custom spacer install gone awry $#^!

[BajaXplorer]

Ok so I spent a LONG weekend messing with the front coils on my X. I had some custom 3" aluminum spacers made by a machinist friend please no comments about ( "you should have gotten RB's spacers)

Anyways the way these spacers are made is they require the top mount to be rotated 90*.

Anyways that easier said then done. The top mount DOESNT move without taking the WHOLE coilover apart.

Thats where my problems started. Ive taken a bunch of coils in/out but these ones on my 02 were the most PITA to put back together. I just couldnt get them compressesed enought to get back the top nut etc.

So after I get it back together(after a full wasted day)
I go to put the coilover back in the X.
now the second PITA, it doesnt want to fit.??!#%^&* too f###ing long( it would bolt up top but bottom munt wouldnt fit!!

SO as a last straw I take apart the upper ball joint from the spindle and get it all back together.

I still didnt get my spacers on because the top mount wont just turn (if you have seen a X coilover apart, you know there is a plastic spacer/catch up top to keep the coil from spinning) thats where my problem lies, if I could turn the top mount 90*.

anyone have any reccomendations...??? (besides new spacers from RB..yet)

thanks all

Doug

[Thelt]

Originally Posted by BajaXplorer

Ok so I spent a LONG weekend messing with the front coils on my X. I had some custom 3" aluminum spacers made by a machinist friend please no comments about ( "you should have gotten RB's spacers)

Anyways the way these spacers are made is they require the top mount to be rotated 90*.

Anyways that easier said then done. The top mount DOESNT move without taking the WHOLE coilover apart.

Thats where my problems started. Ive taken a bunch of coils in/out but these ones on my 02 were the most PITA to put back together. I just couldnt get them compressesed enought to get back the top nut etc.

So after I get it back together(after a full wasted day)
I go to put the coilover back in the X.
now the second PITA, it doesnt want to fit.??!#%^&* too f###ing long( it would bolt up top but bottom munt wouldnt fit!!

SO as a last straw I take apart the upper ball joint from the spindle and get it all back together.

I still didnt get my spacers on because the top mount wont just turn (if you have seen a X coilover apart, you know there is a plastic spacer/catch up top to keep the coil from spinning) thats where my problem lies, if I could turn the top mount 90*.

anyone have any reccomendations...??? (besides new spacers from RB..yet)

thanks all

Doug

You are over my head here but can't you just rotate the bottom connector on the strut to compensate for the turn you have to do on the top?

[BajaXplorer]

You are over my head here but can't you just rotate the bottom connector on the strut to compensate for the turn you have to do on the top?

wish it was that easy...tried

[Thelt]

wish I could help. I have RB spacers and had to get them installed

[JCUZ]

There is a rubber/plastic insert in the top metal cup. You need to remove that (I use a large screwdriver) and then turn it 90*; just make sure you turn it the right way, or you're going to have to remove it and turn it a further 180* to get it the right way.

[jutgin]

Originally Posted by BajaXplorer

SO as a last straw I take apart the upper ball joint from the spindle and get it all back together.

anyone have any reccomendations...??? (besides new spacers from RB..yet)

thanks all

Doug

I think jcuz already answered about the rotating the mount.
But taking the ball joint apart should not have been a last straw effort. It should have been one of the first things you took apart. It is a tight squeeze for these 3rd gens, we need to take everything possible apart to make room for spacers.
Throw up some pics if you get them installed later!

[BajaXplorer]

JCUZ, do I still need to completely undo the strut top nut though, that is what im trying to avoid... It appears since the washer above the top bushing has 2 flat edges it will not allow it to rotate..?

just trying to do this the easiest way to save headaches and anothr wasted weekend..

I really am hating the design of the Gen III Explorers.. to car like...

I will not be putting in the spacers until I replace the upper ball joints, so it will probably be after Thanksgiving now..

[JCUZ]

Originally Posted by BajaXplorer

JCUZ, do I still need to completely undo the strut top nut though, that is what im trying to avoid... It appears since the washer above the top bushing has 2 flat edges it will not allow it to rotate..?

just trying to do this the easiest way to save headaches and anothr wasted weekend..

I really am hating the design of the Gen III Explorers.. to car like...

I will not be putting in the spacers until I replace the upper ball joints, so it will probably be after Thanksgiving now..

Yep, you need to undo the top bolt unfortunately.

[ktford]

I hope others can learn from your mistake, kiss.
keep
it
simple
stupid

[BajaXplorer]

actually my spacers are a simple design, I just didnt know that the top mount didnt spin...

Originally Posted by JCUZ

There is a rubber/plastic insert in the top metal cup. You need to remove that (I use a large screwdriver) and then turn it 90*; just make sure you turn it the right way, or you're going to have to remove it and turn it a further 180* to get it the right way.

yeah ive been inspecting the entire front end suspension on my X, cause you proly already read that i have a loud squeek over medium to large bumps.

I took a look the other day at the strut assembly and noticed at the top a rubber cup was folded under the spring and the other half was outside hugging the spring, could this be the squeak problem i got?

[JCUZ]

Originally Posted by chris's2005

yeah ive been inspecting the entire front end suspension on my X, cause you proly already read that i have a loud squeek over medium to large bumps.

I took a look the other day at the strut assembly and noticed at the top a rubber cup was folded under the spring and the other half was outside hugging the spring, could this be the squeak problem i got?

Yes, it may well be. The squeak would be the spring rubbing against the metal cup - metal on metal = squeak.

Originally Posted by JCUZ

Yes, it may well be. The squeak would be the spring rubbing against the metal cup - metal on metal = squeak.

to fix it, would it require me to remove the strut assembly

[helmsa]

Originally Posted by chris's2005

to fix it, would it require me to remove the strut assembly

Completely. Remove the assembly, disassemble (just like replacing spring), realign everything, reassemble, replace.

[Ford02Exp]

chris, i got that same squeak, if you disassemble everything and put it back together, let me know how that turns out.