[Steering & Suspension] Rear axle replacement

[darrenchadwick]

Thanks all
My neighbouring farmers son (with big shed and free garage services!) is getting wed today so cant get to work on axle till tomorrow. Just want to express gratitude to all help and info provided by everyone on this axle swap. Feel a bit more confident as a result. Ive ordered two new shocks to go with re-con axle and want to put new hub bearings on but cant order the new ones yet until I take old ones off. This vans got ABS and I dont know how many teeth are on the sensor bit till they come off. The on-line suppliers are offering two different bearing options for this model so think it best to get the old ones off and find out before buying. I will probably need some brake bits anyway so not in a rush though my wife is goading me to crack on. Shes having to walk to work 3 miles while I borrow her Terios. Re-conned axle came with refurbed trailing arms, new bearings, ride height set up etc and a two year gaurantee. Cost £250 plus £49 delivery and free return of old axle.

[bikergraham]

Thanks all
My neighbouring farmers son (with big shed and free garage services!) is getting wed today so cant get to work on axle till tomorrow. Just want to express gratitude to all help and info provided by everyone on this axle swap. Feel a bit more confident as a result.  Ive ordered two new shocks to go with re-con axle and want to put new hub bearings on but cant order the new ones yet until I take old ones off. This vans got ABS and I dont know how many teeth are on the sensor bit till they come off. The on-line suppliers are offering two different bearing options for this model so think it best to get the old ones off and find out before buying. I will probably need some brake bits anyway so not in a rush though my wife is goading me to crack on. Shes having to walk to work 3 miles while I borrow her Terios. Re-conned axle came with refurbed trailing arms, new bearings, ride height set up etc and a two year gaurantee. Cost £250 plus £49 delivery and free return of old axle.

I really feel for you ,seriously.Would it not pay you to purchase another Berlingo as a donor vehicle,there seem to be a few being sold on ebay,you appear to have plenty of space.All the best and good luck.

[ron]

As a rule,I never buy 'wear' items S/H.Panels etc are OK but with other items you may get worse than  you've got.Just my thoughts.

[darrenchadwick]

Question
Im mid way through removing the axle now. Had a few glitches. Got one more snag now and before I get carried away with angle grinder and big hammers thought Id ask for help. The 18mm locking nut that holds the forward axle mount (with rubber rings inside) is spinning the bolt and the head of this bolt is hidden in the chassis/body work. The van is plylined and it already looks like I'll have to remove this to get to the four torx bolts that hold the axle on. Will I be able to access the head of the forward mounting bolt too? Im going back to the van now to take the ply out but any help on here would be really appreciated.
Ps. Had a lot of trouble getting top bolts out of shocks....seized and rusted to high heaven. Eventually got them out with a long tube on the wrench and a lot of WD40 and retightening/slackening back and forth. The 14mm allen key needed to be tapped and persuaded into the bolt head after a lot of faffing and cleaning of rust and gunk. Also bearings seperated while being pulled off so have two of those on order. One brake pipe had to be trashed to get it off the hub but its a short lenght so shouldnt be too much of a problem. I think Im heading in the right direction....at least for now.

[ron]

Question
Im mid way through removing the axle now. Had a few glitches. Got one more snag now and before I get carried away with angle grinder and big hammers thought Id ask for help. The 18mm locking nut that holds the forward axle mount (with rubber rings inside) is spinning the bolt and the head of this bolt is hidden in the chassis/body work. The van is plylined and it already looks like I'll have to remove this to get to the four torx bolts that hold the axle on. Will I be able to access the head of the forward mounting bolt too? Im going back to the van now to take the ply out but any help on here would be really appreciated.
Ps. Had a lot of trouble getting top bolts out of shocks....seized and rusted to high heaven. Eventually got them out with a long tube on the wrench and a lot of WD40 and retightening/slackening back and forth. The 14mm allen key needed to be tapped and persuaded into the bolt head after a lot of faffing and cleaning of rust and gunk. Also bearings seperated while being pulled off so have two of those on order. One brake pipe had to be trashed to get it off the hub but its a short lenght so shouldnt be too much of a problem. I think Im heading in the right direction....at least for now.

Good luck.We're all rooting for you.

[JohnM]

STOP!!!!!!!!!!!!!! The SIX only SIX (torx) bolts holding the rear axle to the shell are accessed from beneath the van. Two each side at the front of the axle and one each side accessed via the small holes in the casting towards the rear. Don't undo any other mounting bolts. The only reason you will need to remove the ply lining on the floor is to cut a hole to get to any captive NUT that has broken lose. Don't separate the front rubber mountings, undo the two bolts that hold the rubber mounting to the shell.


http://www.berlingoforum.co.uk/thread-3311.html

http://www.berlingoforum.co.uk/attachment.php?aid=660

[darrenchadwick]

STOP!!!!!!!!!!!!!! The SIX only SIX (torx) bolts holding the rear axle to the shell are accessed from beneath the van. Two each side at the front of the axle and one each side accessed via the small holes in the casting towards the rear. Don't undo any other mounting bolts. The only reason you will need to remove the ply lining on the floor is to cut a hole to get to any captive NUT that has broken lose. Don't separate the front rubber mountings, undo the two bolts that hold the rubber mounting to the shell.


http://www.berlingoforum.co.uk/thread-3311.html

http://www.berlingoforum.co.uk/attachment.php?aid=660

You're a hero John many thanks. Realised pretty quickly that the ply neednt have come out... doh!
Just going back to van now to try and get the last two bolts out (the bolts I couldnt see until reading these posts).
Just shows that I didnt read everything properly.
Thanks everyone. Keep you posted.

[darrenchadwick]

Gents
Got the rear axle on. I'll report on experience soon.
Got a seperate problem now. I'll explain....
After starting the axle removal I had to stop part way through and wait for a long reach torx (for the rear bolts) to come through the post. Vehicle was stood on blocks chocked up for four days with brake pipes disconnected. Got axle off yesterday and fitted new one. Had to replace both rear brake pipes from flexi hose to hubs because they were seized. Now trying to bleed brakes and struggling big time. My neighbour farmer mate has got a stiff leg from all the pumping! So we lowered vehicle on to level ground for fear that air was being sucked into master cylinder from reservoir due to tilt of vehicle. Got a flashing STOP on dash too - probably due to no brakes. Tried a bit longer to bleed brakes but havign problem with rear near side. Tried top find a tutorial for bleeding ABS but struggling here too. Also not sure if van has a load bearing valve...couldnt see one anywhere but not sure what to look for.
Do I need to bleed front brakes as part of an ABS procedure even though theyve not been touched? I think my farmer mate wants van out of his shed now....cant blame him.

[geoff]

Gents
...Now trying to bleed brakes and struggling big time. ......My neighbour farmer mate has got a stiff leg from all the pumping!

 Hi Darren, you need to pressure bleed the brakes with ABS ........pumping the pedal isn't the right way....

[darrenchadwick]

Thanks Geoff
Sounds like I need more tackle..angst.
Im sure I've bled these brakes before but hey ho Im old and my memory is fading. Got any suggestions? Vehicle is in a large farm building and getting in the way. The nearest motoring shop to here is about an hours drive (very rural) so if I can find any other way of doing it that would be great. If not, so be it.