How to Modify Volkswagen Beetle Suspension, Brakes and Chassis for High Performance

by Hale, James

• ISBN13: 9781901295801
• ISBN10: 190129580X
• Format: Paperback
• Copyright: 2000-11-01
• Publisher: Motorbooks Intl

Summary

How to get the best handling and braking from your Volkswagen Beetle. Covers front & rear suspension, 'chassis' integrity, suspension geometry, ride height, camber, castor, kpi, springs, shock absorbers, testing and adjustment. (Not 1302 & 1303 models).

Table of Contents

Introduction & acknowledgements	7	(1)
Introduction	7	(3)
Acknowledgements	10	(1)
Workshop procedures, safety, and tools	11	(1)
Workshop procedures and safety	11	(1)
Tools	12	(2)
Chassis, suspension & brake design	14	(9)
The chassis	14	(3)
Steering gear	17	(1)
Brakes	17	(1)
Suspension	18	(1)
Front suspension	18	(1)
Rear suspension	19	(2)
Later versions	21	(2)
Front suspension & brakes	23	(32)
King and linkpin front suspension	23	(1)
Disc brake conversions for king and linkpin suspension	24	(2)
King and linkpin suspension and brake maintenance	26	(2)
Lowering or raising king and linkpin front suspension	28	(3)
The steering gearbox	31	(1)
Torsion-bars	31	(2)
Track-rods	33	(2)
Custom and Speed Parts disc brake system	35	(1)
Porsche 356 brake parts	36	(2)
Renewing brake shoes, wheel cylinders and bearings	38	(1)
Ball-joint front suspension	39	(1)
Ball-joint maintenance	40	(1)
Dismantling ball-joint suspension and overhauling brakes	41	(1)
Front shock absorbers	42	(1)
Fitting disc brakes	43	(3)
Renovating calipers	46	(1)
Aftermarket calipers	47	(1)
Calipers from other vehicles	47	(1)
Porsche components	48	(2)
Using five-bolt drums	50	(1)
Raising or lowering ball-joint front suspension	51	(4)
Rear suspension & brakes	55	(28)
Swing-axle suspension	55	(1)
Improving handling with swing-axle suspension	56	(4)
Adjustable spring-plates	60	(1)
Urethane bushes	61	(2)
Solid mounts	63	(1)
Rear brakes	64	(3)
Replacing brake shoes	67	(1)
Fitting rear disc brakes	68	(1)
Oil seals	69	(1)
Fitting calipers and discs	70	(1)
Axle gaiters	71	(1)
Transmission oil	72	(1)
Independent Rear Suspension	72	(2)
Replacing CV joints	74	(1)
Standard units	74	(1)
Uprated units	75	(1)
Fitting Porsche stub-axles to Beetle A-arms	75	(1)
Fitting Porsche 944 rear disc brakes	76	(1)
Removing the Porsche rear suspension and brakes	77	(2)
The handbrake	79	(1)
Porsche brakes	79	(1)
Anti-roll (anti-sway) bars	80	(1)
Tyre clearance	81	(1)
Obtaining parts	81	(2)
The chassis	83	(21)
Removing the VW Beetle bodyshell	84	(1)
1302/03 Beetles	85	(1)
Shortening the floorpan	86	(4)
Cutting the chassis	90	(2)
Welding the chassis	92	(1)
Modifying the shortened chassis	92	(1)
Cables	93	(1)
Swing-axle to IRS conversion	94	(2)
Frame-Head Swap	96	(1)
Beetle cables and pedal assemblies	97	(1)
Accelerator cables	97	(1)
Handbrake cables	97	(1)
Heater cables	97	(1)
Clutch cable and pedal assembly	98	(1)
Hydraulic clutches	99	(1)
Gearshifters and locking shifters	100	(1)
The `Quickshift' kit	100	(1)
Gearshift locks	101	(1)
Conclusion	102	(2)
Appendix 1 Suppliers	104	(3)
UK & EU Suppliers	104	(1)
US Suppliers	105	(2)
Appendix 2 Chassis numbers & transmission codes	107	(4)
VW Beetle Chassis Numbers 1940 - 1968	108	(1)
VW Beetle Chassis Numbers 1969 - 1986	109	(1)
Transmission codes	110	(1)
Glossary of terms	111	(15)
Index	126