Koni shocks don't fit....PLEASE HELP!!!

[HPmuirt]

Disaster.....Fitted my konis and new top mounts all round last night, but there is a nasty knocking from the front. Turns out that the koni damper is slightly too short for the Macpherson strut, so it moves up and down, even with the top cap torqued right up. I fitted the following dampers (with stock springs): -

Front - 86-2086SPD2
Rear - 86-2433Sport

According to the instructions (read out to me on the phone this morning but my mate at the garage) you are supposed to remove about 2mm from the threaded top of the macpherson strut! is this really the case? Wouldn't a spacer be a better idea?

Please help as the car is current stripped back down and looking very sad for itself.

Cheers n tears

Si

[Fat Audi 80]

I have not seen it or done it myself but surely an aluminium disc of the right dia and thickness dropped in the bottom would work. !Or even some large washers! )

[mcandmar]

Might not be relevant to an S2 but the Konis for my cq20v have a metal spacer that sits between the top of the shock and the top cap. I wonder if its the same setup and you didnt get the spacers?

[Lloyd]

Not sure if I'm off the mark here but I think I've read something similar to this before - excpept the other instance was a knocking from the rear -

As far as I can recall - it turned out that there are two different lengths of koni's for the car - one set for normal springs and a another set for shorter spring length, hence shorter damper length...?

If you have the shorter damper with normal springs it bottoms out giving the knocking noise?

http://www.rs246.com/index.php?name=PNphpBB2&file=viewtopic&t=49695&highlight=koni

Will have a look for the other post, based on the one above but mentioning a shorter damper option.

http://www.rs246.com/index.php?name=PNphpBB2&file=viewtopic&p=83097&highlight=#83097

Quote:
"The Koni shocks are'nt adjustable for stiffness - the adjustment is for rebound speed. My Audi dealer has adjusted them from slowest rebound speed to quickest rebound speed and on all settings I get bump steer and a slamming sound over speed bumps. I think it was super-q who suggested that the Konis I have, have 25mm less travel than standard shocks which is causing the problem. This is apparently why Konis work best with lowered springs.
Given this situation, I've decided to revert to standard rear shocks whilst still running the Konis on the front. I've also decided to decrease the front roll by fitting Powerflex ARB bushes on the front - I'll let you know how I get on."

So, not sure if this is related but the post above made me think of these threads...

[S2central.net]

I have no direct experience of this, but it sure sounds like the spacers are missing... I would much rather fit those inside the strut than go shortening that threaded area.

If its just 2mm involved then it should be easy enough to get spacers fitted - bit of a pisser though finding out after its all been rebuilt. Dohhhh - thanks for recording it here tho' simon.


Paul

[GT500]

when my UR had bobins konis, there was deffo a spacer!

[martinjs]

Yes there should be a spacer BTDT

[AndyP]

I fitted those part numbers to mine and I didn't fit a spacer and I don't get any knocking, apart from when my genuine Audi blue top mounts fall apart after 2000miles

[S2central.net]

Right - something funny is going on here...

Looked at the family album and there was a change in strut tubes along the way.

First off the 7A parts are different again, but forget that for now.

A 3B Coupe with chassis code M (MY91) has strut tube 895 412 033B and 034B

But for 1992 onwards (chassis code N) the 3B and ABY has a different strut tube - 895 412 033F and 034F.

In all S2 cases they have the same strut cap nut - 431 412 047B

Does this help correlate the info with who has/has not needed spacers with Konis ?

[HPmuirt]

Thanks for the replies folks, but now I am confused.....

Some have used spacers and others have not Did those who used the spacers receive them in with the Konis?

Regarding the length issue, I assume that is the length and travel of the piston, whereas my issue is the length of the Koni body.

Therefore, maybe Paul is onto something. Do those who used spacers have post 1992 cars and those without spacers have 3B cars?

Cheers and tears

Si

[S2central.net]

Simon - A 1992 3B should be same strut as all ABY struts according to FA.

Its the 1991 3B (M) which is the oddball. The comments about 7A and UR with Konis just add to the confusion as they are different struts again.

[HPmuirt]

UPDATE:...Now at the garage...

All 4 units removed and inspected (even swapped front and rear Konis for a try) and can confirm that spacers are fitted in all 4 corners, but the fronts sill have some slack and therefore knock. The knocking is audiable if you gently bounce the corner of the car.

Fronts are def 86-2086SPD2 and springs are OEM.

I have fed my mate some cakes, but that won't last long. At some point he wants his ramp back.....HELP

Cheers n tears

Si

[HPmuirt]

Another update....

All the mechanics are now gathered around the vice, making unhelpful suggestions about which bit to weld to which other bit

We have found some Ford washers that fit in the bottom of the strut tube and raise the damper and spacer above the top of the thread to the correct height but are not quite as curved as the bottome of the damper.

One mechanic suggested using the press to curve the washer and the rest said sod it, we'll just tighten it every week until it has curved to fit the shape of the inner strut and damper

Why are they only cowboys with my car?

[S2central.net]

Cant you fit these flatter washers at top of strut to form a sandwich with the upper cap nut ?

Paul

[HPmuirt]

Cant you fit these flatter washers at top of strut to form a sandwich with the upper cap nut ?

Paul

That's what we wanted to do, but after 15 minutes of all the mechanics seqrching through their stocks of nuts, bolts, washers and 'ooohhhh, what's this' we could not find any that would fit

I will take some pictures for future reference of what will turn out to be this years worst and most unnecessary bodge!

Cheers n tears

Si