Coilover Issue

[karter]

I have a 2001 ARX fitted with BC coilovers. On Saturday I hit a pot hole in a roadworks zone - only doing about 40kmph. There was a loud crashing noise and something was clearly loose in the rear. We had a look today and found that the passenger side coilover top mount had torn out. Wondering if it has happened to anyone else, and what is the best way to repair it, and who best to do it - I'm in Canberra. Grateful for any advice.

[scotty nm35]

The rear suspension isn't coilover, is it the coil or shock you are talking about?

Take a pic if possible.

[Daleo]

Scotty's right; are you referring to the top mount for the shock absorber?

[karter]

Yep - you're both right - it is the shock absorber top mount - will try to take a photo tomorrow - access isn't easy..

[Daleo]

It's a separate piece; I bet "someone" will have one...

[karter]

please excuse my ignorance - it's our first Stagea - which is the separate piece? At least one of the two bolts at the top of the shock absorber unit has sheared off and the plate that it is attached to has separated from the chassis.

[niclol]

Picture

[Brick]

ouch... looks like you will need some new metal welded in there. Very unfortunate

[Ben C34]

Wow. That looks like the bolt has pulled through the mount.

If that is the case I would be putting a decent washer and or reinforcing plate under the bolt, but that shouldn't have been able to happen in the first place.

I wonder if they were installed wrong?

Edited March 11, 2014 by superben

[Trex]

Never seen that before must have been a bit of play on the bottom for it to pull out the top on one side? As Ben said, it will need to be welded and then strengthen it by welding 2 washers on top and bottom side. Do the other side to keep it simetrical.

[GH05T]

some weird caster going on here? would get the setup checked out when repaired too, might be something fundementally wrong.

[MrStabby]

Is it just me or does that hole look rusted out?

[Daleo]

Looks like metal fatigue around the stud has allowed it to break a section clean out of the body; there's no rust there.

I reckon the car has copped a hit in the wheel, and the shock has borne the brunt of the impact. You can see the stress cracks that have propagated around the stud. You can also see where the metal is stretched around the other stud.

I'd be looking for evidence of subframe removal, or rear arm removal; those components would have been badly damaged if it has been hit (or slid into a gutter etc).

You are going to need to get in from above; weld in a reinforcing plate with a pair of captive studs, I wouldn't just tack up the sheetmetal & put a washer in there.

That is going to be a pain, and you are going to want to find someone who is experienced with welding & engineering (like a hot rod or custom car body workshop), and you will be paying for that. I doubt a normal panel shop will even touch that repair.

[karter]

Thanks for all the info - car was on the hoist today - it is not rusted and there is no sign of damage to the sub frame, or indications that it has been removed - no marks on the wheels and it hasn't had a hit in my ownership - except the pot hole the other day - getting at it from above will be a real challenge - the panel that needs to be removed to access it is bolted and welded. Looks like it will have to be done from underneath.

[scotty nm35]

Looks to me like the shock was installed too short, and has dropped hard, ripping the stud out.

Can you get to the top of that stud?

[karter]

No access from inside the car - will have to be accessed from below.

[scotty nm35]

A nutsert might do it, but the hole looks pretty buggered.

[karter]

Car is back on the road - shock mounts plated and welded by M&A Engineering in Mitchell ACT - ended up doing both sides because the other side was also cracked - they didn't think it happened because the shock units weren't installed correctly.

[Daleo]

Car is back on the road - shock mounts plated and welded by M&A Engineering in Mitchell ACT - ended up doing both sides because the other side was also cracked - they didn't think it happened because the shock units weren't installed correctly.

Great to hear mate!

If you don't mind my asking; what did they charge you to do the repair?

[scotty nm35]

Good you found a decent fabricator to repair it, but I have seen many Stagea's and none have ever had that issue. The shocks were installed too short, it's the only way it could pull the stud through, as the spring tension is working against it. Hopefully it doesn't happen again...