Suspension….again

Failing this years MOT on a leaky strut gave me a new dilemma. Since last refreshing in 2009, I have been running with OEM suspension and slightly lowered, uprated springs (Eibach Pro). To replace just the one leaking shock absorber would be the cheapest and quickest option to get me back on the road, but if you know me, you know it won’t go that way!

Looking back at the 2009 replacement, I did not replace absolutely everything and it is quite apparent that the top cups and likely top mounts will also need replacing as well as drop links. If one side is going, then the others probably aren’t far behind.

So the options I boiled down to were:

  • Tein Flex Z Coilovers
  • Bilstein B6 reusing my Eibach springs

Teins would be both cheaper and easier to install, but I’ve never been attracted to coilovers – I don’t think I would use the adjustability after setup and would have to have them setup properly.

Bilsteins would give me a sportier feel without being overly harsh and still allow me to use OEM parts. They also have nothing but positive reviews.

So Bilsteins it is, courtesy of MR2-Ben who sells a complete set that worked out better priced than buying parts individually.

Can see the top cup is tired
Impact driver helped
Will be inserting this bolt the other way round when reinstalling
Bolts removed
Separated from steering knuckle
Droplink threads were shot
Suspension removed

The drivers side was a challenge to remove, but the passengers side was a nightmare, so this gave me an excuse to finally get some breaker bars!

New tools!
Spring compressors
Top cup removed
Spring removed
Disassembled
Top cup
Underside of the top cup to be replaced with new
Top mount looked fine from the other side but is totally done

Having disassembled both sides, I’m glad I didn’t go for just replacing the leaking shock.

Old vs new
Will need to cut a slot for the brake line
New parts!

The springs weren’t looking their freshest, but they are still solid so I will sand them back and looked into options for recoating them. The ideal option would be powder coating, but I want to try a diy option first so I’m trying underbody seal on the basis that it is flexible.

The next pain point was unexpected. The top bolt securing the topmount to the shock had gone from 19mm on the OEM, to 22mm on the Bilsteins, which meant there wasn’t enough room for any of my 22mm sockets! Nothing I had or could find would fit in the space

No clearance, Clarence
22mm socket sitting on top
My existing 22mm socket (top) on top of a “thin walled” 22mm socket (bottom)
22mm Hex head tube spanner almost fits
Ground down the hex edges and it fits!!
It fits!!

I still won’t be able to use a torque wrench but at least I can get everything back together.

Fronts are done, rears to go!