Koni Sport Rear Shock Install - Question

[rodoredas]

hi guys

thought i would install my new rear Koni shocks tonight, had done some reading in the project book and other stuff and it all seemed very simple -
1. install them
2. tighten the top nut
3. bolt onto trailing arm

well, is it?, I am missing something. None of the books or information on the net talks about installing the large rubber bushing/spring on the main shaft. It's clear from the pictures below the main shaft has to be pulled out further to push on the large rubber mount/spring bushing. There is clearly not enough of the stem protruding to attach the smaller rubber bushes and nut.



I've pushed the large rubber bushing onto the stem, attached a nut, mounted in vice and now trying to push this down the shaft far enough so the top fits on properly. The internal diameter of the hole in the bushing is too small and stepped, 2 different diameters, you can see that in the pix below?

what is the go here, do I use some rubber grease on the shaft and force this on, is that OK?



cheers

[bkreigsr]

You should do a test fit with the suspension loaded. The rubbers are only there to prevent damage to the shock body should you bottom the suspension. Use an elastic band or zip tie to mark how much of the shaft is exposed when the shock is compressed.

You could cut out as many of the biscuits as necessary to get the fit you need. Or just use the three biscuit combo and toss the solid portion.

Its okay to force the bumpers over the larger diameter - don't use any lube.
Bill K

[GaryR]

Originally Posted by bkreigsr

Its okay to force the bumpers over the larger diameter - don't use any lube.
Bill K

I've heard that before...

[CBRacerX]

This rubber bushing is the bump stop. It goes INSIDE the metal cap otherwise known as the dust shield (you didn't show that in your pics but you should have one). Use some silicon spray to get the end of the stop over the shock piston - it will find the correct resting spot once on the car. You will have no problems installing once you locate it there. If your car isn't lowered the entire rubber stop will be fine.

[Driven97]

Is the body of the Koni longer than the body of the shock it's replacing? Line it up, you shouldn't have to trim the bump stop unless the Koni is longer than the old shock.

Pretty sure Konis are gas charged and that shaft should be fully extended with no load on it. Do you have to pull the shaft to extend it?

Finally, make sure you put one of those heavy washers before the first small donut. It should sit on the step in the shock shaft, it's what prevents the shaft from sliding up. Then one more on top of the second donut as in your photo that prevents it from sliding down. The body of the car is the meat in that sandwich.

[rodoredas]

Thanks guys, In the end I used a small quantity of rubber grease on the shaft to get the bushing on, just a tiny bit and it was far easier, also taken your advice on the washers above and below the rubber donut at the top. Install was breeze once all seated properly.

cheers
Shane

[kodioneill]

Am I missing something? Those look like front inserts to me!

[bkreigsr]

Originally Posted by kodioneill

Am I missing something?

yes, the tab at the top of the rod.