Help With Koni Dampers

[speedstar]

Hi all

My Trophy came with a spare pair of Koni rear dampers which are obviously used, but seem in fair enough condition.
I want to go about fitting them in the next week or so, but have realised that they are slightly different to eachother and wanted to get the group's thoughts on how to move forward.

One of them (bottom) has an extra rubber piece on the stem - is this needed (and I am missing one from the other damper)? Does it come from the dampers that are already on the car maybe?

Secondly, there is a single metal cup with a hole in. This fits over the stem so assume it forms part of the mounting solution. Again, I only have one so does it come from the existing dampers? Do I need to get on ebay and find another?

Any and all help gratefully received!

 

[Cue]

you've a part missing on the one without the rubber bump stop. You could try contacting Mark Fish motorsport - who specialise in koni dampers, they may be able to supply said bump stop, or recondition them?

 

[Farnsworth]

The Koni do not come with any of the above extra parts, dust covers, bump stops etc. Either reuse what you take off your car or reuse covers and buy new bumpstops from Powerflex.

 

[hoolio]

The Koni do not come with any of the above extra parts, dust covers, bump stops etc. Either reuse what you take off your car or reuse covers and buy new bumpstops from Powerflex.

My bad, Koni come with this little lot but not the dust covers.

 

[speedstar]

My bad, Koni come with this little lot but not the dust covers.View attachment 28116View attachment 28117

Awesome! Thanks for the reply! Exactly what I needed!

 

[Cue]

couldn't tell from the pics but looks like one of yours was missing part 5 from the diagram?

 

[speedstar]

So massive thanks to Mark for supplying the missing bush!

Fitted them, but something is definitely askew! Drivers side seated, tightened and all looks good.
Passenger side... well... see attached.

Been scratching my head trying to figure out what on earth went wrong. Remove, refitted, checked the order of bushes and spacers... all AOK.

It seems like the spacers and and bushes are all free to slide up and down the shaft at will. Nothing holding them in place. And nothing to clamp either side of the hole in the boot.

Any thoughts?

 

[BenG]

Hard to tell from the pic but there should be a small circlip on the shaft, it looks like it’s missing on that damper, you can see the groove where it’s supposed to be.

 

[BenG]

Both the upper and lower section of the rubber mounts sit above the circlip which basically prevents the shaft doing what its done in the first image.

 

[BenG]

 

[speedstar]

Ah ok.
Think that is missing then! I'll add one and see what happens!
Thanks!

 

[speedstar]

This is getting silly now...

So I have the correct circlip.
I have all the correct bushes and spacers.
I have retrieved the bump stops and dust covers from the originals.

I try to assemble as per the instruction sheet...

The dust cover simply will not go over the circlip as the sheet suggests. What on earth am I doing wrong now?
Do I need to remove the circlip, assemble, pit the circlip back on?

Photos attached showing the sheet, the damper, the inside and top of the dust cover and how it all sits.

There could be a set of koni dampers going cheap at this rate ????

 

[speedstar]

It doesn't seem like the shaft actually fits through the rubber bump stop on the top of the dust cover...
Do I just need to push harder?!

 

[speedstar]

Or drill it out?
It seems some of the old dust covers (I have total of 4) go as far as the circlip; others dont get past the threaded section

 

[BenG]

Don’t drill it out. It needs to be tight as that’s the only way it will stay in position when it’s fitted. It sits below the circlip so I’d just remove the circlip to get it past that point, then refit it and go from there.

 

[BenG]

Give it some force if it’s tight, it’s a good thing if it’s still a tight fit.