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Scout012's Avatar
Join Date: Feb 2011
Location: Denver, Co
Posts: 69
Aluminum Front Suspension Cross Bar re-install issue

I am having a difficult struggle with re-installing the Front Alum. Cross bar, the holes on the cross bar don't want to align with the threaded hole mounts on the car.
I recall it being difficult to remove the bar initially, but the holes in the Aluminum bar are about 1/8" - 1/16" WIDER than the threaded holes on the car. The bar is not bent.
The other issue is that on the left front mount there were 2 spacers between the Alum. bar and the mounts, and on the right side there was only 1 spacer. Normal? or did someone F up the re-install at some point?
Something had to have been bent or mis-aligned at some point.
Anyone seen this before? or had this issue?

Pictures show the two spacers, the two that are attached seem to be pressed together pretty snug. even without the spacers the holes don't seem to align.

Once again any help or heckling appreciated!!

Obviously I modified the Tech Drawing for my own purposes. It DOES NOT represent original drawing in any way. Do not use this as a reference for maintenance. Yata, Yata, Yata........................

KEN Euro '80 930

Last edited by Scout012; 04-17-2014 at 10:10 AM.. Reason: clarification
Old 04-17-2014, 09:37 AM
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Registered User
Join Date: Jul 2006
Location: S. Florida
Posts: 7,157
I don't know but that sounds like your car's chassis might be bent and or twisted a little. Hopefully not though.

Others with more experience in that arena will chime in I hope.
Old 04-17-2014, 09:48 AM
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stevie 77 930's Avatar
Join Date: Jan 2008
Location: Chatsworth, CA
Posts: 556
PET calls for only 2 spacers, one on each side.
1974 914
2018 GTS (on order)
2017 BMW 340I M Sport Package
1977 930 (recently sold)
1976 911S , 1973 1/2 911T, 1972 911E (long gone)
Old 04-17-2014, 10:05 AM
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proffighter's Avatar
Join Date: Aug 2007
Location: Switzerland
Posts: 2,179
There should be one spacer on each side, no more or less.

The problem with the measurements difference between bar and chassis are known to me. Had my car on the celette bench, so in specs for sure, but crossmember measurement was 2mm too wide as well.

My solution was: Machined the holes in the bar 1mm bigger but with center 1mm to the middle, then I made some spacers with 1mm bigger seat, so they fit exactly in the bigger holes. Now the two holes are in line

930 Turbo '81 Too many modifications to list
Old 04-17-2014, 02:00 PM
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