I did my coil conversion today...

fossten

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Ok, it's 7 pm and I'm just now done with the front wheels. I started at 9 am this morning, with a 1 hour break and two trips to the store for tools. Murphy's law happened to me every step of the way today.

I'll get to the details later, but I was wondering, the nut that holds the sway bar link to the steering knuckle that I loosened (see Black Ice's instructions) now won't tighten; the bolt turns with the nut. I have about a half inch of bolt that needs to be tightened. How do I fix this? The back of the bolt is smooth and round with a rubber boot, obviously a ball joint. Do I have to buy a new steering knuckle? I'm really pissed about it, b/c I figured out that I really didn't need to loosen that nut after all. I did the other side without loosening it. I'm sort of hoping that you guys'll say, "Don't worry about it, it won't hurt anything", b/c I'm exhausted and sick of this car today and I don't want to screw with it anymore.

Here's the pic with the nut I'm concerned about:
850999_9_full.jpg
 
If it is turning then you need a new end link, about $32 each at the autoparts store. Sounds like the ball joint section is bad.
 
Ok, first of all, this isn't as easy as it looks. The instructions don't tell you how long it takes to loosen each and every bolt and nut, or how long it takes to pound a bolt out of its housing b/c it's so tightly corroded. I used half a can of PB Blaster today, and I had already sprayed everything last Wednesday. Make sure you have deep sockets, because the upper bolts in the engine compartment have very little angle to use a wrench and the bolts are so long a regular socket won't work. Make sure you have a VERY BIG WRENCH for the lower control arm/strut bolt. Even with an oversize wrench I had to put my entire weight on it to get it to budge. Tapping it out is very difficult, since there are metal hoses in its path. It took me 20 minutes of maneuvering, jacking up and down the control arm, and wiggling for EACH BOLT to get them free. Same thing for the knuckle/upper control arm bolts. 20 minutes each. I had to run out twice for tools because I got stuck. Oh, and when it says, "Peel back the inner fender cover," FIRST look for the plastic double pin holding it in place. You have to remove the insert pin first, which will allow the outer pin to release from the fender well. THEN you can peel back the inner fender cover. That pin gave me a lot of trouble until I figured out what it was.

Also, the replacement strut is not compressed, so the lower control arm has to be jacked up to put the bolt back in. Not only that, but I found out that the only way that you can hold the assembly in place under the car while putting nuts on the bolts in the engine compartment is if you're...SUPERMAN! That assembly weighs, I don't know, thirty or forty pounds? I had to use a jack to lift it into position, then get up and work in the engine compartment.

This is not a knock on Black Ice or anybody else who has been so helpful. I just want to be real and truthful for those of you who, like me, may have read these instructions and got the idea that this would be a piece of cake. And have never done this before. A few parts of it were easy. But mostly it was back-breaking, hammer-pounding, grime-covered labor. I would recommend to anyone who tries this to be in a spacious area, with access to specialty tools as well as standard tools, a lift, and definitely some power tools and maybe even some air tools. I could have done this in two hours with air tools and a lift. Also, read the instructions and study the photos over and over again before starting. And be prepared for things to go wrong. They will. I apparently did everything the hard way.

I did have a laugh, though. Despite Black Ice's warnings not to be alarmed when the air came out of the air bag in a rush, it literally scared the bejesus out of me. I had pushed the solenoid out to the first stop, where it snapped tightly into place. I mistakenly thought that it had released the air. Then I twisted it to the second stop, and WHOOOOOOSSHHHHH! I flattened myself against the wall on my butt, heart pounding. Then I started laughing. That air pressure noise is no joke. I was ready for it the second time.

All in all, except for the fact that I now have a ruined end link, and that I didn't get to the back today, I am satisfied with the results. Of course, now that the car is lower in the front and stock in the back, I look like I have some sort of hot rod. But that'll change tomorrow.

Thanks to Black Ice LSC for his directions. I couldn't have even gotten to first base without them. And thanks to Eddie at American Air Suspension for selling me the set of coil overs (that are apparently manufactured by Strutmasters.com). They are tough-looking parts and seem sturdy. I know I will be pleased with the car's new height. With just the front done, I can tell the ride is no worse than the air ride was, and that's good enough for me. No more collapsing suspensions, costly repairs, or error messages for me!
 
Fossten...man...I had no idea you struggled so much.

Now, I dont wear a suit and a cape, but the new assembly IS compressed/assembled, and weighs about 34 lbs each...one hand holds it up in there, while the other threads one top bolt to hold it for you.


Hey Joey??? where are those NEW instructions I sent last week??? They would have saved this poor guy's bacon...
 
Hmmm...the assembly I got wasn't compressed. Which I thought was weird, since the Monroe sensatracs I bought for the rear were compressed with wires.

BlackIce, you're instructions were great. I couldn't have done it without them. I just got beat up by Murphy's law and my own inexperience. I still got the job done, it just took longer than I expected. I'm tackling the rear tomorrow. I'm sure it'll be easier. I even got new shocks and upper shock mounts.
 
Ok, the back is done and my new end link is on. I just took the car for a ride. The suspension responds great, the ride is about the same as the air ride, maybe just a hair rougher, barely noticeable. But it corners better and looks better, no more SUV off-roader look. Also I have the confidence of knowing that this suspension will outlive my car. I also now have a suspension change under my belt, and I understand better how this stuff works. I'm going to replace all the bushings on the rear end links now, since they are old and cracked. Eventually I'll replace the upper control arms in the front since their bushings are old too.

For anybody who wants to do this: Wrenches and jacks is the HARD WAY. DO IT THE EASY WAY, WITH AIR TOOLS AND A LIFT. Even the back took me 5 hours.

I decided not to replace the rear shocks today, mainly because I will have to crawl inside the trunk to examine these contraptions they are hooked to. Anybody worked on these? Are they not too complicated?
 
That's great. I considered the conversion, but I like the air ride much better. Now you are going to have to get rid of the message that says Check Air Ride System now.
 
How hard or how easy something is, is all dependent on your own mechanical abilities. That goes for ANY vehicle repair! Only you know what you can handle. Whats hard for one person, is a breeze for others. All these forums are for the do-it-yourselfers to help you save money by working on your car yourself. All the guys that give advice have no idea of your own mechanical ability and all we can go on is the majority. If you have 30 people saying..."its a piece of cake job", thats what you go by.
 
American Air-1 said:
How hard or how easy something is, is all dependent on your own mechanical abilities. That goes for ANY vehicle repair! Only you know what you can handle. Whats hard for one person, is a breeze for others. All these forums are for the do-it-yourselfers to help you save money by working on your car yourself. All the guys that give advice have no idea of your own mechanical ability and all we can go on is the majority. If you have 30 people saying..."its a piece of cake job", thats what you go by.

Even if everyone had described it to be as difficult as I myself experienced, I still would have attempted it, b/c I don't want to pay labor. What really helps, though, to be fair, is to describe actual pitfalls and mishaps that can trip up any amateur. For example, each time I did the second wheel of the front and the back it was easier, since I knew what to expect. There was nothing wrong with Black Ice's instructions. What I encountered falls outside the scope of the directions, though, and into the category of what can go wrong and how to be prepared for it. One thing that really helped was a PM I got from BlackIce that told me to use a hammer on the clips holding the air bag into the lower control arm. That warning literally saved me probably an hour of frustration. I just banged it once or twice and it popped free.

EDIT: Gman, the reason I did this conversion is that I have already been burned for over $1500 before for the front about 3 years ago, and the back sometimes is on the ground in the morning, and the front driver side fell down while I was on the highway the other day. I realized this was going to be a never ending thing, and I was tired of worrying about it, so I decided to end it once and for all. Believe me, I would much rather keep a perfectly functioning and reliable air ride system, but I had had enough. If it wasn't the compressor, then it was the sensor, or maybe the air line, or the bag, who knows?
 
I honestly didnt think to put my article into layman's(sp?) terms. I often forget that until I myself had tried to navigate uncharted territory, I was just as lost as you were.

I think I need to go back and adjust my tech article slightly. The problem is, I assumed most who would dig in to a task like this, would be familiar with the basics(splash shield clips, etc).

Foss, those mechanical devices are called "rear shock actuators". They are a built in "anti-dive" device. You can un-clip them, and remove them from the bracket that holds them above the shock. You dont need them. New shocks are dual action with anti-dive features already built into the valving.

I went with the Monroe sensatrac part number 5965 for a 92-97 T-Bird(non-sport/SC) direct replacement, dual action shock that will compliment your new front gas shocks perfectly.

You did yourself proud pal. I should have warned you...working in cramped spaces, with the wrong tools makes ANY task unbearable...but you did it. I just hope your posts dont scare others away from doing this job.

The right tools, a clean, well-lit work area, time, and room to manuever are key. I have the luxury of air tools and a lift, which is why I take the time to make descriptive posts/how-to articles, so the do-it-yourselfer can determine if this is a task they wish to partake. You tried it, and succeeded...you must feel pretty stout right about now. I know I did.
 
BlackIceLSC said:
I honestly didnt think to put my article into layman's(sp?) terms. I often forget that until I myself had tried to navigate uncharted territory, I was just as lost as you were.

I think I need to go back and adjust my tech article slightly. The problem is, I assumed most who would dig in to a task like this, would be familiar with the basics(splash shield clips, etc).

Foss, those mechanical devices are called "rear shock actuators". They are a built in "anti-dive" device. You can un-clip them, and remove them from the bracket that holds them above the shock. You dont need them. New shocks are dual action with anti-dive features already built into the valving.

I went with the Monroe sensatrac part number 5965 for a 92-97 T-Bird(non-sport/SC) direct replacement, dual action shock that will compliment your new front gas shocks perfectly.

You did yourself proud pal. I should have warned you...working in cramped spaces, with the wrong tools makes ANY task unbearable...but you did it. I just hope your posts dont scare others away from doing this job.

The right tools, a clean, well-lit work area, time, and room to manuever are key. I have the luxury of air tools and a lift, which is why I take the time to make descriptive posts/how-to articles, so the do-it-yourselfer can determine if this is a task they wish to partake. You tried it, and succeeded...you must feel pretty stout right about now. I know I did.

You're exactly right, and thanks for all the help. I definitely learned a lot, and now I own a lot more good tools.:L
 
fossten said:
You're exactly right, and thanks for all the help. I definitely learned a lot, and now I own a lot more good tools.:L


so, how about some pics! No...not of the tools... of the new ride...cant wait to see it!
 
BlackIceLSC said:
so, how about some pics! No...not of the tools... of the new ride...cant wait to see it!

I'll post some pics tomorrow. My chrome stripping is coming in I hope, so I may install that first.
 

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