Tonight's vexation: Top mounts on the Koni's; SOLVED

[njoconnor]

After getting the c-arms and springs on, I figured I'd just forge ahead with the shocks. Well, the Irish car gods decided to have a vote on that idea, so I'm briefly (I hope) stuck.

With the new Koni's came a nice little bag of hardware. Reading the mildly inscrutable paper direction enclosed, it looks to me like the hardware is supposed to bolt up like so (new bottom bolt used for illustration only):



From left to right: 2 nuts, 1 large flat washer, 1 rubber washer inserted over steel sleeve, 2nd rubber washer (also inserted over sleeve), large flat washer, then shock body. Good so far.



First flat washer and lower rubber washer went on the shock shaft no problem. Steel sleeve went as far as the bottom of the threads....and stopped.

Top view of sleeve on threads:



The old shocks had a similar steel sleeve, a tad shorter and narrower. I suspect installing without the sleeves would be a Bad Idea (tm), since the shock could eventually slop around the top fender hole causing damage. Do I need to find different sleeves at a local Koni purveyor, or are there other suggestions?

Thanks, as always.

Neil

(And, no, I just can't wait to balance all this underneath the intake manifold.... )

[81SPIDERMATT]

is it just the yellow paint holding it up ? .... if you give a little tap does if feel solid or does it push off some yellow ?

and are the washers flat ... if not I think you want to "cup" the rubber parts

[DieselSpider]

Did you try calling Koni North America on the phone at 1 859 586 4100 or leave a customer inquiry via email?

Koni North America:
http://www.koni-na.com/

Koni North America Customer Service:
http://www.koni-na.com/contact.cfm

I am a bit surprised that the Koni especially considering the high cost have an open vent with no filter or shield to prevent grit or water from entering the tube.

Can't really see well enough from the pics however as already mentioned it could just be the paint preventing things from sliding down to where they need to be.

[garion]

I'm pretty sure when I installed mine, the sleeve went right on.

[vandor]

> I am a bit surprised that the Koni especially considering the high cost have an open vent with no filter or shield to prevent grit or water from entering the tube.

That is the upper shaft cover, not the body of the shock. The holes are there so a spacer can be pushed out. The spacer prevents to shock to be completely compressing. By removing the spacer one can compress it fully where it can be adjusted by rotating the upper part vs the lower part.

Either way, the top of the shock is inside the shock tower, a ~3" near vertical tube over the spring. One would have to drive into a lake to get water to go in there.

[njoconnor]

is it just the yellow paint holding it up ? .... if you give a little tap does if feel solid or does it push off some yellow ?

and are the washers flat ... if not I think you want to "cup" the rubber parts

It's more than paint, Matt. I squirted some WD40 and twisted by hand, and got no movement at all.

I'll give Koni a call, Diesel; thanks for the links!

Csaba, I easily got the spacer removal/reinstall done on the rears, but the fronts don't seem to extend that far. I fully compressed them, and e=was able to feel the adjuster move; turned it full counterclockwise for full soft (did the same on all four corners).

I figure I have mispacked (by the factory) hardware bags. I'll call Koni and see what I can work out. Thanks, all!

Neil

Update: went out this AM and put my calipers on the shock. Shaft is about 1/4 - 1/2 mm wider than 10mm, sleeve is about the same amount less than 10mm.

[bluespider262]

Are you sure that sleeve isn't for the other end of the shock?

I'll admit I'm new to Fiats but I've been around Jeep CJs and wranglers for years and years and I've never seen a shock with a stem mount that used a sleeve through the center of the bushings in that manner. Not to say other vehicles don't do that though.

Otherwise, if it does go there, I'd probably just hit it with a rat tail file until it fit, or sand the paint off that stem. It does look really close to fitting.

[njoconnor]

Yup, goes on the top threaded rod. THAT much I can make out from the pictogram paper instructions in the bag. Doesn't come close to fitting in the bottom, which has its own fixed sleeve.

I'm thinking, yeah, sand down the paint and see what happens. Waiting for an email from Koni before doing that. Plenty of other stuff to get lined up/bolted on....

Thanks...

Neil

[njoconnor]

Wow. Just checked my home email...and Koni responded! They tell me that the paint sometimes makes things a bit tight; go ahead and sand down. If that doesn't work, let them know and they'll ship some new sleeves to me.

Can't ask for better than that. So out with the dremel and the drum snaders!

Neil

[DieselSpider]

I'd just use a strip of light emery cloth but I am a bit Old Timey at times. My Dad would bring us rolls of defective emery cloth or the cut offs from those that were off-sized for the machines in the tire plant so we could cut it into 16" long strips to use for shaping/sculpting wooden toys so it is the first thing that comes to mind now even after over 50 years have passed.

[njoconnor]

Emery cloth. Yeah! First used it when my father in law convinced me to replumb our 95+ year old Sheboygan house with copper pipe. He taught me to solder copper pipe, and emery cloth was used to clean up the surfaces, inside and out. I recall being amazed at how well that stuff worked. Also recall that week in the basement as some of the best memories I have of Tom, and how it cemented our friendship. Thanks for the reminder!

Neil

[njoconnor]

Had some time early this morning, so I found my plumbing toolbox, grabbed the emery cloth suggested by Diesel Spider, and headed out to the garage.

Starting point (paint interfering with sleeve):



Potential solution: 120 grit emery cloth strip



A little light sanding:



Very happy with the result!



Thanks, Diesel!!

Did all four shocks, and re-staged the parts. Son-the-youngest is arriving tomorrow to 1) cook a Brazilian beef dish for Father's Day and 2) help me put the rear axle back on the car . Once yard chores are done this AM (rain inbound), I'm plan to wrestle the front shocks into place, and....who knows....might just keep on going with the front brake shields and steering arms!

Thanks, all!

Neil