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Gerry | Vanagon
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VanagonEuroVan
Subject:Re: Sway bar links breaking.
Date:Wed, 6 Jul 94 12:07:07 CDT

Sorry, I'm a bit slow on the draw here.  Just now getting caught up with
my e-mail.

Well I'm glad I'm not the only one who has problems with his (anti-)sway
bar linkages.  The bolt on my right hand one snapped about a year ago.  Rather
than spend the $70 some that VW wanted to replace it, I did the following:
I drilled and tapped the shaft where the threaded extension had snapped off,
and put in a good strong bolt.  Graphically:

           Old:                         New:
                                            ____
               ____                        /  _  \
             /  _  \                       | | | |
             | | | |                       \  ~  /
             \  ~  /                        |   |
              |   |                         |   |
              |   |                         |   |
              |   |                         \   \
              \   \                          \   \
               \   \                          |z=z|
                |   |                         |z=z|  <-- Drilled and tapped
                +---+                         +z=z+
                 z=z   <-- snapped here        z=z   
   Threaded-->   z=z                           z=z
 protrusion     Nz=zN  <-- Nut                Bz=zB  <-- Bolt head

About a month later, the other side snapped too, so I did the same thing
to it too.  So far things have held together.  It sure feels a lot better
on those tight off ramps on I70.

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