DIY Network

Tricked-Out Suspension: Strut Assembly, Part 2 From "Tricked Out" episode DTRK-101

Tricked Out host Andrew Totolos talks tires. "When it comes to tires," he says, "performance and comfort are on opposite ends of the spectrum."

In this segment of Tricked Out the suspension work continues on the 1996 Honda Civic hatchback with new coil-over kit and adjustable shocks. Performance wheels and tires are also discussed.

DIY Difficulty Rating for Repair: This job is fairly straightforward. We gave it a difficulty rating of 2 on a 5-point intermediate-level scale. Experienced gear-heads should have no problem installing these upgrades.

Upgrades in this episode:

Performance coil-over kit
Adjustable shocks
Strut tower bars
17-inch wheels and performance tires

Other materials:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), some of the specialty tools that will be needed for this project include small flat-head screwdriver, cordless drill and 2-1/8 hole saw, spring compressor, a jack and jack-stands. An air-compressor and set of pneumatic tools is optional, but may help speed the assembly process.

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Figure A

Strut Assembly, Part 2

• With the stock front-struts removed from the 1996 Civic, the new struts can be prepped for installation. An O-ring slides over the new strut to prevent the threaded perches from rattling and wearing once they are installed onto the strut.

• You'll need to remove the factory strut-cap from the old struts. Removing the top nut from the strut will allow you to remove the cap, but you'll first need to secure the springs using spring compressors.

• Safety Alert: Spring compressors (available for purchase or loan at most auto centers) are used to stabilize the springs (figure A) before the nut at the top of the strut is removed. Without the spring compressors, the springs could break loose and cause injury once the tension is released.
  
• The bump-stops will also need to be removed from the old struts. But because the new suspension is lower, the bump-stops will need to be cut down to compensate for the adjusted height. Once it's cut to the proper size, slide the bump-stop into position on the new strut (figure B).

• Now, using the old bump-stop and strut-cap, you can assemble the new strut following the manufacturer's instructions. In our case, on top of the adjustable perch, we placed the spring followed by two washers, the original factory strut-cap, another flat washer, and the top nut (figure C).

  Figure B

  Figure C

  
  
• To install the new strut assembly, simply reverse the removal procedures used earlier. Position the strut assembly from below (figure D) and secure it from above with nuts.

• For now, simply hand-tighten the nuts (figure E). Later in this project, we install a strut-tower bar at this location.

  Tricked Out Factoid: Strut-tower bars keep cornering forces in check for predictable handling.

  Figure D

  Figure E

  
  

• The procedure for changing out the rear struts is basically similar to that for the front. In this case, there are two bolts that need to be removed (figure F). One connects the strut assembly to the control arm.

• The other connects the control arm to the hub assembly. Use a 14mm socket to remove each of the bolts (figure G).

  Figure F

  Figure G

  
  
• In the hatch (or trunk), it will likely be necessary to remove some of the plastic panels to access the top ends of the rear struts. Use caution when removing the panels, and place the fasteners and small pieces in a container to keep up with them for re-assembly. In our case, we also had to temporarily remove rear speakers to access the strut towers from above.

• Once you can access the strut, use a 14mm socket and extender to loosen the bolts (figures H and I). As on the front strut, as you loosen the bolts, have an assistant support the strut from below to prevent them from dropping to the floor.

• Tip: In a situation like this, when working between an interior trim-panel and the body, first loosen the nuts part-way using the ratchet. Then loosen them the rest of the way by hand to prevent them from falling down inside the body panel where they would be hard to retrieve.

  Figure H

  Figure I

  
  
• Once the old struts are off the rear of the vehicle, you're ready to assemble and install the new strut assemblies. In our case, the adjustment ring was positioned about 1-1/2 inches from the cup (figure J). Once the assembly is installed on the vehicle, the height can be fine-tuned further.

• As you did in the front, position the assembled coil-over from below (figure K)

  Figure J

  Figure K

  
  
• Once the top of the strut is in proper alignment (figure L), secure it with the nuts.

• Then secure the lower portion of the strut below (figure M).

  Figure L

  Figure M

  
  

  Figure N

When it comes to selecting wheels and tires, your choices are many. Looks are important, but the most critical factors in terms of performance are weight and size. The heavier the wheel, the more your suspension has to work to keep it under control. For performance, stick with lightweight tires. As for size, performance and comfort with respect to tires are at opposite ends of the spectrum. A big wheel with a low-profile tire handles well, but since the side-wall is what absorbs most of the shock, and these side-walls are so thin, you'll really feel the pot-holes. For our Civic, we compromised with a set of 17's (figure N) -- big enough for solid cornering, but without rattling the fillings out of our teeth as we drive to work.

In the segment that follows, tower bars are installed to round out the suspension upgrade.
Important: Included in this segment are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: Always wear eye protection, and follow proper safety precautions, when working with power tools or pneumatic tools.

RESOURCES :

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

Honda & Acura Performance Handbook (Performance Handbooks)
Author: Mike Ancas
Order this title from Amazon.com.
June, 1999
Publisher: Motorbooks International
ISBN: 0760306699

Honda/Acura Engine Performance: How to Modify D, B and H Series Honda/Acura Engines for Street and Drag Racing Performance
Author: Mike Kojima
Order this title from Amazon.com.
April 2002
Publisher: HP Books
ISBN: 155788384X

Honda/Acura Performance Handbook: High Performance Modifications for Street and Drag Racing Applications
by the editors of Sport Compact Car Magazine
Order this title from Amazon.com.
November 1999
Publisher: HP Books
ISBN: 1557883246