Astro AWD "Stroverlander"

Stroverlander

Adventurer
Installed the new sway bar bushings and end links tonight.

The Adjust-A-Link end links come with two different length bushings to fine tune fit. I wanted slightly longer than stock end links so am using the two smaller bushings on the outside and the longer bushings on the inside to give the most length.

With new bushings in place, measuring both sides from subframe to eye to center swaybar before tightening shells.

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The swaybar bushings are greasable but clearance is too tight with the idler arm underneath so picked up some set screws to plug the holes with and I'll just remove the set screws when I need to lube the bushings. Easier than drilling new holes for the zerk fittings like I was originally planning on doing.

Swaybar bushing installed and lubed, the swaybar is also wrapped with teflon tape (yellow gas) to reduce the possibility of any noise.

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Clearance (or lack of) for the zerk grease fitting to idler arm while test fitting.

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End link installed and torqued to factory spec: 13 lb ft.

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I opted to install the bolt through bottom of control arm this time around, the install goes much faster and don't have to fight holding the bushing and washer in place inside the control arm while trying to thread the nut.

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Swaybar is still slightly low so may shim the center spacer with a couple of washers, there is enough thread should I choose to do so.

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Test drive tomorrow to see if I notice any difference.

Couple of thoughts - I need to do some rust cleanup and painting on the subframe and suspension components! Any recommended products for rust coating? I've used some of the rust reformer type spray paint in the past to cover but is there anything better or more durable?

I'll probably get the chance to do the rust cleanup soon as my control arm bushings are not looking that good, especially the lower. I would wager that is where the Stevie Wonder (steering wander) is coming from lately. I am still undecided on whether or not to use Moog Problem Solver bushings or urethane bushings. The urethane bushings don't come with shells so would have to burn the rubber out of the old shells for use so potential for more work there.
 
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mapper

Explorer
Howdy Strover. Your van continues to look amazing. You make me want to do a lot of projects on mine (Breadvan) but with over 210k now I just feel like driving it until something is needed. Mine will never be pretty.

Took a couple of good trips recently in her. Got out to Bend, OR for a some Mt. Biking and beer drinking with my GF and 3 large dogs between us. Camped in the van the Astro took it in stride. Then just last weekend, GF and a friend of ours took 4 dogs total up to the Pioneer Mts in ID. Camped on a 4x4 Jeep road, amazing site, up Wildhorse Canyon. Set up tents for a 3 night base camp there, used the van to run out to nice alpine hikes every day. Saw a Grizzly with a cub one day.

On the last day we took the van all the way to the end of the road where we had only seen ATVs, OHVs and a couple 4x4 trucks go up. The trucks were stock so I figured the Astro could do it. Made it up no problem, was a bumpy ride but the van didn't break a sweat. We hiked a bit then headed down. On the way down I caught up to a fully built Sportsmobile and Vanagon Syncro...thought it kind of funny they were taking things slower than I was in the Astro..figured I probably had a cushier ride :sombrero: Anyway, the Stro was representing!!! And it was kind of funny rolling past a couple of ATVs headed up canyon in a pack of 3 vans!!

Glad all is well. I'm getting a bit worried about my trans as I get a pinging sound from underneath everytime I come to stop. Hoped it was a heat shield but it is clearly related the van going into Neutral. Still drives great though. Gotta love the underdog! :smiley_drive:

IMG_20130726_064307[1].jpg
Looking up Wildhorse Canyon early morning.
 
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Stroverlander

Adventurer
Thanks intothewild! Yeah, not gonna happen. :REExeSquatsHL1: On road mannners outweigh the limited time in any other enviro at this stage. :bike_rider:
 

Stroverlander

Adventurer
Howdy Strover. Your van continues to look amazing. You make me want to do a lot of projects on mine (Breadvan) but with over 210k now I just feel like driving it until something is needed. Mine will never be pretty.

Took a couple of good trips recently in her. Got out to Bend, OR for a some Mt. Biking and beer drinking with my GF and 3 large dogs between us. Camped in the van the Astro took it in stride. Then just last weekend, GF and a friend of ours took 4 dogs total up to the Pioneer Mts in ID. Camped on a 4x4 Jeep road, amazing site, up Wildhorse Canyon. Set up tents for a 3 night base camp there, used the van to run out to nice alpine hikes every day. Saw a Grizzly with a cub one day.

On the last day we took the van all the way to the end of the road where we had only seen ATVs, OHVs and a couple 4x4 trucks go up. The trucks were stock so I figured the Astro could do it. Made it up no problem, was a bumpy ride but the van didn't break a sweat. We hiked a bit then headed down. On the way down I caught up to a fully built Sportsmobile and Vanagon Syncro...thought it kind of funny they were taking things slower than I was in the Astro..figured I probably had a cushier ride :sombrero: Anyway, the Stro was representing!!! And it was kind of funny rolling past a couple of ATVs headed up canyon in a pack of 3 vans!!

Glad all is well. I'm getting a bit worried about my trans as I get a pinging sound from underneath everytime I come to stop. Hoped it was a heat shield but it is clearly related the van going into Neutral. Still drives great though. Gotta love the underdog! :smiley_drive:

View attachment 176151
Looking up Wildhorse Canyon early morning.

Just trying to stay ahead of maintenance issues and make improvements along the way on the old workhorse! :Mechanic:

Seems like while I'm tinkering, I can always find the next idea or project.

Your adventure sounds like a good time and nice to see an Astro represent! Pretty nice view you had there...
 
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T.Low

Expedition Leader
You are a major asset to the AstroSafari community. Thanks a ton for all your work and detailed documentation. Right on!
 

T.Low

Expedition Leader
Thanks. I can still hop up into the pop top. And I still have enough dexterity to light the camp stove so I'll be good to go for a long while yet. Keep on truckin.
 
Read all of this thread straight through and want to thank you for starting it. I'm in the process of looking for a new expo vehicle and was leaning heavily towards a SUV but dang if this isn't looking incredibly practical. Back to the drawing board! :)
 

Stroverlander

Adventurer
Hey, you're welcome, nice to see interest and some benefit still being generated. I almost gave up when I couldn't find my own thread! :sombrero:

Hasn't been too much to report lately, project time has been moving along at a slow pace and feeling kind of like Han Solo frozen in carbonite! :Wow1: It hasn't been total colony collapse disorder though, I do have a few minor things I've done.


I performed some refinishing work on the mirrors and wiper arms as they had been looking a bit tattered, and as any refinishing work I've performed it the past, it all seemed to take longer and required more effort than anticipated. :wings: The major issue was with the paint selection - I tried using Rustoleum Trim & Bumper matte black paint only the end result was less than spectacular. It looked okay on the little test spray I did and I probably would have been fine with it, if I didn't have any standards at all! :drool: The finish wasn't matte but more satin-like or even semi-gloss and not close to matching the wheels like what I was after. Also, every single can had spray issues about halfway through which meant not much coverage per can at all.

Barely being able to look at the mess I had created, I let the paint cure for as long as I could stand and then pretty much started over on preparations at the sanding/priming stage. This time around I used the more generic Rustoleum Professional flat black (silver can) which sprayed quite a bit better and actually left the desired matte-like finish. Bingo. Done. Finally.

No boring prep/paint stages, just the finished product:

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I have been holding off installing the new urethane body/subframe mount bushings yet as I want to do a bunch of things at once. At least that's what I keep telling myself!

The stock rubber mounts have seen better days:

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I got frustrated with my sometimes functioning key fob remote and so disassembled to see what was going on. Turns out it was a fairly simple fix.

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The battery terminal/holder had worked loose from the circuit board, more of GM's poor cold soldering no doubt!

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Someone was asking about ground clearance, I don't remember who, or where and I keep forgetting to measure the low points front and rear. So shameless vanity shots instead!

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mhiscox

Expedition Leader
Thanks for taking the time to bump your Astro back into our consciousness. One of the Portal's great builds.
 

Slicky72

Adventurer
Great thread with a ton of useful info. I have scanned through a couple of times and read what you did in search of resolving your driveline vibes . I couldn't find if you were successful.

I was also not sure which lift arrangement you are currently using. 2 inch pucks, stock keys fully crancked, lift springs with lift shackels?
 

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