StuB Posted November 24, 2011 Share Posted November 24, 2011 Have the planned the above as my first serious solo work on the car with the intention to get it cleaned up and powdercoated. Have been assured that removal is a fairly simple job but has anyone ever put together an idiots guide? Trying to ensure that the car doesn't spend to whole of the winter months with the front end in pieces! Any advice appreciated (but please don't use any complicated words). Stu Link to comment Share on other sites More sharing options...
Roger Ford Posted November 24, 2011 Share Posted November 24, 2011 I disagree - it's quite a hard job. The lower shock bolt is really small and tends to seize in - making rounding it off or breaking it a definite possibility (I broke it this time - I've rounded it off before). The LH bottom wishbone bolt fouls the alternator, so won't come out without jacking up the engine (which may require you to undo the engine bolts - I'm assuming K-Series here) and the top wishbone bolts are awkward because you have to move the aluminium paneling out of the way to extract them. And there's the brake cable joints to remove - which are non-obvious and tend to use unusual spanner sizes like 15mm. I can certainly think of easier jobs. Link to comment Share on other sites More sharing options...
Jason Plato Posted November 24, 2011 Share Posted November 24, 2011 its an interesting job but fairly straightforward as Roger says above al,ost all of the front suspension bolts have their own snag 😬. But it realy is the reverse of the build manual. the top tip I would give is spray penetration oil ( not wd40) onto the lower damper bolt and damper bush for about a fortnight before attempting removal- if you used copperslip to assemble it will all be ok. I then use a cut down 30mm section of realy good quality allen key ( 3/8 if I recall) and then attach a 3/8 socket to gently undo in one smooth draw. if the allen head rounds your realy stuffed ☹️ Link to comment Share on other sites More sharing options...
myothercarsa2cv Posted November 24, 2011 Share Posted November 24, 2011 I rounded one off, took the lower wishbone and shock to the local 7 friendly garage, and they drilled it out no problems at all It is a pain, but there you go I don't find the bolts foul the alternator, perhaps we have a slightly different setup Roger? The only thing I would advise on is the brakes - the lines go through the wing stays on standard calipers. I ziptied the caliper and wingstay to the body so I don't have to disconnect the lines. Another option could be to whip off the wishbones and put the upright back in the wheel, put a couple of nuts on, and prop the wheel against the car... To pop the ball joint out of the upright, use the bolt and nut method - it WILL save you at least half an hour. Link to comment Share on other sites More sharing options...
stuart147 Posted November 24, 2011 Share Posted November 24, 2011 Hi Stu Give me a ring at some stage. I have done this before and have correct allen socket for removing bottom damper bolt and a couple of other useful AF sockets necessary for job. I could come over and give you some help if you need it. If I can do the job though, anyone can. You have my number or e-mail me. Stu Link to comment Share on other sites More sharing options...
Chewie Posted November 24, 2011 Share Posted November 24, 2011 It's one of those jobs that once you work out how to do and of course, have all the necessary tools, you can do it quite easily and quickly. I fitted widetrack on mine. I picked the nearside to start off with. It took me 10 hrs to replace the wishbones. *eek*When it came to the offside, I did it in 2.5 hrs. 😬 . Don't be put off. It's only a Caterham. Everything is in easy access. A lot easier to work than a Peugeot 306. Link to comment Share on other sites More sharing options...
StuB Posted November 24, 2011 Author Share Posted November 24, 2011 Thanks all for the advice, Stuart I may take you up on your offer. Going to get it on the axle stands first and take a look. Link to comment Share on other sites More sharing options...
DJ. Posted November 24, 2011 Share Posted November 24, 2011 If you are powder coating, you'll probably want to remove the bushes. I'm not sure of the best method to remove them, and you might need a press or large vice to replace them. Duncan Link to comment Share on other sites More sharing options...
Area Representative Nick Chan Posted November 24, 2011 Area Representative Share Posted November 24, 2011 Hi Stu (B), Give me a shout if you need a hand 😬 Cheers Nick Link to comment Share on other sites More sharing options...
Roger Ford Posted January 21, 2012 Share Posted January 21, 2012 The LH bottom wishbone bolt fouls the alternator, so won't come out without jacking up the engine I've just hit this problem again. Anybody got a solution which DOESN'T involve demounting the engine? My engine mounts were brastards to line up right, so I don't want to remove them unless I have to. Next time, I'm going to take an angle grinder to the alternator before fitting it Link to comment Share on other sites More sharing options...
jonboylaw Posted January 21, 2012 Share Posted January 21, 2012 As for pushing the aluminium body out the way. I used sections of old 4litre milk carton to protect the skin whilst taking out the upper bolts. These can be taped the the body at the appropriate places. Re-fitting the lower can be a pain as you need to get the castor washers in and lined up. It just takes patience and time. Do not try to force anything, it will all go back together with the right amount of wiggling and the correct angles found. What year is the chassis and what engine do you have ? Jon Link to comment Share on other sites More sharing options...
Roger Ford Posted January 21, 2012 Share Posted January 21, 2012 Sorted now. I had to grind the head of the 4 inch bolt down by about 2mm, then it would just fit. 2004 K-Series. Next problem is that the shock doesn't fit. Think either it or one of the wishbones must be bent. Link to comment Share on other sites More sharing options...
CharlesElliott Posted January 21, 2012 Share Posted January 21, 2012 Surprising given that the damage was caused by a car hitting you at about 70 mph. Link to comment Share on other sites More sharing options...
Ozzy Posted January 21, 2012 Share Posted January 21, 2012 I've recently done all this, and the only niggly bit was the nearside lower wishbone bolt hitting the alternator. However, I found (with a bit of patience) that you can just about wiggle it into a certain position at an angle, that just allows enough room to remove the wishbone, by removing the forward pair of washers first, and sliding the wishbone towards front of car. Lower shock bolts were ok, as I've had them out before, and liberally coated them with coppaslip. Link to comment Share on other sites More sharing options...
Z3MCJez Posted January 21, 2012 Share Posted January 21, 2012 Roger, If you're on standard Bilsteins in the Grads, and it's the shock tht's bent, then I still have my old narrow track kit. I have wishbones too, but I think they might be different for metric ... Jez Link to comment Share on other sites More sharing options...
Roger Ford Posted January 21, 2012 Share Posted January 21, 2012 It's not bent, I'm just incompetent. The only reason it wouldn't line up was the spring fouling. Thanks anyway! Link to comment Share on other sites More sharing options...
StuB Posted February 5, 2012 Author Share Posted February 5, 2012 Parts back from Kelcoat and nylon coating looks brilliant, plan to get them back on the car next week thanks to the help of Stuart147 Before I can complete the job I plan to relace the bushes and spherical joints, please see my wanted ad here Link to comment Share on other sites More sharing options...
Michael Downing Posted July 23, 2014 Share Posted July 23, 2014 Quoting myothercarsa2cv: To pop the ball joint out of the upright, use the bolt and nut method - it WILL save you at least half an hour. Sorry to drag up an old post, but I was searching for tips on doing exactly that (managed to bend my track rod end while racing on Sunday). Can someone clarify what the "bolt and nut method" is please? Link to comment Share on other sites More sharing options...
Member Jonathan Kay Posted July 23, 2014 Member Share Posted July 23, 2014 I searched the archives for "nut bolt ball joint" and came up with this. Jonathan Link to comment Share on other sites More sharing options...
Michael Downing Posted July 23, 2014 Share Posted July 23, 2014 Perfect, thank you Link to comment Share on other sites More sharing options...
Michael Downing Posted July 24, 2014 Share Posted July 24, 2014 Worked a treat. Thanks Jonathan, thanks BC Link to comment Share on other sites More sharing options...
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