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[Steering & Suspension] Rear axle replacement
#1
Hi All
My rear torsion bar snapped on Friday. Its a 2lt HDi ex forestry van on a 2006 plate. Van has 107K on clock. Ordered a new rear beam as Ive learned that its easier to just change the whole beam particularly as I think the bearings are affecting the tyre wear.
Anyway, Ive tried to find a "how to" on replacing the beam and seem to be struggling to get a tutorial for this model of van. This afternoon Ive lifted the van up with a farm vehicle using a ratchet strap round the tow bar to try and locate the fixing bolts and see how hard a job it would be. I could see one main bolt on each side forward of the axle but not sure where the other fixings are. Can anyone point me where to find some instructions on how to remove please. Be very grateful to anyone who can try and help me save a few more quid on garage costs.
Thanks
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#2
(16-08-2015, 02:46 PM)darrenchadwick Wrote:  Hi All
My rear torsion bar snapped on Friday. Its a 2lt HDi ex forestry van on a 2006 plate. Van has 107K on clock. Ordered a new rear beam as Ive learned that its easier to just change the whole beam particularly as I think the bearings are affecting the tyre wear.
Anyway, Ive tried to find a "how to" on replacing the beam and seem to be struggling to get a tutorial for this model of van. This afternoon Ive lifted the van up with a farm vehicle using a ratchet strap round the tow bar to try and locate the fixing bolts and see how hard a job it would be. I could see one main bolt on each side forward of the axle but not sure where the other fixings are. Can anyone point me where to find some instructions on how to remove please. Be very grateful to anyone who can try and help me save a few more quid on garage costs.
Thanks

AAAgh have you a death wish.A ratchet strap ....REALLY !!!
[+] 1 user says Thank You to bikergraham for this post
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#3
A picture of a rear beam will show you the fixing points, you need a long torx bit to reach the bolt heads
[Image: 671377892_o.jpg]
So where does this bit go then ?
[+] 1 user says Thank You to ffrenchie for this post
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#4
Dont worry, the strap was doubled up and fixed with heavy bolted 'D' shackle onto the tow bar bracket and hooked by a heavy chain onto the Kramer. After looking beneath the van, the strap was not too difficult to remove so although the method is a little unconventional it was safe enough for a brief inspection and much safer than chocking up on stands. The main risk would have been a hydraulic hose blowing on the Kramer but I only wanted to have a quick look at the job in hand and wasnt actually working on the van. Anyway, for anyone conerned with my safety and welfare Id appreciate info on the rear beam mountings as its the Berlingo thats affecting my health more than anything.
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#5
(16-08-2015, 04:00 PM)ffrenchie Wrote:  A picture of a rear beam will show you the fixing points, you need a long torx bit to reach the bolt heads
[Image: 671377892_o.jpg]
Thanks Ffrenchie. This gives me a chance to consider if I can do the job myself.  Can I assume that it can all be done from underneath the van? The whole beam and attachments (brake hose mountings etc) seem very scaled up with rust and muck to the  point that some parts look like they will b*gger up when worked on. Im planning on doing the job on my neighbours farm next door and they've got a full compliment of tools and gear so I'll have pretty much every tool I think I'll need.
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#6
(16-08-2015, 04:00 PM)ffrenchie Wrote:  A picture of a rear beam will show you the fixing points, you need a long torx bit to reach the bolt heads
[Image: 671377892_o.jpg]
Thanks for the great pic.That should be a great help to everyone who does that job.
Strawberry flavoured windows  Dodgy
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#7
How difficult is it to replace a torsion bar in reality - someone must tackled it before! Wink

Sent from my GT-I9300 using Tapatalk
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#8
Darren.It you have the time,soak everythiing in WD40 a couple of times over a few  days.
Strawberry flavoured windows  Dodgy
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#9
If you are replacing the whole axle assembly, it is quite straight forward. Road wheels off. Disconnect shock absorbers, hand brake cables, brake pipes and any ABS plugs.
Remove the axle beam. Swap over the hubs and brake backplate assemblies. reassemble it all and bleed the brakes.
It should all be in a Haynes manual if you have one.
The hubs and brakes are probably the hardest part, so if you have ever changed brake shoes and wheel cylinders, then you should have no problem with the rest- easier still if it has discs.

If you are just replacing the torsion bars that is a bit trickier as it needs setting up.
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#10
Cheers Col and all
Done quite a lot of home auto mechanics over the years....most of it on this Berlingo alas. I would never buy another ex-forestry van as Ive virtually replaced everything major on this van in last three years. Ive done:
Steering rack, alternator, power steering pump, inner tie rods, track rods, two sets of front wheel bearings, brake servo and master cylinder, steering column uv joint, front shocks, coil springs, strut bearings....as well as general wear and tear stuff. This rear beam sounds within my capabilities so long as nothing snaps off. I think the oil-soaking is a given but not sure how I'll get it to soak into fixed bolts when gravity is against me. Anyway I think the new beam is coming on Tue so I can get some more WD40 tomorrow and get spraying! Wish me luck.
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