OE springs don't fit brand new KYB GR-2's

[hercdrvr2000]

I have a stock 2003 LE with 4 cyl. I have 124k on the car and developed a clunking in the L. rear when going over speed bumps or pulling into driveways, etc. I jacked the car, removed the wheels and inspected everything. The only thing I found was some worn rear sway bar bushings. Replaced, no prob.

I decided it was high time I replace the struts/strut mounts/bellows - the works. I removed the rear struts and ordered 4 new KYB GR-2's - correct part numbers as researched on the KYB site. I thought I could swap the rear, jack the front, replace, align and away we go.....OH NO!!!

Now my problem...

The original springs - both front and rear, which I don't intend to replace, have a reduced diameter of the spring bend on the bottom which fits into a notch on the spring plate welded to the strut. The spring isolator is made to fit this notch on the OEM strut and the spring bottom sits in this notch - not on the outer lip of the plate. The new KYB's do not have this notch. I ordered new spring isolators and they fit the outer lip of the spring plate - not the reduced dimension of the bottom loop of my actual spring. Are there two different spring designs on these Camrys? The plate that the bottom of the spring rests on is totally different between the KYB and the original as is the spring isolator gasket. See pics below.

Please tell me how I'm supposed to put this back together. I waited a week for these KYB's to be shipped. Nobody, other than the dealer, has struts for this car in stock (small town). I don't see any way to use these springs with these KYB struts. We won't be keeping this car more than a year or two so I don't want to replace the springs unless I have to. I'm just amazed that these KYB struts which are supposed to fit this car, don't have the same spring notch as the OE struts.

I will say thanks now. I really appreciate your knowledge and help.

Old vs. new - pointing to spring notch - you can see lack of notch on new KYB on the right.



Old assembled strut showing how spring sits in notch.

[gdanaher]

Assuming you have the correct part numbers, 334340/341, you should take some close up photos and be on the phone to KYB America. They have overlooked something, you have, they shipped the wrong parts, something. Talk to them this morning.

[ASG14]

Unfortunatley, I am not too knowledgeable ont he gen 5 suspension, but I think your OEM struts/springs are that of a 2004. The TRD springs I have installed in Gen 4 Camry's/Gen 1 Solara's use the same springs up to 2003, and do not look like that. Those look like my mom's '05 Springs. I'll have to take a look later.

What is the build date of your car?

[ScrooYoo]

I also have an 03 LE. I replaced the OEM struts with KYB's, then later replaced the KYB's with OEM SE struts. I don't remember running into problems with the springs when I put the KYB's in.

I actually still have the old KYB's with the OE springs on them sitting in my shed. I'm at work now, but I'll go take a look at them for you tomorrow morning and let you know if they have a notch or if maybe your springs are different than mine.

[ASG14]

Just checked, my mom's 05 has the ones like you. You have the '04+ suspension if I think right.

[hercdrvr2000]

ASG14-

You may say you don't know the gen 5 well but you were spot on with your analysis!

I know the car has not been modified because the factory put some paint markings on the top of the struts. Those marks were painted over the nut and bolt on the top of the strut. When I removed the strut from the spring, the paint shattered - almost like a wax seal. Therefore, I am sure these struts are OEM and not something a previous owner installed.

My Camry is a domestic build from KY. The build date was 08/03. According to KYB tech support, Toyota claims that they didn't switch to the 2004 style strut until 09/03. So, either the sticker on my car is wrong or they switched a little earlier than they say. Either way, after crosschecking the part number from my current struts, I definitely need the "04-'06 style strut. KYB gathered VIN, part numbers, photos etc and will follow up so hopefully it will help someone else later.

Another surprise I found was that the left rear strut had the nut spacer mounted UNDER the strut mount. This would not allow the notches at the top of the strut to engage into the mount. I had a difficult time removing the top nut because the strut shaft kept spinning. I wonder just how much torque was actually applied to the nut when it was installed? I think I found the source of the clunking. Some genius in KY back in late 2003 assembled the strut incorrectly and the nut was never torqued down well.

Thanks for you help!

[ASG14]

Just so you do not feel alone. The Gen 4 TRD rear sway bar fits the Gen 3, BUT you need the Gen 4 sway bar bushing bracket. I told this to one person with a '96, who's family was the original owner (never been touched). He then realized his '96 HAD the Gen 4 brackets. I told him look at the build date, I bet it;s the last month of production. And? It was. Near the end, if they run out of the parts, they will but on the newer one, which it seems liek they did to you unfortunatley.

If you like, PM me your VIN number and I'll check it at the dealer tomorrow. I'd like to see what the computer shows as your struts/springs being. It SHOULD show you as having the 04+ ones.

Also, are you the original owner? If not, I'll check to see if there was some sort of work done in the past on your car which may accound for this.

Glad I can help out.

[hercdrvr2000]

ASG- No thanks - not needed. I spoke with KYB tech support and they crossreferenced the part numbers off the struts on the car. I definitely have the '04-'06 struts - front and back. The only visible change was the design of the spring and spring seat. I now know that I need KYB #334386/387/388/389.

No need to check on anything else. All I have to do now is go through all the shipping hassles. At least I know how to fix it.

Thanks again.

[hercdrvr2000]

ASG- Also wanted to say your XLE looks sweet! The pics of it completely gutted are scary for me but it looks like it turned out great. TURBOCHARGED?!?! SWEET! I wonder if the wifey would mind if I.......