Bongo Fury

Hi fellow bongonauts

I'm working on a 1996 4WD AFT 2.5TD, which needs a fair few jobs done.
So far, I've fitted out a conversion in it, replaced rear pads, shoes and drums, rear droplinks, refitted exhaust manifold, and started dealing with rust (heaviest on transmission/suspension components, but extensive surface rust on carcasse / subframe)

Up to now its not been a walk in the park, as I have to DIY everything (can't afford garage bills), but have found your forum to be a great help and inspiration - thanks for that.

I'm not a professional, but I am competent and safety conscious, maybe a bit too shy at times - but I'd rather the work took longer and I did it right.
The Bongo is bang on for cruising and camping, and I've had it out a fair few times now. So far so good.

I need to replace the front outer CVs, and I'm feeling a bit daunted, but its got to be done - so I'd really appreciate your feedback..

I've got the workshop manual, and know the links to lushparts etc, so I have a few resources to hand - but I need to know the following-

1) Will I need to withdraw the shafts to do this work?
2) Will I need to drain the diff? (just wanted confirmation on that)
3) What is the minimum amount of dissembling I need to do on the suspension / joints to accomplish this job
4) Is there a walkthrough available anywhere?
5) If I decide to replace wishbones while I'm at it (I think lower arm balljoint boots may have had it)(have to re-check that), any tips for doing that, and...
6) What post installation checks should I make afterwards (eg tracking etc)

So I know that's a hefty list, and a big ask for a forum noob, but if you feel you have time to chip in with any encouraging advice, I would be most grateful

(I have new CVs at the ready, also new front discs and pads. Most retaining bolts/nuts are pretty badly rust welded on, but I'm tackling the rust a bit at a time and its going pretty well - no nasty surprises yet)

Many thanks in advance
Hope you are all keeping well out there in bongoland

Jeff

Hi and welcome jeff I'm not too knowledged to answer your qs but just a warm welcome
Peter

Cab-ova pete wrote:Hi and welcome jeff I'm not too knowledged to answer your qs but just a warm welcome
Peter

Why thanks Peter for the warm welcome, good to be here

Hi there,

Just replaced my CV joints along with most of the front suspension.

I dropped out the diff at the same time and replaced all the oil seal.

Steering rack also as it happens along with hub bearings.

I digress.

Well the thing is if you are not replacing the wishbones/swinging arms then you do not want to tamper with the ball joint.

So just undo the bolts on the shock absorber and also the bolts on the x member side of the swinging arm.

If you do not have air tools then remember to loosen the hub nuts when the vehicle is on the ground and the handbrake applied.

I removed the complete drive shafts from the diff. Used a bolster with a hammer to free the shafts from the diff.

I found that the pattern CV gaiters to be somewhat short and have had a problem with the once side pulling off.

I have resolved this now though .

The CV joint will knock off with a few good hammer blows.

The retaining ring will probably shoot off into the distance.

You get a new one with the CV joints.

Not to terrible a job to do as long as you have a vice.

I used my Super Jaws which was great for replacing the CV joints as you could use it to compress the shaft and joint.

Anyway once all fitted up makes for a much quieter ride when turning.

Hi Titan

That's exactly what I was after, cheers for taking the time to post that up mate.

Glad that all went well for you, luckily for me, steering rack is holding in there pretty well, although I'm sure that job is in the pipeline. Hub bearings seem good too. I'll probably put new seals on the list.

Isn't it annoying when you do all that work and then run into a stupid snag like CV gaiters too short - can I ask how you sorted that ?

I'll keep the forum posted on how I get on.

Huge thank you

Jeff

Hi bongonauts

I know its a very late reply, but I just wanted to thank you, especially Titan, for your much needed advice and encouragement

In the end it was straightforward enough. Both CV's done, both Wishbones done, track rod ends, new discs and pads, everything thoroughly de-rusted and cleaned up, re-aligned, Diff refilled.

The most difficult parts of the CV job, was marrying the M/F splined parts together over the retaining ring, (fiddly as you like), and refitting the shafts. It was phone a friend time, to give it that bit of extra welly it needed.

Just wanted to send a huge thanks to you Titan for making the world of difference to the work. Nice one mate, very much appreciated.

Hope all is well with you

regards
JeffDee

Sounds like you're going to have a nice bongo there mate
And the value of them is going up
We like piccys we do