Introduction
Suspension
is one area where a dramatic increase in performance can be gained
simply by
upgrading
components. The syncro has the potential to have
pretty good suspension, but the stock components
are not up to the job. Better shocks, springs and
suspension-related bushings can significantly enhance the feel and
performance of the vehicle. Ground clearance can also be modestly
increased through stiffer or taller springs. But increasing ride
height beyond stock specs will result in increased stresses on and even
premature failure of the CV joints, and may increase risk of a rollover
accident..
Overview
The goal when
upgrading the
suspension should be to maximize the performance of the existing
design. That means keeping static ride height
within the range
that the system was designed for in order to avoid topping out problems
and to permit the wheels to drop into
holes. Maximum static ride
height for the Syncro is roughly 19.4 inches, measuring from axle
center to the lower lip of the
(metal) fender).
The damping on the
stock Boge shocks and on
the Old Man Emu shocks (which are valved a
little stiffer than the Boge "C") also
impose limitations. Both
shocks are valved for 14" wheels (except the Boge "N" shocks are valved
for 16" syncros) and neither is re-valvable or adjustable. This
puts an effective limit on
tire/wheel weights and spring stiffness options that will in fact
result in optimized performance.
Specifically, a custom spring that
is more than modestly stiffer than
stock or a wheel/tire combination that is
more than modestly heavier
than the stock 14" setup will impose forces beyond the
performance
parameters of the damping
of the available shocks.
Consequently, if you
want to upgrade
to bigger wheels and tires, the more they
weigh than the
stockers, the more they will impact negatively on suspension
performance due to inadequate damping/valving of the shocks. The
van
will top out easier and the front end will pop wheelies easier
over
whoop-de-doo type bumps, especially at speed. It may affect
cornering, too. In addition, if a custom spring
is too stiff for the stock shock rebound valving, it will also cause
the vehicle to feel too bouncy and too busy over bumps. The
further away from stock you get in wheel/tire weight and spring
stiffness, the worse the symptoms will be.
For this reason, unless you are going to have custom shocks made, or
are
going to purchase Boge "N" shocks for the 16" syncro, or do not mind
some degradation of suspension performance, it is best to stay
reasonably close to both stock spring stiffness and stock wheel/tire
weight when making upgrades. Choice of tires is also critical to
suspension performance since the tires work with and act as a de facto
component of the suspension. (See the Tire
page.)
Coil
Springs
VW sells only one stiffness in coil
springs
for all of the syncro configurations despite the great variations in
vehicle
weight. As a result, the stock springs are simply too soft for
the
heavier Westfalia models, and they produce symptoms of "wallowing,"
"kneeling" and shifting in the wind on the heavier vans.
Moreover, the one-size-fits-all stock
springs
are expensive at about $1,200 a set. There are several options
available for custom springs that address these problems and also
provide increased ride height.
- Syncro.org Syncro
and Vanagon Coil Springs: These
high-quality front and rear springs are slightly stiffer (less
than
10%) than the stock springs, and thus get rid of the ill-symptoms
produced
by the too-soft and worn stock springs on most syncros today, but they
are close enough in stiffness to the stock rate that the suspension
remains
supple and responsive. The springs also raise the ride height of
syncro westfalia's roughly .8 -1.25", and thus provide increased ground
clearance
and more usable suspension travel while still maintaining stock syncro
specs
for allowable ride height. (Disclaimer: we sell these
springs, but we also use them and provide an accurate description
above. ... despite our obvious bias!)
.
- Auto
Seikel Tested
by syncro.org, these are high-quality T-3 syncro springs designed by a
pioneer in
modifying syncros for off-road competition, including
Paris-Dakar.
The down side is that they are very stiff, with double the spring rate
of the stock front springs. This is too stiff for many/most
applications
and requires the "N" Boge shocks with stiffer damping. The stock
("C") Boge shocks on USA syncros will not work well or last long with
these
springs; the damping is much too soft for the stiff spring rate.
However, with the right shocks, these are excellent springs if your use
requires a very stiff spring rate.
.
- Fast
Forward Lift Kit:
Fastforward's
"lift kit" consists of stiffer and taller front springs and thick steel
spacers to be used with the stock rear springs. The goal with
this
kit is to lift the van ride height ~ 2". There are
compromises
involved in the kit in order to obtain the additional height
economically
and without the additional cost of a set of rear springs: (1) The new
front
springs are not matched in height or stiffness to the stock rear
springs;
(2) The need for the steel spacer for the rear springs effectively
limits
available suspension travel in the rear by the width of the
spacer.
(3) The ride height achieved with the kit leaves less than 1-1.5" of
sag,
resulting in potential topping-out problems. For some uses,
however,
the primary goal of increased lift overrides these concerns.
Shocks
The
stock shocks (USA models) are not adequate for sustained
off-pavement
use. They do not hold up well, fade easily and require frequent
replacement
with routine off-pavement use. VW does list two stiffer Boge
shocks,
one for heavy use for 14" syncros One is the "M" shock, which came
standard on 14"
syncros sold in Australia. The "C" shock that comes on USA sold
syncros was not stiff enough for Australian use.
The "M" shock has
stiffer damping and is designed for "heavy duty" use with 14" wheels.
The other
shock is the "N" shock for the 16" syncro. The
"N"
shock has stiffer compression damping like the "M" shock, but it also
has stiffer rebound damping to compensate for the heavier 16"
wheels.
These shocks are not
standard
USA parts and are difficult to get and are also very expensive.
The only other option for shocks are the Old Man Emu shocks or custom
made shocks. Here is info on each option:
-
Old Man Emu shocks from Australia are better than the stock
Boges, and are the only alternative,
fully matched set of shocks available for the Syncro
off-the-shelf.
Click the link for info.
- Bilstein..Syncro
Shocks Project Monotube technology,
adjustable
and rebuildable, these custom shocks were hand-fabricated for the
Syncro
Westfalia and are not available commercially. Re-worked Bilstein
shocks are available from a shop in South Africa. Custom made
monotube shocks from South Africa were also available for some time,
but the travel specs were not correct and resulted in the upper control
arm hitting the spring on full extension.
- Stock
Boge Shocks VW
Part Numbers for the three different sets of VW Boge shocks available
for
the syncro are:
Front: 251
413 031 C
standard 14" syncro shock (USA)
251
413 031 M 14''
HD shock "Schlechtwegepaket"
251
413 031 N
16'' syncro shock
.
Rear: 251
513 031 D standard
14"
syncro shock (USA)
251
513 031 M 14'' HD
shock
"Schlechtwegepaket"
251
513 031 N 16''
syncro
shock
.
- Adjustable
Air Springs :
Rubber,
bladder-like Inserts for the Coil Springs to adjust ride height and
suspension
stiffness. These are great for fine tuning the rear suspension
for
exceptionally heavy loads.
Bushings
Bushings
are also critical components of the steering and suspension
systems.
Worn bushings introduce slop into the performance and subject other
parts to wear and damage. Stiffer poly
bushings are tougher than the
stock rubber ones, and tighten everything up for a more responsive
ride, but they also flex less and thus absorb less vibration than the
softer rubber stock bushings.
Bushings are found in the following Syncro components: Upper
control arms, lower control arms, thrust bars, stabilizer bar, shock
mounts, power steering rack and rear trailing arms. There are
also bushings in the steering linkage. There are also rubberized
bushings/mounts for the engine, transaxle and front differential.
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251 407 077
Upper control arm bush (4)
251 407 183 Lower front A-arm bushing (2)
251 407 625 Front wheel bearing, Syncro (2)
251 407 629 Front wheel seal, Syncro (4)
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Other Wear Items
Other wear items that
will
significantly affect performance include upper and lower ball joints,
tie rod ends, and the power steering universal joint. Be careful
of shoddy after market items. There is great variation in
quality. It is not worth the cost in labor to install cheap parts
in these critical areas which are subject to severe stresses.
251 407 187 Lower Ball joint
(2)
251 407 361 Upper Ball Joint (2)
Installation
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