Rear Coil-Over Shock and mount

<< Mount Rear Suspension                         Fuel Tank Finish Panels >>

Major System Category: Brakes & Suspension
Task: Install rear shock mounts and coil overs
Parts:

• shock mounts
• shocks
• cutting tools
• grinders
• a really big hammer

Prerequisite Tasks:
Additional Costs: N/A
Time Requirement: 3 hours
Date Started: July 25, 2012
Date Completed: July 25, 2012
Factory Five seems to have a penchant for understatement. The manual states that you have to remove some material from the lower control arm. There are a few other items they fail to mention. The rear shock mounts are sprung really tight so just getting them on and off the lower control arms might require either a big hammer (strongly recommended) or Godzilla or both.

I used a Dremel tool to open up the inside of the washer. Orientation: Driver's side  rear suspension.

I used both a Dremel tool with the sanding stone, and a die grinder with a cutting wheel. I used the Dremel to open up the holes where the bolts slide through. Basically, my bolts stopped right away due to the powder coating. I also suggest reaming out the washer as well. You are going to want a tad bit more play in order to get the 24 mm black bolt through the control arm and bolt sides of the mounting bracket. Finally, I used the Dremel to remove material around where the washer sits. This will make easier to get the bracket on and off. Count on doing this at least twice.

This is the lip that needs to be trimmed back on the lower control arm.. If you look at it straight on, the lip extends 1/4 inch  out from the control arm. Orientation: Passenger side rear suspension.

Use the die grinder to trim off the lip on the lower control arm. I cut straight through, then buffed it a bit to get rid of any sharp edges. There is no easy way to do this. I tried to be nice and used a rubber mallet. It was a waste of time. The 10 lbs sledge proved decisive. You have to bang the bracket in two places to move the bracket so it aligns with the holes. Once the smaller hole on the end of the bracket was close, I slid a screw driver through the bracket and control arm to guide it into place. 

I also removed material around the seat for the washer. This just makes it easier  (a relative term) to slide/pound the bracket into place. This was not a great deal of material (perhaps a 1/16 inch or so). Orientation: Passenger side rear suspension.

Consideration: I disconnected the tie rod on one side so I could turn the rotor to the side for shock bracket. This gave me the extra room I needed.

Task complete. rear shocks mounted. She is ready for the rear tires. Orientation: driver's side rear suspension.

The spacers had the same issues as front mounts. I drilled out the spacers with a half inch drill bit, and filed down two of the rear spacers to reduce the width. I did not have any width issues with the top spacers.