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1969 Alfa Romeo: Rear Suspension Refurbishment From "Classic Car Restoration" episode DCR-104

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Figure A Figure B Figure C Figure D Figure E Figure F Figure G Figure H Figure I Figure J Figure K Figure L Figure M Once the rear suspension components have been reinstalled, Ron finishes up with some paint and undercoating in the wheel-well to help seal it against the elements.

Rear Suspension Refurbishment

In this segment, the replacement and restoration of the front suspension on the 1969 Alfa has been completed, so we now proceed to the rear suspension.

The suspension system on the Alfa was based on racing designs, and incorporated separate coil springs and shock absorbers -- as opposed to modern suspension systems that employ integrated strut-and-coil-spring assemblies.

The complete restoration on the rear suspension includes the coil springs, shock absorbers, control arm, sway bar and differential housing. Following are highlights from the process.

• The top of the rear-shock is double-nutted. Using an open-end wrench and a socket wrench or air-ratchet, remove the top nut, then remove the bottom nut using only a socket (figure A). With these upper nuts removed, the bottom nuts can be removed to free up the shock absorber, allowing it to be removed from the car by pushing it down through the floor-pan.

• For the lower control arm, the situation is similar to that at the top of the shocks. Using a socket, remove the nuts one at a time (figure B), followed by the bushings.

• Remove the retaining nut from the sway bar (figure C), then pry the sway bar loose (figure D).

• Once the end of the sway bar has been separated from the control arm, the control-arm nut can be removed as well.

• With the control-arm nut removed, the control-arm can be lowered and removed from the car by using a floor-jack to carefully lower it. The floor jack is essential for this step, as it allows for control of the coil spring as the control arm is lowered, taking the load off gradually (figure E).

• With the control-arm lowered, the shock and spring can be removed as well.

• As the other end of the control arm is loosened, it drops down. Drive the retaining bolt out (figure F) -- being careful not to damage the threads of the bolt -- so that the control arm can be removed.

• Once removed from the vehicle, the control arm can be cleaned up in a wash tank, and cleaned further using a sanding disk (figure G).

  Safety Tip: Chemicals used in parts washers are caustic. Always wear protective gloves when using a parts washer, and follow all safety precautions that come with this piece of equipment.

• With the control arm cleaned of debris and corrosion, it can then be prepped and painted.

• Unbolt and remove the sway-bar from the vehicle so that it can be cleaned and painted in the same way.

• With the sway-bar removed, there's a good opportunity to clean and paint the differential housing as well (figure H).

• Once cleaning and painting are complete, the sway-bar can be reinstalled (figure I).

• To replace the coil springs, the ends are lined up with the perch to position the spring (figure J).

• Once again, the floor-jack is used to control the spring and keep it in check as it is reinstalled (figure K).

• Once lined up, the retaining bolt can be inserted through the control arm and differential housing, and the inner nut installed.

• With the bolt installed, tighten the lower nut on the shock absorber.

• Replace the nuts on the top of the shock absorber to complete the reattachment. Put the bottom nut on tightly, then follow with the upper nut. Don't tighten the upper nut all the way. Once it makes contact with the lower nut, tighten it with a ratchet (figure L) until the bottom nut spins. The nuts are then as tight as they need to be. Replace the cap on the top of the shock absorber.

At this stage, the rear suspension and rear axle are complete. Rubber bushings in the control arms have been replaced. The differential (figure M) has been checked to make sure there are no bad seals or fluid leaks, and that the bearings are in good operating condition. Coil springs and shocks have been replaced with new parts. Sway-bar bushings have been replaced. The rebound strap is a discontinued part, so it was simply removed from the car, cleaned up, repainted and reinstalled.

In the segment that follows, the mechanical emergency-brake system is replaced.

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