HOW TO GUIDE: Front & Rear suspension change - Alfa Romeo Forum
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Old 03-03-11
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Thumbs Up HOW TO GUIDE: Front & Rear suspension change

HOW TO: Spider TS front and rear suspension and spring change:

OK folks, as some of you may have gathered over the last week or two I have been changing the suspension front and back on my Spider. There are a whole lot of options out there to consider when changing the suspension, I was working to a limited budget so I went for KYB Excel front struts and KYB Gas-adjust rear struts: both ordered from Camskills.co.uk for the grand total of 220 quid (150 fronts and 70 rears). I found a bargain pair of new Eibach Pro -20mm on Ebay for 80 quid

The suspension on my car (as far as I know) is original and is definitely at least 5yrs/50k miles old (as thats how long I have had the car)! Depending on the age of your car rusted/stubborn bolts are going to be the biggest issue you will face.

Theres nothing too difficult in the whole process, you will need the following:

-Bloody good breaker bar
-Penetrating oil/WD40
-Good socket/ratchet set, from memory 13mm,15mm,17mm,19mm and 22mm are needed
-Ratchet/open ended spanners: 13mm,15mm,17mm,19mm
-Jack
-Axle stands
-Patience

Id advise to you to order new bolts/washers/nuts for the parts you are renewing, but this can cause its own problems, as you will see later.

My car was polybushed at the rear about 3 years ago, this also caused its own problems with my car , which I will also come to later.

So, where do we begin:

- Jack the car and get it on stands, one at each corner of course and make sure its secure. You will need to have your head and body right under the car on various occasions so make sure you are happy that its not going to fall off. I put my wheels under the sills as a last fail-safe to catch the car should it fall.

http://img.photobucket.com/albums/v7...e/DSC02016.jpg

FRONT:

http://img.photobucket.com/albums/v7...e/DSC02020.jpg

Unhook the brake line, ABS sensor and brake pad wire from the suspension strut.
http://img.photobucket.com/albums/v7...e/DSC02022.jpg

http://img.photobucket.com/albums/v7...e/DSC02023.jpg

- There are two bolts on the bottom of the suspension strut that attach the McPherson strut to the hub upright. If your car is anything like mine these will be rusted SOLID. Soak them in penetrating oil/WD40 and leave for a while to make your life easier. The front bolt head should be a 15mm and the nut on the back 17mm. Access on the back is an issue, especially on the lower bolt as it is blocked in by the ABS sensor. If you want to get a socket on there you will need to remove the ABS sensor from the hub, mine look to be welded in with grime, so I passed on that and used a closed head spanner on the back and a socket on the front. It very likely you will need a breaker bar of a decent length to get these loose.

http://img.photobucket.com/albums/v7...e/DSC02024.jpg

http://img.photobucket.com/albums/v7...e/DSC02021.jpg

- Once the bolts are loose take them out (with the assistance of a hammer) and separate the upright from the McPherson strut.

http://img.photobucket.com/albums/v7...e/DSC02027.jpg

- The next job is in the engine bay – the struts are held in place via a top mount to the chassis with 3 smallish bolts per side. **WARNING**. These bolts are not very strong and will break if you are not careful. Of the 6 bolts 3 snapped on mine when trying to get them out. If your car is as old as mine its likely they will be just as brittle. The top mounts for my car were completely knackered so I was going to order new ones anyway – however if you want to keep your top mounts make sure you either dont snap the bolts or are prepared to spend a long time drilling out broken bolts! Once the bolts are out you can withdraw the whole strut/spring as once piece. The spring is held in by a captive nut so dont worry about it flying off somewhere.

Broken nut:
http://img.photobucket.com/albums/v7...e/DSC02031.jpg

Strut removed:
http://img.photobucket.com/albums/v7...e/DSC02033.jpg

McPherson strut and spring:
http://img.photobucket.com/albums/v7...e/DSC02034.jpg

- When you look at the top of the McPherson strut there is a large (22mm) bolt with a hex head shaft inside. If you read the workshop manual it advises you to use a special Alfa tool which allows you to hold the shaft with an allen key (7mm) whilst rotating the bolt off. Sounds easy....... its not! I struggled with this for about 2hrs before giving up. Take my advice find a friendly mechanic with an impact gun – he had both nuts off insde 1min per side. VERY IMPORTANT: If you are doing this yourself you need to compress the springs. Front springs are under a lot of pressure and will do you a lot of damage if they shoot off and hit you.
N.B. The Alfa manual states the hex head on the shaft is 6mm – its very definitely NOT. Its 7mm, you will also find a Torx T40 fits OK.

- You can then take the strut to pieces and recover (if any) the parts you want to re-use. I kept the bump stop and the rubber mount for the spring to sit in at the top (on TS models there is no lower rubber mount). I also kept the locating ring that goes on top of the top mounts. The plastic protection for the outside of the strut is not available from Alfa at the moment – you might be lucky and find some dealer stock, but its not too important anyway, I did without.

Component parts of the front strut:
http://img.photobucket.com/albums/v7...e/DSC02046.jpg

Shiny new top mounts (€80 per side!)
http://img.photobucket.com/albums/v7...e/DSC02043.jpg

Old spring / Eibach -20mm spring:
http://img.photobucket.com/albums/v7...e/DSC02047.jpg

- Re-assembly is very straight forward and should cause no issues. I used shorter springs which meant I hardly had to compress them at all to get them back on – if using OE springs you will need to compress them a lot. Put the big nut on the end and tighten as much as possible!

New strut:
http://img.photobucket.com/albums/v7...e/DSC02048.jpg

- Getting the strut back on the car is a little fiddly, but you can do it yourself. Locate the top mount in the chassis (these are handed LH/RH so make sure you put the right one on the right side) and get the 3 bolts in the top. Like I said, fiddly, but doable if even if working by yourself. Get the top bolts finger tight and then relocate the bottom of the strut in to the upright and put the bolts through to hold it in place.

- You then need to tighten the 3 bolts on the top. Be very careful, I used brand new bolts and they were still as soft as hell. The workshop manual states to tighten 25-32Nm – I accidentally torques the first one to 35Nm and the bugger snapped on me! I had to take the strut back off the car but was able to get the broken bolt out easily.
Tighten the bolts on bottom of the strut. No recommended Nm figures from the manual so I just made sure they were bloody tight.

- Put the brake lines etc back in the holders et voila.
- Front done!

Brand new bolt snapped
http://img.photobucket.com/albums/v7...e/DSC02049.jpg

Strut in:
http://img.photobucket.com/albums/v7...e/DSC02050.jpg
http://img.photobucket.com/albums/v7...e/DSC02052.jpg
http://img.photobucket.com/albums/v7...e/DSC02054.jpg
http://img.photobucket.com/albums/v7...e/DSC02053.jpg


REAR:

http://img.photobucket.com/albums/v7...e/DSC02019.jpg

The rear is more straight forward in many respects, however you will be faced with bigger (and therefore tighter) bolts. A breaker bar on the back will be essential.

- The spring on the rear is held in by a spring pan and the shock is separate.
- I replaced the shock first – not much to tell really; release the bolts top and bottom, old shock out, new shock in and voila. I used a jack on the spring pan arm to slightly compress the suspension and thus take the strain off the shock.

Old/new:
http://img.photobucket.com/albums/v7...e/DSC02037.jpg

New shock installed:
http://img.photobucket.com/albums/v7...e/DSC02038.jpg

- To get the spring out you will need to release the spring pan arm. It is connected inboard to the Aluminium rear subframe and at the other end to the wheel upright (and then the dog bone arm that holds the shock).
- As mentioned earlier my car was Powerflexed a while ago. The workshop manual recommends that you release the inboard bolt in order to drop the spring pan. Once I got the bolt off (which required a LOT of force) the pan arm would not drop out of the subframe due to the slightly over-sized Powerflex bushes. In fact it was stuck solid! This may well NOT be the case on your car. Dont go bashing and forcing things around the subframe as you can quite easily snap it at the mounting point resulting in much $$$ of damage.

- So, I had to release the bolt at the outboard end of the spring pan – the only disadvantage of doing this is that it will also release the dog bone arm and may be harder to put back together again later.

- The bolt that runs all the way through is a big bugger and will be tight! I think the head is either a 19/21mm. You are advised to soak this in penetrating oil for a while first.
Once you have the nut off, bash the bolt out and separate the pan arm from the upright. I needed the assistance of a jack to 'help' it along.

- You then need to rotate the spring arm away from you in order to remove the spring. Dont worry the spring is not under tension like on the front.

- To get the spring out there is a small round plastic clip on the bottom of the spring that is connected to the pan arm. Lever this off and then you should be able to push the pan arm completely out of the way, toward the centre of the car.

- The spring is only loosely held to the turret via a rubber boot. I could remove mine by hand, others have needed a hammer to work them loose.

- I re-used the rubber seats as they were in pretty good condition. Now is the time to replace the bumpstops if you need to (I didnt).

- Seat the new springs in the rubber boot and reattach to the car in the reverse manner – it really is that easy.

- You will need the assistance of several jacks to line all the components up so that you can get the bolt back through. Take your time and its quite easy. I used my powerful torch and a 'snake' to make sure everything lined up by eye before trying to get the bolt through.

- Fasten everything to recommended torque setting and you are good to go!

I wanted to use new bolts/washers/nuts on the rear. I looked at Eper and found the diagram to be very confusing, so be careful with what you are ordering. I ordered new bolts for both the inside and outside of the spring pan arm. The inners were OK but the bolts for the outboard side did not match what came off my car and would NOT fit. They are the correct parts according to Eper but are longer and also slightly thicker then the bolts that come off. I had to re-use the originals and now have €40 of useless bolts in the garage!

When the spring pan arms are 'down' you can take the opportunity to tidy them up with a stiff brush and hammer. It was quite amazing how much dead metal (not structural) I got off the rear arms in the renewal process. If you scrape deep enough you will uncover small drain holes in the bottom of the arms, unblock them to allow future drainage.

Use a jack to separate the pan arm from the upright, once the bolt is removed:
http://img.photobucket.com/albums/v7...e/DSC02039.jpg

The pan arm will probably look like this – give it a tidy!
http://img.photobucket.com/albums/v7...e/DSC02040.jpg

Old/new spring:
http://img.photobucket.com/albums/v7...e/DSC02042.jpg

New spring in:
http://img.photobucket.com/albums/v7...e/DSC02045.jpg

And thats pretty much it.

If you want to order new bolts etc you can use the online version of Eper, just inout your chassis number at the start to make sure you get the right bits for your car.

FIAT ePER

Theres nothing too difficult in the process, working by myself I think it was about 10 man hours, but I took things slowly and learnt on the way. Make sure you re-tighten bolts to the correct torque settings and I adivse to mark the bolts/nuts with nail polish or similar so that you can check they arent slipping a while later.

You should get a 4-wheel alignment done if fitting lowering springs as it alters the geometry of the suspension.

I hope this helps at least someone!

Alex (Euroboy)




-1998 916 Spider 2.0TS Lusso-
Polybushed -- New roof
Ragazzon Alfisti.net edition centre exhaust --
6000k HIDS -- FK -30mm springs & KYB shocks -- 18" Azev TypA wheels.
Almost everything on the car replaced, say hello to Trigger's Broom!
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Old 03-03-11
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Nice.

Edit: how come you Eibach springs are black, when mine are red?
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Old 03-03-11
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No idea!
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Old 03-03-11
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Almost certainly different paint
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are you ever gona drive this thing ????
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Old 03-03-11
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Been driving it all day!

Its the amount of miles I put on it that is the reason a lot of things are so old and tired.

Its not on its original clocks or ECU anymore so the exact mileage is somewhat vague, but its probably over 130k now, so its no garage queen!
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Old 03-03-11
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Originally Posted by euroboy View Post
Been driving it all day!

Its the amount of miles I put on it that is the reason a lot of things are so old and tired.

Its not on its original clocks or ECU anymore so the exact mileage is somewhat vague, but its probably over 130k now, so its no garage queen!
how do the KYB's feel with your eibachs, is there sufficient damping?
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Old 03-03-11
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Beat me to it euroboy! I've almost finished my guide to rear, although I did a bit more renewal than you (and I think I had an easier time reassembling) Perhpas when I put mine up on forum some kind mod could edit and join them?
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Old 03-03-11
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Very informative - I'm preparing to install a new subframe and poly-bush the whole of the rear suspension, can confirm the new bushes are an easy fit on the inner lugs, I tried them tonight. Once done I'm renewing the front so this will be useful.

Thanks for posting.
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Old 03-03-11
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Originally Posted by msgtv View Post
how do the KYB's feel with your eibachs, is there sufficient damping?
So far so good.

My old suspension was so knackered that anything will feel better, so im going to give it a couple of weeks before I make my mind up - but like I say the first drive today felt great.
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Ive also managed to cure the annoying squeak from the rear right suspension and the cyclic vibration from the front right.

So apart from anything else it was worth it for these two issues, in particular the front vibration as that was getting steadily worse.
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Brilliant.. I'd get some waxoyl on those spring pan arms though..

Last edited by seadart; 04-03-11 at 06:25.
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Old 04-03-11
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Nice post
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Originally Posted by seadart View Post
Brilliant.. I'd get some waxoyl on those spring pan arms though..
Yeh, I was tempted whilst I was in there, a job for next time I think!
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Old 04-03-11
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did the same job on my v6 a week ago....fecking gazella racing + eibach...20mm drop my ***! mine has dropped over 30mm on the back and i get BAD tyre scrub..so I am out there this morning to put the originals back on the back end...the front looks fine.
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Originally Posted by msgtv View Post
Almost certainly different paint
hee hee ..yes.. it is almost certainly down to the fact that the black spring was painted using a tin of black paint and the red spring was painted using a tin of red paint..

I find this site so useful...

(well you have to have a sense of humor to run one of these things in the first place)
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I would add that while you are there, free up both the track rod adjusters and the rear tie rods, the rear rods are virtually impossible to free up in-situ and when you take it for alignment they will either not be able to do it, or charge you for the time to free them up. I took the rear rods off (not too bad a job, much easier if you have ratchet open wrench for the inner bolt!) stuck them in a vice and freed them using a blow torch and harsh language!

Reassemble with a load of copper grease.
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Just back from getting it aligned - its like a new car! Some of the values were comically out, although some of that will be because of the lowering to be fair. Ill scan and post the results sheet later.

He did have a bit of a struggle with the rear but he managed in the end - took him about 90mins all in, whereas usually I think it takes about 45-50mins

Still charged me the same though, €55.

Here is how she looks now:

http://img.photobucket.com/albums/v7...d/DSC02080.jpg

http://img.photobucket.com/albums/v7...d/DSC02075.jpg

http://img.photobucket.com/albums/v7...d/DSC02070.jpg

http://img.photobucket.com/albums/v7...d/DSC02074.jpg

I also chopped me knob! Much nicer with the shorter shaft

http://img.photobucket.com/albums/v7...d/DSC02082.jpg
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Originally Posted by euroboy View Post
Just back from getting it aligned - its like a new car! Some of the values were comically out, although some of that will be because of the lowering to be fair. Ill scan and post the results sheet later.

He did have a bit of a struggle with the rear but he managed in the end - took him about 90mins all in, whereas usually I think it takes about 45-50mins

Still charged me the same though, €55.

Here is how she looks now:

http://img.photobucket.com/albums/v7...d/DSC02080.jpg

http://img.photobucket.com/albums/v7...d/DSC02075.jpg

http://img.photobucket.com/albums/v7...d/DSC02070.jpg

http://img.photobucket.com/albums/v7...d/DSC02074.jpg

I also chopped me knob! Much nicer with the shorter shaft

http://img.photobucket.com/albums/v7...d/DSC02082.jpg
The ride height looks spot on!
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Originally Posted by euroboy View Post
Just back from getting it aligned - its like a new car! Some of the values were comically out, although some of that will be because of the lowering to be fair. Ill scan and post the results sheet later.

He did have a bit of a struggle with the rear but he managed in the end - took him about 90mins all in, whereas usually I think it takes about 45-50mins

Still charged me the same though, €55.

Here is how she looks now:

http://img.photobucket.com/albums/v7...d/DSC02080.jpg

http://img.photobucket.com/albums/v7...d/DSC02075.jpg

http://img.photobucket.com/albums/v7...d/DSC02070.jpg

http://img.photobucket.com/albums/v7...d/DSC02074.jpg

I also chopped me knob! Much nicer with the shorter shaft

http://img.photobucket.com/albums/v7...d/DSC02082.jpg
Looks great..
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Old 04-03-11
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Looks great
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Nice work - mebee report thread to the mods for adding to the sticky one at the top?
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Old 04-03-11
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If one of them sees this they are welcome to link it to the index at the top of the page, although id like this thread to be left open and running
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You keep it running, it's only a 'reference' in the sticky
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Old 04-03-11
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Heres the alignment sheet:

http://img.photobucket.com/albums/v7.../alignment.jpg

Im struggling a bit with some of the translations myself, but as far as I can tell:

Belangrijkste hoeken : main angles
Voorzijde : front
Achter : rear
Naloop : trail ??
Wielvlucht : camber
Toespoor : toe
Stuwhoek : thrust angle ??

Secundaire hoeken : secondary angles

Im pretty sure 'eerste' means how it started, the two figures in the middle are where it should be between and 'laatste' is what its at now. I noticed one or two figures are still outside tolerances even now, but imagine thats the impact of lowering it 20mm.

The camber and toe on the front wheels were way, way off!
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