Koni Insert into the existing casing - HOW?

[Jimbo_Jet]

It’s one problem after another at the moment. The garage that is fitting my new Koni kit has just hit a problem and is stumped. They’ve fitted the front shocks and springs ok, but the rears won’t go in.

This is because the metal collar (for want of the correct term) that I’ve indicated below is spot welded to the existing casing.



There are four small holes around the perimeter of the casing, just below the collar itself, through these holes they can see the spot welds themselves. So they can’t get the old insert out without breaking the welds to remove the collar. The problem is that through these holes they can’t see any screw thread on either the collar itself or the inside of the casing, so if they do remove the collar they’re sure they’ll be no thread to screw the new collar, which came with my Koni insert, in to.

Ok, hands up, I haven’t got a clue what to do now and my cars still off the road and I need it hell or high water by Friday.

Has any one got any advice? Where can I get new casings from straight away and will they have a screw thread inside that the new collars can screw to? Is there something obvious that they’re doing wrong?

Please help.

[Jim-SR]

sounds like your struts have been replaced for Mr T replacements in the recent past. Toyota now only sell sealed strut units, not the old insert setups like before. youll need to source some used original struts/cases.

[WeirdNeville]

There are rear struts on eBay at the minute, just get in touch with the seller to check that they're not sealed as well.

I do have a pair of rear struts but I'm working so couldn't get them to you by Friday...

It'll be worth it, I've just driven mine with the Konis in it and it's awesome.

[IanClements]

I bought a new strut casing from http://tcbparts.co.uk/ a while back which was OK and cost £40. Definately easier to replace the casing imo.

[Jimbo_Jet]

Bu88er! Now that's sod's law for you! I've read loads about replacment koni suspension over the years but this is the firs time I've ever heard about sealed units like this before?

Thank you very much one and all for your help, guess I'm on the look out for some new rear casings then! Anyone know of some local to me?

I'm just going to have to tell the garage to put the rear back together for the time being and get the rear done one I have some new casings. What a pain in the ar5e!

[Jimbo_Jet]

Oh here's a second question for you - are the rear casings the same from a MK1a to a Mk1b?

[kaiowas]

No.

Different diameter tube and consequently the spacing between the lugs which bolt to the upright is also different (Can never remember which is the smaller of the 2)

[omracing]

Phil I think they are smaller on a Mk1a.

[kaiowas]

Phil I think they are smaller on a Mk1a.

That's what I thought but didn't want to commit either way if I wasn't certain.

[Jimbo_Jet]

It'll be worth it, I've just driven mine with the Konis in it and it's awesome.

That's what I want to hear!

[Jimbo_Jet]

Phil I think they are smaller on a Mk1a.

Thanks - MK1a casings it is then. Cheers!

[DJJAW11]

Bu88er! Now that's sod's law for you! I've read loads about replacment koni suspension over the years but this is the firs time I've ever heard about sealed units like this before?

Thank you very much one and all for your help, guess I'm on the look out for some new rear casings then! Anyone know of some local to me?

I'm just going to have to tell the garage to put the rear back together for the time being and get the rear done one I have some new casings. What a pain in the ar5e!

from TCB http://tcbparts.co.uk/

I would sell you one of mine but its converted to a coilover, so aboves is one of the best bets

I feel for you, should of been a easy swop/job, just delays u some

David

http://www.carpron.com/multisite/v/Upload/DJJ/

[Jimbo_Jet]

Yeah, it's been a right pain alright! It's taken me well over a month to find some MK1a casings, they're like rocking horse poo to come by!

Just got a pair delivered two days ago courtesy of Kev-Crazylegs

[DJJAW11]

Yeah, it's been a right pain alright! It's taken me well over a month to find some MK1a casings, they're like rocking horse poo to come by!

Just got a pair delivered two days ago courtesy of Kev-Crazylegs

glad to here.

Like your little Outrun avatar

David

http://www.carpron.com/multisite/v/Upload/DJJ/