SWAY BAR AND SPRING INSTALLATION
Tools/Parts Required:
- 13mm & 15mm flat wrenches (although a full set is preferable)
- 13mm & 15mm sockets (although a full set is preferable)
- 21mm socket (if working on a 97)
- Torx bits
- Spark plug socket
- Spring compressors
- Rubber mallet (or a hammer with a pad of some kind)
- Hammer
- Pickle Fork (optional)
- Bearing grease (to lube bushings)
- Waterproof grease (for the shock nuts in the strut tower)
- Coarse sand paper (for sanding new bushings, if needed)
Front:
- Remove the wheels, then the original sway bar.
You may have to remove the sway bar even if you aren't changing
the bars just to get it out of the way. You will at least need
to unbolt the end links. On the driver's side, the front sway bar
bushing doesn't connect with 2 bolts as shown in the manual -
it has 1 bolt and 1 stud. Over the stud is a little bracket
which attaches to inside the wheel well and inside the front
fender behind the wheel well. You have to get it off to unbolt
the stud and remove the sway bar. The 10mm screw inside the wheel
well is easy. The one inside the fender requires fiddling around
blind with a 10mm flat wrench to get it backed out. Once off (it's
not going back on), put a glob of silicone over that bolt
hole to prevent rattles and only bolt the bracket down to the other 2
accessible holes.
- Unbolt the tops of the shock units from under the hood.
On the passenger side, there is enough clearance around the A/C pipes,
but you need to be careful not to damage them. On the driver's side,
you must first remove the master cylinder by unbolting two 15mm nuts
and carefully easing the cylinder out of the way. You don't need to
open the cylinder, so no brake bleeding will be necessary. This side
has the Torx head bolts. You may find it easier to remove the two
small plastic clips that hold the brake-lines apart from each other.
- Unbolt the lower end of the shock units from the lower control arm.
At this point, you have a choice. The manual says to remove the lower arm
from the lower ball joint. But removing the upper arm from the upper
ball joint is easier. To do that, remove the cotter pin and back off
the castle nut several turns. Don't take it off completely or when
you separate the ball joint, the knuckle will fall off and stress the
brake hose before you can catch it. Take your rubber mallet and whack
the end of the ball stud several times until the joint separates and
bottoms against the castle nut again. Then you can unscrew the nut all
the way and separate the upper arm from the knuckle. This sounds more
complex and difficult than it is in practice. Make sure to support
the lower control arm once you remove remove the castle nut on the
upper ball joint (so that it doesn't fall down all the way and stress
the brake line). Using a regular hammer may work better so as to
"shock" the balljoint. Using a pickle fork (< $15 tool) makes this
much easier - you can jack up the lower control arm (so as to raise
the upper control as well) and then jam the pickle-fork between the
ball joint and the steering knuckle. If the ball joint pops, cool.
If not, lower the jack and the spring will push the lower control
arm back, which will pull the upper control arm down, which will
have the effect of popping the ball joint (since the pickle fork
is in the way).
- Remove the shock unit and upper control arm.
You don't actually need to remove the upper control arm, but it should
come out anyway to make reassembly easier. The unit should slide right
out with a bit of coaxing as it weighs 15 - 20 pounds. You should
now be holding a unit of the shock body, two spring perches, and the
spring. Whether you are changing the shock or spring, or both, you
need to get them apart.
- Decompress the spring
The spring is under a lot of compression and
unbolting the top without first installing spring compressors will
cause injury to yourself! Attach the compressors and
crank them down until the spring is loose. You are now almost ready to
unbolt the top retaining nut. Before you do, though, take note of
the orientation of the upper shock mount to the lower shock mount.
You'll need to have things lined up when you bolt it back together.
There is a little rubber piece on the top mount which aligns nicely
with the front lower mount hole. Unbolt the top and slide everything
off. Now you have the spring compressed with the shock dust cover
rattling inside it because it can't fit past the jaws of the
compressors. So uncompress the spring and remove the compressors and
the dust cover. When selecting which coils on the spring to locate
the spring compressor on, make sure you leave some room for the
spring compressor to expand as the spring decompresses (as the spring
will elongate). Make sure to leave at least 2 inches of threads
between the end of the threaded shaft of the spring compressor its
finger/jaw.
- Reassembly
Assemble the new pieces in the reverse of order. Be careful when you
attach the compressors to the new spring that they are located so
you can fit the spring over the shock and get everything bolted back in
place (including the dust cover). Be sure to line up the upper and
lower shock mounts. Compress the spring, then bolt the unit back
together. Uncompress the spring, and remove the compressors.
- Reinstallation
You should now have a shock assembly in your hand ready for
re-installation. You should cover the top nut and the threaded
portion of the shock rod with some kind of water proof grease. Water
tends to sit in and rust the nut and shock rod. This will make
future removals easier. At this point, it helps to have an assistant
to help orient the unit as you slide it back up into place. You can
bolt the top mount into place then the lower mount, but it might
be easier to get the bolts in the lower mount first since with
the control arm all the way extended the bolt holes won't all line up
right. Torque them down and install the ball joint stud, castle nut,
and cotter pin. Refit the master cylinder (if on the driver's side).
Repeat the process on the other side.
- Sway bar reinstallation
Bolt on the sway bar and fit the end-links. You might not be able
tighten the end-links completely with the car on stands, so put
the wheels back on and drop the car and then finish tightening the bar
end-links. You may also want to use the jack to jack up one side of
the car to start the nut on one end-link, then jack up the other side
of the car to start the nut on the other end-link.
Rear:
- Rear spring removal
Put the back of the car up on stands and remove the wheels. Unbolt
the end-links and sway bar. If you are not changing the bar, you
may not need to do this. Unbolt the large nut from the lower shock
mount (on a 97 car, the nut will require a 21mm socket). Use a jack to
gently take the axle weight off of the shock and pull the shock free
of the mount. Gently lower the jack and drop the axle until you can
pull the spring out from the seat. Take note of the orientation
of the spring (which directions the ends of the springs are pointing).
If you put the rear springs in at a different angle, you may experience
a clunk when going over bumps. Be careful of the brake hoses.
- Rear spring installation
Put the new spring in the seat and raise the axle up again. Stick the
shock back in the mount and bolt it down. Repeat the process on the
other side. If you are changing the bar, then bolt on the new bar.
Put the wheels back on and drop the car.
Thanks to Kevin Stevens (KeS@crl.com)
for the original instructions, and to Bob Bigwood
(bigwood@stimpy.phs.uiuc.edu)
and Jody Shapiro
(jshapiro@bit-net.com)
for additional tips/tricks.