sts-zx3
TEAM Member
Reged: 12/31/02
Posts: 267 Loc: Webster, NY |
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Since it looks
like the weather may finally give us a break this weekend, I will be
doing some installs of "toys" bought over the winter, possibly
including H&R coilovers if there is time.
I know I will
need a spring compressor for the front, but probably not for the
rear. But my question is that according to the shop manual from Helm
(pg 204-01-24), I will need to detach the lower control arm.
Further, to detach the tie-rod end, they recommend using a special
tie-rod end removal tool (211-001 TOOL-3290-D).
So is it
really necessary to detach the lower control arm? And is this
special tool really needed?
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sts-zx3
TEAM Member
Reged: 12/31/02
Posts: 267 Loc: Webster, NY |
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back to page 1
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dan-d
TEAM Member
Reged: 04/12/01
Posts: 3430 Loc: Space Coast, FL |
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no special
tool required. I've done MANY focus suspensions. I'll email you some
step-by-step instructions. You'll have to adlib a bit if your
installing an adjustable and follow their installation instructions.
And YES, you have to disconnect the lower control arm, it used a
15mm as does the rear shock (I tinik)
-------------------- 02 ZX3 5 Speed, JRSC,
Esslinger gears, FCTB, ProFlow MAF, CoolFlow, Kamikaze Header, FS
Flex pipe, APEXi (quiet) , Z-mount, B&M , Autometer Boost &
A/F Gauge,SunPro Tach / light, Progress springs, Eibach Pro dampers,
17 GK11 wheels, 215/45/17 Kumho, 2002 Euro lights, Smoked corners,
Bullitt Gas Cap, CF Hood, CF Side Mouldings, Razzi Kit, Reverse
Indiglos, FJ Stickers
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jinstall
TEAM Member
Reged: 02/21/01
Posts: 4696 Loc: Wiesbaden GE/Dixon KY |
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No problems
installing my H&R CO. Yeah I released the lower control arm but
not the tie rod end. Got an alignment also. Rear is really easy if
you have the rear carpet removed, if not it is a PIA. The rear
springs I put in by hand after the OEM came out. Pretty easy job.
-------------------- Focal Jet European Photographer NOW
DIGITAL/Yes it is US Specs http://www.imagestation.com/album/?id=4291080125
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sts-zx3
TEAM Member
Reged: 12/31/02
Posts: 267 Loc: Webster, NY |
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Thanks guys -
Dan, rather than emailing me the instructions, why not just post
them here so all can benefit.
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dan-d
TEAM Member
Reged: 04/12/01
Posts: 3430 Loc: Space Coast, FL |
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OK
Focus Spring/Strut Replacement (Also see footnote at the
bottom of page)
Focus Spring Replacement
1. Open the
hood and loosen the nut in the center of the strut tower (strut
shaft). Don’t remove it all the way; just loosen it so that later
removal will be easier after you compress the spring. 2. Loosen
wheel lug nuts and place the front of the car on jack stands and
remove the wheel and tire assembly. 3. Remove the brake line from
the mounting bracket on the strut tower, it just slides out. 4.
Remove the nut holding the sway bar to the strut then remove the
strut end out of the bracket (you’ll need a 15mm wrench and a 5mm
allen to hold the stud from turning). 5. Loosen the three nuts
holding the top of the strut into the strut tower, don’t remove them
completely yet. You just want to have some freedom of movement to
help in getting the bottom of strut out of the control arm
socket. 6. Remove the pinch bolt (completely) securing the bottom
end of the strut into the pocket on the control arm, push down on
the control arm assembly and forward out of the way, this may take
some effort but it’ll come out (I just remove the pinch bolt then
give the hub a downward stomp with my foot, works every time).
7. Remove the three nuts holding the strut assembly to the upper
strut tower, be careful when you remove the last nut or the assembly
may fall to the ground and squish your little toes. 8. Remove
the strut assembly. 9. Install a set of spring compressors to the
old springs and tighten them down just enough to put a little
tension on the springs so that they won’t expand too much during the
removal of the center (shaft) nut and cap assembly. There have been
several reports of the removal being done without the use of spring
compressors, but for safety, I’d recommend using them. (OK, I’m
chicken). 10. Install your new springs onto the strut assembly.
Be sure that the coil ends are securely seated in their pockets
before you install the top spring cap. you may not need a spring
compressor if your installing lowering springs onto the stock
struts, they are short enough that you can get the cap and nut on
without a problem, having someone assist would help. But you may
need them if your assembling an aftermarket lowering spring and
strut kit, because the struts are shorter. Just run the center nut
down enough to hold the assembly together, install the strut
assembly onto the car, you can finish tightening the center nut
after both struts have been re-installed. It’s easier to tighten
them up once you have the weight of the car on them.
Now the
Rear:
1. Loosen the wheel lug nut’s. 2. Jack up the car
and place on jack stands and remove wheels. 3. Remove the nuts
holding both ends of the sway bar and swing it out of the way (push
it down and forward). 4. Place a floor jack under one of the
control arms and raise the arm (compress the spring) 5. Remove
the bolt securing the control arm to the spindle. 6. Slowly lower
the control arm with the floor jack. Once the arm is completely free
you should be able to wiggle the old spring out of it’s seat. 7.
Remove the spring cushion from the top of your old spring and place
it on to the new spring, be sure to use the spring cushion or your
springs will make a hell of a noise. 8. Install the new spring
making sure that you seat the spring ends into the pocket, then
reverse the rest of the steps to complete the job. 9. Remove the
trim from around the bottom of the rear hatch opening as well as
both inner side panels. Once these are removed you will have access
to the top of the rear shocks for removal, remove the nuts holding
the top of the shock in place. 10. Remove the bolt holding the
bottom of the shock to the control arm and remove the shock, reverse
the order to install your new ones.
NOTE: When lowering the
front control arm you may experience a problem with it not swinging
down far enough to release the bottom of the strut. This didn’t
happen on my car but it did on another guy’s car I did this
replacement on.
If you run into this problem, crawl under the
car and look at the inner end of the control arm (between the pivot
points), you will see where it is making contact with the frame
cross member. Get a drill (what I used was a dremmel roto tool) with
a grinding disk and grind away a small amount of material from the
end of the frame where it makes contact with the control arm. I had
to remove about as much material as about the thickness of a credit
card and it only took about 5 minutes per side. It’s amazing at how
such a little amount of material removal equates to so much travel
on the outer end of the control arm.
Another thing you may
want to do. The bump stops for the front struts are located on the
strut shaft under the dust cover. You can shorten them with a razor
blade by cutting off one of the ripples (you’ll see what I
mean).
There are two set’s of bump stops for the rear of the
car, one set is located on the shock shaft dust cover, it actually
snaps into the top of the cover. You can pull it out and cut off one
of the ripples and re-install it before assembling the dust cover to
your shock. The second set of bump stops are located on the control
arm, these too can be trimmed with a razor blade. I cut off about
half an inch from mine.
-------------------- 02 ZX3
5 Speed, JRSC, Esslinger gears, FCTB, ProFlow MAF, CoolFlow,
Kamikaze Header, FS Flex pipe, APEXi (quiet) , Z-mount, B&M ,
Autometer Boost & A/F Gauge,SunPro Tach / light, Progress
springs, Eibach Pro dampers, 17 GK11 wheels, 215/45/17 Kumho, 2002
Euro lights, Smoked corners, Bullitt Gas Cap, CF Hood, CF Side
Mouldings, Razzi Kit, Reverse Indiglos, FJ Stickers
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sts-zx3
TEAM Member
Reged: 12/31/02
Posts: 267 Loc: Webster, NY |
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Awesome -
thanks Dan - you da man!
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sts-zx3
TEAM Member
Reged: 12/31/02
Posts: 267 Loc: Webster, NY |
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I did my
coilover installs this weekend. This was an ambitious project for my
limited wrenching skills. Thanks to Dan-d for the instructions -
they were spot on. Here are some pics I took along the way to go
with his notes. Please point out anything that needs to be changed.
I'm a novice mechanic, so you won't be insulting my
skills.
1. Open the hood and loosen the nut in the center of
the strut tower (strut shaft). Don’t remove it all the way; just
loosen it so that later removal will be easier after you compress
the spring.
2.
Loosen wheel lug nuts and place the front of the car on jack stands
and remove the wheel and tire assembly.
3.
Remove the brake line from the mounting bracket on the strut tower,
it just slides out.
4. Remove the nut holding the sway bar to the strut then
remove the strut end out of the bracket (you’ll need a 15mm wrench
and a 5mm allen to hold the stud from turning).

[
03-24-2003, 06:17 AM: Message edited by: sts-zx3 ]
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sts-zx3
TEAM Member
Reged: 12/31/02
Posts: 267 Loc: Webster, NY |
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5. Loosen the
three nuts holding the top of the strut into the strut tower, don’t
remove them completely yet. You just want to have some freedom of
movement to help in getting the bottom of strut out of the control
arm socket. 6. Remove the pinch bolt (completely) securing the
bottom end of the strut into the pocket on the control arm, push
down on the control arm assembly and forward out of the way, this
may take some effort but it’ll come out (I just remove the pinch
bolt then give the hub a downward stomp with my foot, works every
time).
7.
Remove the three nuts holding the strut assembly to the upper strut
tower, be careful when you remove the last nut or the assembly may
fall to the ground and squish your little toes. 8. Remove the
strut assembly. 9. Install a set of spring compressors to the old
springs and tighten them down just enough to put a little tension on
the springs so that they won’t expand too much during the removal of
the center (shaft) nut and cap assembly. There have been several
reports of the removal being done without the use of spring
compressors, but for safety, I’d recommend using them. (OK, I’m
chicken).
10. Install your new springs onto the strut assembly. Be
sure that the coil ends are securely seated in their pockets before
you install the top spring cap. you may not need a spring
compressor if your installing lowering springs onto the stock
struts, they are short enough that you can get the cap and nut on
without a problem, having someone assist would help. But you may
need them if your assembling an aftermarket lowering spring and
strut kit, because the struts are shorter. Just run the center nut
down enough to hold the assembly together, install the strut
assembly onto the car, you can finish tightening the center nut
after both struts have been re-installed. It’s easier to tighten
them up once you have the weight of the car on them.
A
few of the things that I noticed during the install of the
fronts...
- I couldn't believe how weathered everything looks
after just one winter. - Getting the strut out of the control arm
wasn't too tough, but getting it back in was a pain. I was trying to
use the jack under the wheel hub to lift, but just grabbing the arm
under the strut and lifting upward worked better. - As you can
see in the pics, I installed a camber adjuster at the top if the
coilover. This required using the bottom half of the existing strut
top. At first this threw me, but it just pulls apart by hand. -
When I first installed the fronts, I set the perch about an inch and
a half up from the bottom of the threads. This gave me way too much
drop, almost three inches! So then I was faced with taking the
wheels back off and cranking them up by rotating the spring perch.
This could have been avoided if I set them closer to the top of the
threads. So in other words, the the lower portion of the threaded
part of the strut isn't really usable. - Not required, but using
an impact wrench made things much easier. (Why are factory bolts on
so tight?)
I'll post my pics for the rear tomorrow.
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proxemac
TEAM Member
Reged: 01/14/03
Posts: 299 Loc: Seattle, WA |
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Thanks sts-zx3
and dan-d. Hopefully
I'll be able to use this in a couple of weeks.
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jinstall
TEAM Member
Reged: 02/21/01
Posts: 4696 Loc: Wiesbaden GE/Dixon KY |
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Dan-d the
bumpstops will not fit the H&R coilovers, the piston is too
large. FYI
-------------------- Focal Jet European Photographer NOW
DIGITAL/Yes it is US Specs http://www.imagestation.com/album/?id=4291080125
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sts-zx3
TEAM Member
Reged: 12/31/02
Posts: 267 Loc: Webster, NY |
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I mentioned my
first setting on the front coilovers was a little too low - here's
the pic.
Now on to the rear installs.
1. Loosen the wheel lug
nut’s. 2. Jack up the car and place on jack stands and remove
wheels.
3.
Remove the nuts holding both ends of the sway bar and swing it out
of the way (push it down and forward).
4.
Place a floor jack under one of the control arms and raise the arm
(compress the spring)
5.
Remove the bolt securing the control arm to the spindle. 6.
Slowly lower the control arm with the floor jack. Once the arm is
completely free you should be able to wiggle the old spring out of
it’s seat. 7. Remove the spring cushion from the top of your old
spring and place it on to the new spring, be sure to use the spring
cushion or your springs will make a hell of a noise.
8. Install the new spring making sure that you seat the
spring ends into the pocket, then reverse the rest of the steps to
complete the job.
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sts-zx3
TEAM Member
Reged: 12/31/02
Posts: 267 Loc: Webster, NY |
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Did anyone
notice what I did wrong in the previous picture?
Take a
close look at the adjustable spring perch... It's kinda hard to
tell, but it is just sitting under the spring and on top of the
control arm. It didn't occur to me at first, but as you can see in
the following pic, I believe that it is designed to be split by the
control arm and attached above and below. I could just see braking
into a corner hot at an autox, lifting up the rear inside wheel,
hitting a bump and having the spring perch bounce out. As it is, it
seems like at full droop that the spring could just drop out. Well
not really, but it does just seem to be kinda sitting in
there.
Here's a closer look at the spring perch. Notice the tiny
hex tightening screw. Surprise - it's metric.
Now on to the shock replacement.
9. Remove the trim
from around the bottom of the rear hatch opening as well as both
inner side panels. Once these are removed you will have access to
the top of the rear shocks for removal, remove the nuts holding the
top of the shock in place. 10. Remove the bolt holding the bottom
of the shock to the control arm and remove the shock, reverse the
order to install your new ones.

A couple of things I noticed removing the rear shocks. You
don't really have to remove the upper trim panel just below the rear
side window. The key is the screw up under the seat belt attach and
the plastic plug. I also removed the cover just over the hatch
opening. I did encounter a problem loosening the top shock screw. It
seemed like the shock was turning. Anyway, since I have long arms, I
was able to turn the top nut with one hand while holding the shock
body with the other hand. It may help to have a second person for
this. The final note is that when you remove the bottom bolt, the
shock will be ready to drop down - be prepared.
Here's an
interested bystander who kept coming to the garage door to find out
why I was hanging out in the garage all weekend.
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sts-zx3
TEAM Member
Reged: 12/31/02
Posts: 267 Loc: Webster, NY |
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Just a couple
more details on the rear install.
Here's the the delrin
inserts.
Here's where I modified the top bump stops.


Here's
what happens when trying to release the factory tightened anti-sway
bar bolts using a cheap imported socket.

Here's
the finished job.
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