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The Ultimate Focus Resource

Performance >> Suspension

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sts-zx3
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Reged: 12/31/02
Posts: 267
Loc: Webster, NY
Special tools needed for H&R coilover install?
      #68312 - 03/12/03 03:08 AM (66.66.74.190)

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
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Re: Special tools needed for H&R coilover install? [Re: sts-zx3]
      #68313 - 03/14/03 02:13 AM (66.66.74.190)

back to page 1

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dan-d
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Re: Special tools needed for H&R coilover install? [Re: sts-zx3]
      #68314 - 03/14/03 02:58 AM (24.27.236.17)

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
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Reged: 02/21/01
Posts: 4696
Loc: Wiesbaden GE/Dixon KY
Re: Special tools needed for H&R coilover install? [Re: dan-d]
      #68315 - 03/14/03 05:38 AM (217.234.145.197)

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.

--------------------
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sts-zx3
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Reged: 12/31/02
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Re: Special tools needed for H&R coilover install? [Re: jinstall]
      #68316 - 03/14/03 05:55 AM (66.66.74.190)

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
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Re: Special tools needed for H&R coilover install? [Re: sts-zx3]
      #68317 - 03/14/03 07:17 AM (24.27.236.17)

OK [Smile]

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
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Reged: 12/31/02
Posts: 267
Loc: Webster, NY
Re: Special tools needed for H&R coilover install? [Re: dan-d]
      #68318 - 03/14/03 05:06 PM (66.66.74.190)

Awesome - thanks Dan - you da man!

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sts-zx3
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Reged: 12/31/02
Posts: 267
Loc: Webster, NY
Re: Special tools needed for H&R coilover install? [Re: sts-zx3]
      #68319 - 03/23/03 06:12 PM (66.66.74.190)

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
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Reged: 12/31/02
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Re: Special tools needed for H&R coilover install? [Re: sts-zx3]
      #68320 - 03/23/03 06:50 PM (66.66.74.190)

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
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Reged: 01/14/03
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Loc: Seattle, WA
Re: Special tools needed for H&R coilover install? [Re: sts-zx3]
      #68321 - 03/23/03 11:18 PM (12.228.187.159)

Thanks sts-zx3 and dan-d. [Thumb Up] Hopefully I'll be able to use this in a couple of weeks.

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jinstall
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Reged: 02/21/01
Posts: 4696
Loc: Wiesbaden GE/Dixon KY
Re: Special tools needed for H&R coilover install? [Re: proxemac]
      #68322 - 03/24/03 10:13 AM (217.234.151.112)

Dan-d the bumpstops will not fit the H&R coilovers, the piston is too large. FYI [Thumb Up]

--------------------
Focal Jet European Photographer NOW DIGITAL/Yes it is US Specs
http://www.imagestation.com/album/?id=4291080125


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sts-zx3
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Reged: 12/31/02
Posts: 267
Loc: Webster, NY
Re: Special tools needed for H&R coilover install? [Re: jinstall]
      #68323 - 03/24/03 04:17 PM (66.66.74.190)

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
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Reged: 12/31/02
Posts: 267
Loc: Webster, NY
Re: Special tools needed for H&R coilover install? [Re: sts-zx3]
      #68324 - 03/24/03 04:56 PM (66.66.74.190)

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
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Re: Special tools needed for H&R coilover install? [Re: sts-zx3]
      #68325 - 03/24/03 05:14 PM (66.66.74.190)

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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