front suspension re-build

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marky
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front suspension re-build

Post by marky »

On Saturday I decided to check the car over for possible MOT work and found that the nearside front lower suspension bush was split. I thought that I may as well make a start straight away as I had a couple of days off. I have been planning to replace the front springs and dampers at some point anyway and decided to remove the lower arms as well and replace the two bushes and the ball joints and anything else that needs doing at the same time.

Six hours of hard work later over the weekend and I have one side stripped out. Unfortunately I sheared off one the bolts holding the dirt shield on so that will need to be replaced. I initially tried to modify and use a pair of spring compressors but that didn't work and in the end I threw the towel in and reached for the angle grinder!! I don't recommend doing this as it is potentially very dangerous - but it was less dramatic than I expected - I had to cut through twice to get enough slack to get the spring out.

Next I have to get the parts and either buy a press or find someone to replace the bushes and ball joints in the lower arms.

The more immediate problem is that the metal part of the bush is rusted onto the roll bar and I will need to find a way to remove it without damaging the roll bar - any suggestions would be welcome.

Mark.

P.S. I was surprised to find that I had to slacken off the steering rack bolts in order to get the long bolt out from the inboard end of the lower arm.
Last edited by marky on Tue Jan 03, 2017 17:39, edited 1 time in total.

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Re: front suspension re-build

Post by AndyC »

Metal part of what bush is rusted to the ARB?
I cannot think of one that attaches to the ARB that has a metal part.
ARB goes through a bush in the lower link, the bush is just rubber like two rings stuck together, and goes through an ARB mount that is horse-shoe shaped.

Image

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marky
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Re: front suspension re-build

Post by marky »

Thanks Andy - I have had another look and it is just the way the anti-roll bar is finished - I assumed the bush had a metal centre but as you say it is just rubber. I should be able to cut 2 hours off the other side but not messing around trying to compress the spring. I will do what others have done and clamp and bind the new springs to get them on.

Mark.

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Re: front suspension re-build

Post by Jason.goad »

Hello. I'm in the process of stripping and re-painting the front suspension.
You don't need a spring compressor if you remove the anti-roll bar. I removed everything except the stub axle (the bit where the wheel hub mounts on to). That holds the spring in compression between the top and bottom ball joints. Place a jack under the lower ball joint and jack until the full weight of the car is on it, then just ease it back a tiny bit. Undo the top ball joint then lower the jack. This will take the tension out of the spring. It's a bit easier if you remove the lower wishbone bolt (the one through the chassis) before removing the spring (the tension is off at that point). Re-fitting should be the opposite of removal, although I've not re-fitted it yet, so no promises.
I've removed the ball joints in the lower wishbones today and will post some images of required.
http://www.ebay.co.uk/itm/262585372642? ... EBIDX%3AIT
This proved to be a very handy tool.
Not replaced the A.R.B bushes... but good luck with that :roll:

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marky
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Re: front suspension re-build

Post by marky »

Would be very interested in any info of photos relating to the removal or replacement of the ball joints or the bush at the other end - was thinking of replacing the anti-roll bar bush but it is still intact and everything I have read says don't. But I will be upset if it goes in 5 years time.

Can anyone who has replaced the anti-roll bar bush in the lower link please let me know does it go in from the front or the back I understand one side of the rubber has to be re-shaped slightly - any more info on that would be useful.

Jason did you use the kit in the link to replace the inner bush? how did you replace the ball joint? Please feel free add as much to this thread as you wish as you are ahead of me and it will be helpful.

thanks

Mark

P.S. Anti-roll bar front bushes have been done by PO so I was not planning to remove it. Just wondering if it would be easier to jack up the other side at the front carefully - maybe this would release some tension on the anti-roll bar and make things easier? I only have one side jacked up at the moment.
Last edited by marky on Tue Jan 03, 2017 17:42, edited 1 time in total.

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Re: front suspension re-build

Post by Lotus Jim »

Hello Mark, I have just started stripping down the suspension on my Excel and replacing the bushes too. The lower arm anti roll bar bush is tricky to get in. It requires a "conical shaped tube" press tool. Whilst all the other bushes and ball joints can be fitted using fairly normal press tools and a bearing press, I would thoroughly recommend taking your arms to a specialist who has the tool for that bush (Lotusbits has one as they did my antiroll bar bushes). The bush is also shaped with a thick and thin side and from what I have read doesn't need to be reshaped post fitting, however I believe the thick side faces forward (please double check with an adult though as I might be wrong and am going from the parts diagram!).
Jim
1990 Lotus Excel
Previously Owned - 1991 Lotus Excel Celebration in Red
1998 Lotus Elise S1

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marky
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Re: front suspension re-build

Post by marky »

Thanks Jim - I had thought about sending the lower arms to a specialist rather than doing them myself and will make some enquiries to that effect - I only want to do this job once!!

Since Jason mentioned the anti-roll bar I have realised that I made a school boy error by only jacking up one side and could probably get the new springs in a lot easier if I jacked both sides up so the roll bar was level. It would probably mean less compression of the new springs in order to get them in.

Mark.

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Re: front suspension re-build

Post by Jason.goad »

Hello. You're bob on with jacking both sides to remove the anti-roll bar. It just slides out (maybe a bit of tweaking with the jacks).
I'm not replacing the inner wishbone bushes or the A.R.B bushes, as they still look ok. I wouldn't have changed the ball joint to be honest and it was only due to the fact I had to grind the nut off and damaged the thread slightly. They were still stiff to move and the dust covers weren't perished. Top ball joints which have been replaced more recently have perished (what does this say about modern parts?!).
As requested here are some pics of how I removed the lower ball joints:
Image
Above is the kit I bought:
Image
Removing the ball joint inner (it pushes the ball through the bottom):
Image
Now you're left with the casing.
I didn't take a photo to show it, but one of the cups on the tool will fit across the case and you can push that out. It's close to the metal web on the wishbone, but pushes it out ok.
Image
The old methods help as well:
Image
Bits left fit for the scrap bin.

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Re: front suspension re-build

Post by AndyC »

Top ball joint covers do seem to perish quite easily these days, I just bought a dozen or so covers and replace those at the slightest sign of failure.

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Re: front suspension re-build

Post by marky »

Thanks for the excellent photo's Jason - that's a handy tool and I am still undecided how far to go. I do have some perishing on the inner bush but only on the surface of the rubber - the bush itself is basically still solid and in good condition and as stated previously the ARB bush is intact and basically in good condition. Will have to get the other side apart and see what that's like before making a final decision. Assuming the other side is the same then I could get away with doing exactly what you have done and it would probably last for several years. Will give it some more thought.
Probably won't get the other side apart till the weekend.

Mark.

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Re: front suspension re-build

Post by Tanz »

marky wrote:Would be very interested in any info of photos relating to the removal or replacement of the ball joints or the bush at the other end - was thinking of replacing the anti-roll bar bush but it is still intact and everything I have read says don't. But I will be upset if it goes in 5 years time.

Can anyone who has replaced the anti-roll bar bush in the lower link please let me know does it go in from the front or the back I understand one side of the rubber has to be re-shaped slightly - any more info on that would be useful.

Jason did you use the kit in the link to replace the inner bush? how did you replace the ball joint? Please feel free add as much to this thread as you wish as you are ahead of me and it will be helpful.

thanks

Mark

Some info here might help. http://www.lotusexcel.net/phpbb/viewtop ... t=arb+bush Getting the ARB to lower link bushes in is a difficult job. If they look ok I would leave them or get Lotusbits to put them in for you.

P.S. Anti-roll bar front bushes have been done by PO so I was not planning to remove it. Just wondering if it would be easier to jack up the other side at the front carefully - maybe this would release some tension on the anti-roll bar and make things easier? I only have one side jacked up at the moment.
Cheers, Phil
Never take life seriously, nobody gets out alive anyway!

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Re: front suspension re-build

Post by marky »

Thanks Phil - very useful thread. I am wondering about taking the roll bar off rather than messing around with string. Am I right in thinking that the headlamp pods have to be removed in order to get at the front bolts and that two people are needed??

Also It has been mentioned that Protech dampers can't be fitted through the lower arm with the spring already in place due to the adjuster fouling and that they have to be fitted with the spring - did the earlier cars have a different lower arm?? It looks like there's loads of room on mine??

thanks

Mark.

OK - I think I have just worked out what the problem is - it's getting the spring in the right position so that you can get at the adjuster.

The best solution would be an internal spring compressor but they are not cheap and at present I can't find a supplier in the UK! - will keep looking.

I found this - available for about £20 in various places online.
Image
But I would have to get the adjustment correct on the dampers before putting them in. I don't need them to be adjustable as I don't do track days - so just need a good match for the original setting?? any advice on setting them up would be useful.

Mark.

PS I found an old post suggesting 9 clicks at the front and 6 at the rear for Protech's.
Last edited by marky on Sat Sep 02, 2017 00:37, edited 11 times in total.

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Re: front suspension re-build

Post by Jason.goad »

Hello. I took the headlamp pods out to gain access to the anti roll bar brackets, but in all honesty I didn't need to. The nuts are right in the corner of the headlamp well, close to the radiator. You can't get a socket on it from above. The easiest way is using the ring end spanner from below. Taking the pod out does give you
a good idea of what a bizzare place it is though.
You won't need 2 people to remove the anti roll bar.
My car has protech shocks. I managed to remove them without removing the spring, they will fit in ok. One of the adjusters has been damaged with suspension movement, so I need to look at the positioning a bit more closely. Don't be to concerned about spring compressors just make sure the top and bottom ball joints are secure and the spring won't move. Easiest way to put the anti roll bar back is jack up both sides put the ends in the wish bone, then do the body clamps. I'm being sluggish this year, but I'll try and post some pics when possible. Cheers J

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Re: front suspension re-build

Post by marky »

OK - just stripped the second side of the front suspension. Two hours dead - first side took six hours - it's amazing how much time you can save when you know what problems you are going to face and how you solved them the first time!

Have arranged for Lotus bits to supply and fit the ball joints and all the bushes to the lower arms - they were very helpful as always.

Have ordered new springs and Protech dampers etc from SJ using their excellent on-line ordering system.

While I am waiting for the parts I have a lot a cleaning up to do and I have decided to fit new wheel bearings to the front while everything is apart. I have already knocked out the old bearings with a 5mm punch but I had to remove an enormous amount of grease from the centre of the hub before I could see what I was doing!

I just need to figure out how to get the 6mm sheared off bolt out of the near-side dirt shield!! - might take it to my friendly local garage and see if they can apply some heat and get it out - absolutely stuck fast at moment. I will drill it out if I have to but I am hoping it doesn't come to that.

Will post some pictures when I get all the new parts on.

Mark.

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Re: front suspension re-build

Post by Jason.goad »

Handy tip when fitting new wheel bearings. To make a drift for tapping the new races in the hub, grind the outside edges of the old races down a tiny bit and use them. That way you can make sure they go in straight. Probably everyone knows that, but it sounded like I knew what I was talking about for a moment 8)

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