount though still solid has a bone dry bearing so I think its on its way out and have ordered new for both sides, the rubber bump stops, gators and spring seat pads have all perished so they're all ordered and should be here in 2-3 days so we can get on with re-assembley.

Meanwhile bongo is out of commission for the first time in my ownership with the affected side chocked up on timbers on the drive, only one left to do now, cant wait lol.

Thanks again Geoff, would you happen to know the torque settings for those two large bolts and the drop links, all of which were ridiculously tight with the drop links easier to cut off with the grinder.

[g8dhe]

See the diagram here not quite sure which bolts your referring too the torque figures are Nm (Kgcm) next to the nut involved.

[Hazzobongo]

Thats ideal Geoff, I knew they were bloomin tight and no surpise they are over 150nm, the highest I've encountered previously is 140 for the rear axle nut on my motorcycle. Thanks for the prompt replies once again. Hazzo

[Hazzobongo]

Spent hours rebuilding the shock today after derusting, treating and painting the spring which has gone back in, it was relatively clean and still had lots of paint/powdercoat on it so I'm wondering if it had new shocks fitted either before it left Japan or in the 5 years its been here even though the seal on it gave out.

Anyway, hoping it doesn't rain here tomorrow so we can chuck this new one in and pull the other side apart.

I'll personally not be fitting any more shocks as the stripping out and putting the new one together has this 69 year old absolutely ******, the boy watched the procedure so he'll be on the tools tomorrow and I'll concentrate on undoing the shock from underneath the expansion bottle and grinding the drop link off. Soon be bongoing again.

[Hazzobongo]

Well not too soon, made a cock-up and assembled the wrong side shock thinking they were both the same and it wasn't till we had it almost all bolted up I realized the droplink was at the front side and would foul the brake line so out it came, stripped it and set to work on the other shock which was quicker and easier with two pairs of hands, anyway the right side which was the busted one is all sorted now.

Having a rest day tomorrow and will do the other side on Monday.

[Hazzobongo]

Well after a bit of a chew with the upper spring plate which is a non existent part as its not advertised or on google/duck duck go/ebay then I advize you to look after yours when your shock bursts, the part is not solely a Bongo part as these shocks are in numerous vans and 4x4's and thats the job done on mine, another fortnight and its jollyhollys time, see ya. H