Front Coil-Over Shock Mounting

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Major System Category: Brakes & Suspension
Task: Mount front shocks
Parts: Koni Coil Over assembly
Prerequisite Tasks:

• Mount front suspension
• Assemble coil over shocks

Additional Costs: N/A
Time Requirement: 1 hour (provided no modification is required for spacers); Otherwise, 90 minutes.
Date Started: July 21, 2012
Date Completed: July 21, 2012
The shock mounts go on pretty easy. They are packaged together in a zip lock bag under the major part number for the assembly. Everything is off the shelf with the exception of the mount itself. Ensure the 450 lbs spring set is mounted on the front. This is a good time to check that the shocks are set up the same way. This isn't to say that you are done with adjustments, but it is best to start with everything as close to same on both sides as possible.

This is the mount for the front coil over shock. It bolts to the lower control arm.  Orientation is driver's side front suspension looking from the front of the car towards the rear.

 Issue: I ran into two issues related to the spacers.

1. The spacers need to be enlarged so they fit on the bolt. This is easily handled by drilling out the center with a half inch drill bit.
2. The spacers were too wide to fit on the mount points. This is solved by filing down one spacer for each pair. I used a hand file. You don't need to take too much off. Just enough to fit.

Issue: I ran into problems with the steering rack due to excess powder coating. The same thing happened with the shock mount point on the chassis. This was handled with a Dremel tool.

This is the coil over shock installed. It is my understanding that we currently install the shocks right side up . This is a departure from the manual.

I used a small floor jack to lift the suspension so it was roughly parallel to the ground. Based on this height and the same number of turns on the shock collar, I mounted the front coil overs. I will worry about alignment and that sort of thing when I have an engine (some 13 to 14 months off).

Coil-Over Shock Assembly

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Major System Category: Brakes & Suspension
Task: Install sleeve, spring and cup hat on each shock.
Parts:

1. Shock absorbers (4)
2. 750 lbs spring (2) 
3. 450 lbs spring (2)
4. Shock Collar (packaged with each spring) (4)
5. Spring Hat (4)

Prerequisite Tasks: N/A
Additional Costs: N/A
Time Requirement: 30 - 45 minutes
Date Started: July 1, 2012
Date Completed: July 1, 2012


My intention is to upgrade the black Koni shock to Genesis Aluminum shocks. However, I just got done paying for the kit with all the bells and whistles, delivery and tires. I need to give the wallet a breather. So for now I am proceeding with the stock Koni shocks.

The springs and shock collars are wrapped in brown paper and wrapped in plastic under the paper. The springs are marked either 450 (front) or 750 (rear).

The shocks are packaged in cardboard sleeves.

This is the C clip at the top of the shock hat. Make sure it reseats properly.

The spring hats were wrapped in tissue paper.

This is a fairly easy task. The hardest thing was keeping the C clip on the snap ring pliers. Basically, you do the following:

1. Push the shock collar over the top of the shock. This is a little tight due to the orange rubber stopper at the top. The collar will come to rest against the O rings on the shock body.
2. Load the sprint on top of the collar. Loosen the ring on the bottom of the collar so there is slack to work on the top of the shock.
3. Secure the top of the shock, loosen the jam nut (22mm) and unscrew the top ring on the shock.
4. Use a snap ring pliers to remove the C clip from the top of the spring hat. (I got better at this by the time I was done).
5. Place the spring hat om the shock and screw the top ring back on. Tighten the bolt.
6. Replace the C clip.
7. Tighten the ring at the bottom.

When you get tot he point of putting these on the car, you will want to make sure both sides are set up the same. My biggest problem here was not understanding how to take off the top of the shock. Once I figured out there was a jam nut that needed to be turned everything else was simple.