Boxster 986 Complete Suspension Overhaul

[madmods]

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[Bala]

I guess I'm going to be highjacking this thread quite a bit. Sorry Madmods!

So, started taking out the front strut, wishbone, drop links, rotor, control arm. The drop link bolt is pretty snug into the housing where the shock is inserted. Tried quite a bit with air ratchet as well to no luck. Also the shock is in very tight into the housing. Maybe due to the fact that the drop link bolt is still in there?

Also having issues with the big bolt on the boomerang thingy under the sway bar. Can I take a propane torch to these nuts? Am I nuts?

Need replacement so far for front: wishbones, control arms, tie rods (in and out), sway bar bushings, drop links, shock bearing plates, bump stops, boots and wheel bearings, 2 cases of beer.

When I checked the wheels by shaking them they seemed fine. But once they were off and the rotor was off as well there is a slight play.

Shocks and springs seem fine. I don't get the point about buying new hardware and not using the old ones. 3-5 bucks a nut is crazy. Will have to try local hardware stores for less price.

[shlim8]

Originally Posted by madmods

PS: Driven out and around Sepang, Malaysia and S'pore a few time (rentals of course) and found out the roads to be fairly good there. I'd say your problem can't be only because of the roads alone. But again, I'm not a pro and one would need to see the car to judge accurately

Luckily, all the control arms/links etc I used was TRW branded. Frankly, the markings on the arms and links looked identical to the originals, except that they had the porsche logo removed . Looks pretty much oem quality.

The roads in Sepang are excellent but unfortunately, I'm a foreigner working in Kuala Lumpur/Petaling Jaya area... and the roads are horrible... I've never upgraded from 17" rims to anything bigger due to that reason (I dented 3 out of 4 rims on my prev bimmer in 9 months ! And finally the potholes even got the alignment so out of specs, I had to get the chassis straightened ! Apparently, it's pretty much common on a e36 on Malaysian roads !). It's pretty hard to avoid dropping into potholes at night or when it rains and can't see the *&^%!! potholes.

I'm sure you are going to enjoy your renewed suspension ! It made a huge difference on my car.

[Bala]

What a pain these bolts are. Maybe its just my car. Spent 6 hours removing the wishbone, sway bar, drop link bolts. Propane torch speeded up the things. Still broke the abs sensor ones and need to deal with it. Aso remaining are the bolts over the wheel bearing housing.

Both wheel bearings seemed fine when checked with the wheel on but when all was reoved there is some play. Recommend folks taking out the wheel assembly to check. "Better to do it while you are in there".

[Bala]

Heads up:

Vertex has just put out a kit that includes 4 wishbone, 2 front ontrol arms, 2 rear control arms and 2 track rods for 995. These will also have the upgrded polyurethane bushings. They even split the shipping with me. Of course these are the rebuilt ones. Lets see how they fare. Got to be better than the crap i took out.

[thstone]

Originally Posted by Bala

Both wheel bearings seemed fine when checked with the wheel on but when all was reoved there is some play. Recommend folks taking out the wheel assembly to check. "Better to do it while you are in there".

Agree. Same on my car. Checking the wheel bearings with the wheel/tire on the car there was no play whatsoever but I planned to replace them since I was doing the CV joints. After I had the bearings out, I could feel a slight ginding and some play which would have only got worse with time/miles. Definitely better to replace them as long you're in there.

[shlim8]

Madmods,

just a quick update - it was one of the front control arms - the one with a fork like links and a ball joint. One side with excessive movement on the balljoint and the other slight.

They were TRW branded (or at least the box said TRW) and lasted 1 yr + and about 28k km.... (and a number of big potholes) hmmmm...

Changed the 2 front control arm and now the vibration through the steering wheel is almost gone and the handling is tidier as well. AND no more wooden floor board noises when going to uneven roads.

[madmods]

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[Bala]

Completed my front last week. What a pain without the right tools. Struggled for two day on the wheel bearing without the SIR toolkit. Then it was a breeze. Car feels very rigid and tight up front. Haven't test drove it for long but waaaaay different and me loves it. Will be doing the rear suspension, bearings and maybe CV boots this week. Maybe while Im in there i should look at the clutch, IMS? When does it all end?

[WhipE350]

Originally Posted by madmods

... Middle in all respects (materials and prices). So in perspective and in terms of durability, you could see a "scenario" like below:

Genuine Porsche parts = 5 years
TRW aftermarket parts = 3 years
Hamburg Technic = 1 year

So you got me buying parts and changing out a few for fun, not sure yet if I needed them but I enjoy something to keep me busy in the evenings. I got some control arms from TRW...they are the exact same as the ones I took off my car, the original ones are even stamped TRW. I'm thinking you can update that chart above ....oh and thanks for causing me to spend more money, guess I'll enjoy it while I can. I'm sure I'll be purchasing more, I just have to fool myself and do a little at a time

I'll report back if car feels any different. Oh I need ideas on sway bar bushings, my car is a 2000 Boxster 'S'.