Hi people, I open this thread to share my experiences installing rear Koni inserts to the AE100/101. There are many threads in this respect, but none for our cars! For example, one of the best I read:
http://forums.nasioc.com/forums/showthread.php?t=1219607
First of all, I live in Costa Rica, and because of the roads here, with potholes every corner, my rear suspension was almost collapsed, too soft and bouncy. About one month ago, I hit one of this asteroid's gifts with my car, and one of the rear shock decided to die in the process. Thanks to Piloter, one of this forum contributors, I have one almost new set of rear Koni inserts, and the last week I decided to install it in my Corolla.
First step, was take the rear suspension out of my car:
![Image]()
My car have a set of rear blue Australian-made-by-Toyota gas shocks, I never saw this setup in other car. By the way, I have a 1994 base model, with almost 170k miles on it. Because this shock's body has less diameter than the KYB OEM, I bought a pair of collapsed shock in the junkyard for about $20. In the next picture, you can see my old setup (right), with the OEM AE100/101 normal setup (left), cut and ready to accept the Koni insert:
![Image]()
But is in this step when the first problem emerged: the OEM strut is too thick, and insert the Koni cartridge in it is a nightmare. You can see this in the next picture:
![Image]()
But with patience, force and a lot of McGyver thinking, you can do it...and then, the second problem shows: the last third of the OEM strut has a contraction, near the base where the suspension arms attachs. Hope you can see it in the next 2 pictures, in the second I draw a pair of yellow arrows where this happens:
![Image]()
![Image]()
When this happens, you can call all the japanese engineers and send them to the h....one day lost!!! But, checking my dad's car (an AE92), in special the rear struts, they are almost the same of the AE100/101, but without the contraction.
![Image]()
Other trip to the junkyard and $20 after, this is what I found:
![Image]()
At last! In the next picture, you can see the diference in thickness, the AE92 to the left, the AE100/101 to the right:
![Image]()
The problem is the base plate (where the spring rest) is smaller in the AE92. Solution: transplant the base plate of the AE100 to the AE92 assembly. This way, the first $20 weren't a waste after all! In the next pictures, you can see the lower part of the AE92 strut (no contraction here), and the assembly completed, a mix of AE92 with AE100 parts. As you can see, I installed on it a set of H&R springs, and when the Konis are set in full soft, they are about twice as stiff than my old OEM setup!
![Image]()
![Image]()
![Image]()
![Image]()
![Image]()
I'm still waiting for the Whiteline rear sway bar I bought on eBay, and because my car don't has front sway bar, I bought an used one, $30 in the same junkyard. All the bushings are in good condition (I tested each one, and can't believe it!) Next step: buy the front Konis, when I have the money for this...I'll keep posting, hope to improve the ride in my car! DTM style anyone??? :facepalm: Just kidding! :lol:
http://forums.nasioc.com/forums/showthread.php?t=1219607
First of all, I live in Costa Rica, and because of the roads here, with potholes every corner, my rear suspension was almost collapsed, too soft and bouncy. About one month ago, I hit one of this asteroid's gifts with my car, and one of the rear shock decided to die in the process. Thanks to Piloter, one of this forum contributors, I have one almost new set of rear Koni inserts, and the last week I decided to install it in my Corolla.
First step, was take the rear suspension out of my car:
My car have a set of rear blue Australian-made-by-Toyota gas shocks, I never saw this setup in other car. By the way, I have a 1994 base model, with almost 170k miles on it. Because this shock's body has less diameter than the KYB OEM, I bought a pair of collapsed shock in the junkyard for about $20. In the next picture, you can see my old setup (right), with the OEM AE100/101 normal setup (left), cut and ready to accept the Koni insert:
But is in this step when the first problem emerged: the OEM strut is too thick, and insert the Koni cartridge in it is a nightmare. You can see this in the next picture:
But with patience, force and a lot of McGyver thinking, you can do it...and then, the second problem shows: the last third of the OEM strut has a contraction, near the base where the suspension arms attachs. Hope you can see it in the next 2 pictures, in the second I draw a pair of yellow arrows where this happens:
When this happens, you can call all the japanese engineers and send them to the h....one day lost!!! But, checking my dad's car (an AE92), in special the rear struts, they are almost the same of the AE100/101, but without the contraction.
Other trip to the junkyard and $20 after, this is what I found:
At last! In the next picture, you can see the diference in thickness, the AE92 to the left, the AE100/101 to the right:
The problem is the base plate (where the spring rest) is smaller in the AE92. Solution: transplant the base plate of the AE100 to the AE92 assembly. This way, the first $20 weren't a waste after all! In the next pictures, you can see the lower part of the AE92 strut (no contraction here), and the assembly completed, a mix of AE92 with AE100 parts. As you can see, I installed on it a set of H&R springs, and when the Konis are set in full soft, they are about twice as stiff than my old OEM setup!
I'm still waiting for the Whiteline rear sway bar I bought on eBay, and because my car don't has front sway bar, I bought an used one, $30 in the same junkyard. All the bushings are in good condition (I tested each one, and can't believe it!) Next step: buy the front Konis, when I have the money for this...I'll keep posting, hope to improve the ride in my car! DTM style anyone??? :facepalm: Just kidding! :lol:
I'll put this link in the 
