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Just got done installing new rear struts and springs. What a PITA!!!

11K views 26 replies 11 participants last post by  NJMIKE  
#1 · (Edited)
The main problem is rust in an 11 year old car. Every bolt was frozen. I used the best...Kroil, to loosen them, applied heat and an impact gun...but no go. A nut cracker would not fit over the main two 19mm nuts, because of interference from the mount flanges. I ended up using a small die grinder (dremel sized) to cut, laboriously, through each nut. Then came a nasty surprise. The dealers don't stock the mount bolt and nuts. They had to order them which takes a couple days.

It took about 4 hours to just do the rear mounts (after wasting too much time trying to free the nuts.) I had to stop there...to order new bolts and nuts...but was able to get and salvage enough bolts and nuts to reassemble the rear.

With new rear mounts, bumpers, Tokico struts and Vogtland lowering springs, the car was hugely stiffer in the back. Before, just one person sitting in the back and a mild bump was enough to bottom it. With three people in the back the tire was sitting with 1/8th inch of room between the tire and fender and the mildest turn caused the tires to scrape. Now I could stand on the door sill in the back and jump up and down and still have more finger room between the wheel and rim.

Driving feels funny...you get even more motion in the front as all load inputs are transferred from the stiff back to the front causing the front end to yaw...like a boat accelerating and turning. Yet, strangely, it handles better than when both the front and back were soft. I tried to see if I could break the rear loose by tossing it around but the inch and a half of lowering seems to counteract the stiffness and it stays well planted. Getting on the juice when coming out of a corner appears to cause about the same amount of wash out and understeer as before.

As far as ride, it definitely feels stiffer in the back...but not worse than my Acura TL...not excessively so. The ride is much quieter....without the old loose mounts knocking over bumps and without the tires scraping. Funny, I hadn't really noticed the suspension noise coming from the front, because the rear was so noisy but now I do.

I can't wait to get the new front and rear shock mount bolts I ordered so I can get the full effect of the suspension upgrade....though I'm less enthused about dealing with another half dozen frozen bolts and nuts.

FYI, the stock shocks were shot...but mostly in compression. The extension damping seemed to still be pretty good. This masked how bad the shocks were doing the shock test where you push down on a corner and wait to see how quickly the car damps out. It would damp well on each rebound and only cycle maybe three times. Not great but the reality was it was much worse in actual driving as it didn't damp at all on compression. After the changing the rear strut and spring it damps in one cycle...barely traveling over center. The front is a pogo stick in comparison.

Here is the Vogtland spring compared to stock.
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Here is the Tokico strut with Vogtland spring assembled compared to stock (with spring compressors.) The Vogtland was short enough and soft enough at the travel top not to require compressors to install.
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#2 ·
I removed the brake back plate to provide easy access to the 19mm mounting bolts and I am glad I did. I discovered a fair amount of rust from water leakage which was about to get into the axle hub bearing. I cleaned things up but had too much pitting for a new Oring to seal so I used a bead of red RTV. I have a 99 Avalon. Now I know my bearings are dry and will stay that way until they fail from something other than water exposure.


With the backing plate off, I could get a square bite on the 19mm bolt. Using a breaker bar and a 16" pipe wrench for an extension, the mounting nuts cried "Uncle".
 
#3 · (Edited)
I thought of removing the brake rotor, but was afraid I'd open a whole 'nother can of worms. I could imagine the brake bolts shearing off in the knuckle. :eek: Also, access to those bolts looked as bad, or worse, than the access to the strut bolts. How did you approach them and did they stick badly too? I will have to deal with the brakes eventually. The rear pads look a bit worn and the rotor more so.

There was a hellacious pile of rust underneath the wheel when I got done. I wasn't sure where it was all coming from.

P.S. I have an 18" breaker bar but darned if I could find a pipe around here to add to it. Must have thrown them all out during the last garage cleaning. I also have a "625ft.lb." HF impact wrench but that didn't budge it.
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#4 · (Edited)
Today I did the front springs and struts. The entire job took 2 and a half hours...much better than the rear. No seat to remove to get at the top of the towers. More clearance around strut bolts...freed up with 25" breaker bar...no nut cutting and splitting required.

The new Vogtland front springs were stiffer (then the rear) and therefore required a spring compressor to assemble onto the struts.

The old OEM Toyota shocks were really shot (the Avy is at 105,000 miles and I don't know if they were ever replaced.) When bouncing the front of the car up and down you could hear them hissing. When I lifted the removed shock by the top of the piston shaft, the shaft just slid out of the piston...in a second. There was effectively zero rebound damping. The front springs, on the other hand, looked fine, unlike the rear ones that had sagged. I had to replace the front springs anyway, with Vogtland, to match the lowered rear springs. The front pillow bearing looked new. I suspect the previous owner must have had it replaced...maybe because of the front end noise. He should have replaced the shocks as well. In the end, there were parts that definitely didn't need replacing. The upper front shock bracket is a simple piece of steel that bolts to the body. I could have saved a few bucks not buying that. The front strut bolts were salvageable, though I replaced them with unrusted new ones.

After buttoning it all up the first thing I noticed was the height. The car seemed wayyy lower. It is surprising what 1.8" of lowering feels like. Took it for a test drive and it was insanely better. No more knocking sounds from the front shocks. I was surprised to find the ride still quite soft...softer than our '03 Acura TL. It still feels loose during sudden steering inputs, but corners much flatter and assuredly. The stiffer Tokico shocks and lowering springs by no means turned the Avalon into a sports car....or even a sporty car, but they do improve handling.

P.S. There isn't any camber adjustment, in the Avalon's front suspension. Lowering the car increases the negative camber...and toe-in. The toe can be adjusted as in all cars. I'm going to have to measure the camber to decide if it is too much. If so, will have to find an aftermarket camber adjustment kit.
 
#21 ·
I was flipping through my owner's manual the other day (probably a textbook definition of boring) and found that my 97 has a lifetime warranty on the shocks and struts to the original owner of the car...that's me!!
Where do you find that in the manual? My struts/springs both need to be replaced desperately!

P.S. There isn't any camber adjustment, in the Avalon's front suspension. Lowering the car increases the negative camber...and toe-in. The toe can be adjusted as in all cars. I'm going to have to measure the camber to decide if it is too much. If so, will have to find an aftermarket camber adjustment kit.
I am wondering what the verdict is witht he camber on the Vogtland springs. I'd like new springs when i replace the shocks but am concerned with all the extra things that then have to be changed as well...such as addition of a camberkit.

I wonder if using the Vogtlands will even make a drastic change due to how badly my springs are worn and sagging right now. Car has 245k miles on the original suspension.

I love the way your Avalon sits, though! Looks great with the wheels, too.
 
#10 · (Edited)
Those are 17" 215/50 series and with the wheels, from TireRack, they sit inside the fenders. If I recall, the back was lowered .2" less than the front. I think that makes sense, since the back will move more under load. This is because the back runs softer springs (less weight) and will move more when people are in the rear seat. Spare is in back. Mine didn't come with sub so I installed one under the driver's seat.

These tires rubbed, in the back, with the stock suspension and there is even a little rubber missing from one of them from the scraping. I haven't had a problem the new suspension, other than when hitting speed bumps a bit too fast. The problem would go away if the rear fenders were rolled and you could probably even get away with wider rubber if you did that...maybe 235.

Practically, I don't think I'd want to go lower. Lost almost 2' in ground clearance and I have to be a lot more careful what I drive over and of parking lot curbs. My regular floor jack no longer fits under where I used to jack it up and I now have to use a low profile jack.
 
#11 · (Edited)
Your car looks great! Just wondering: did you have to use special, shorter struts/shocks with the lowering springs or would stock-spec struts/shocks work? On my '85 BMW 6 series I had to get Bilstein "Sport" (as opposed to "standard") struts/shocks when I installed a set of Eibach lowering springs. The "sport" versions are supposed to be slightly shorter, to work with shorter springs.

The PO of my '96 Avy had recently installed new Monroes front and rear; if I install lowering springs it'd be a shame to let them go to waste.

Where did you buy your parts? From the short time I've owned my Avy it seems like it could benefit from larger front & rear anti-sway bars, if nothing else.

It's amazing how much more driving enjoyment you can get out of mods like this. On my previous DD, a '96 Accord, I installed Tokiko shocks, H&R lowering springs, and a rear anti-sway bar, plus camber correction kits front and rear and 16X7 alloys with Yokos. The car handled like a real sports car; would out-corner Porsches through the local canyon roads. It was actually more fun to drive than my BMW.
 
#12 ·
I'm using stock Tokico shocks, which I suspect, are the same ones they sell with VogtlandSuspension sells with their lowering kits.

The Avy drives much better...much less dive and roll. The weak link now is the sloppy steering. I'm not sure how much of this is age and how much is just what you get with the Avalon's steering. The steering is a bit of a weak link and will need replacing soon. Mine is making a clicking noise, which makes me think a gear is on it's way out.
 
#13 ·
How much is your camber off since you've lowered the car? Is it very noticeable?

As nice as it looks though, I'm not sure if I want to lower my car and deal with ground clearance and camber issues (I've got to keep in mind this is supposed to be my wife's daily driver). However, I WOULD be interested in a rear sway bar.

I've done some searches and it seems there aren't many vendors who supply performance parts for Avalons and Camrys. Where's a good source for a sway bar and other performance goodies? Can I safely assume that any suspension parts for a 3rd generation Camry will also fit the 1st generation Avalon?
 
#14 ·
I didn't measure the actual camber but I haven't seen any tire wear issues (but it's early yet), and it handles much better...especially when pushed hard. Worst case I'll buy one of those camber nut adjustment kits, but I suspect it is fine the way it is. Keep in mind, this car (and I've seen others like it) had trashed rear springs and was riding low to begin with....for a long time. I'll take a camber gauge to it and report back here when I get some time.

The ground clearance is, IMHO, the biggest compromise. Having said that, I've never bottomed any underbody components since making the change. I wouldn't be surprised if it actually has better dynamic underbody clearance because of the stiffer springs and shocks. Before, the wheels rubbed inside the fenderwells way to often...now, it never happens. I've only noticed the lost clearance when jacking up the car to change the oil, and when parking up close to curbs. Before those curbs were rarely an issue, now I have to park it more care, like my Acura...or how you would most modern cars with their lower front ends and air dams.
 
#15 · (Edited)
Lost two of the aftermarket wheels to potholes and the third one to an unfortunate intersection mishap. The wheels were no longer available so had to replace all 4. This time I bought a name brand, vs. TireRack's "Sport" brand. I'm hoping Konig's will be easier to find if I need to replace one. These are also, fairly light, at 17lbs. Probably 5 pounds lighter, which really helps performance.

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http://www.discounttire.com/dtcs/wheels/konig/product/submitProductSize.do?v=006904|1999&r=MIDINT|pc|48304&pc=61241
 
#17 · (Edited)
No sag whatsoever. Interestingly, the OEM rear springs had sagged real bad. I'm surprised more people haven't had that issue.

The car handles much, much better with the stiffer springs and shocks, but, as you'd expect, the ride is a bit harsher (the lower profile wheels contribute to this as well.) The main weakness in the handling now is the steering...which feels really loose. I wonder if there might be some bushings I could change to tighten things up a bit. I suspect the rack is worn as well. There is a ticking sound and I've read the steering rack is a weak point on Gen 1 Avalons.
 
#18 · (Edited)
My rear sags also, and make a lot of noises. Basically the I need a suspension overhaul also:facepalm:. New front sway bar bushing, LCA bushings, alignment, and new struts and springs. Yeah the steering is extremely loose on mine, only had one alignment in its life.:facepalm: Check out energy suspension parts, I got my rear sway bar bushings from them, good quality and it comes with a package of grease.:thumbsup: Also I have some interior rattles that I am taking care of, DYNAMAT FTW!!!. Does anyone else's coin holder rattle? bugs the shit out of me.
 
#19 ·
Nice choice of wheels! They look great, especially with the lowered stance.

My Avy has the 15" 7-spoke OEM alloys, which have a nice style but are scratched up from the PO's curbing incidents and/or careless tire installers. I've been scouring CL looking for an inexpensive replacement set (cost to refinish them would be $125-$150 each) but if I can't find a set by the time I need new tires, I'll probably get aftermarket wheels in 16" or 17".
 
#20 · (Edited)
The Konig's are inexpensive, quality wheels....$118/piece @ Discount Tire.
http://www.discounttiredirect.com/direct/wheels/konig/product/submitProductSize.do?pc=61241&typ=Car/Minivan&tmn=Zero-In
Really like the Lightning's too...but they didn't have those in stock at my local store and I was in a bit of a hurry.
http://www.discounttiredirect.com/direct/wheels/konig/product/submitProductSize.do?pc=64539&typ=Car/Minivan&tmn=Lightning
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You can also refinish the wheels yourself. Mine had horrible corrosion where the wheel weights had dug through the finish, and various curb rash. I had mine beadblasted for $80 bucks, then repainted with about $50 of spray can wheel paint from the auto store. Came out great. I didn't bother fixing all the little nicks...just rounded them off so they weren't as noticeable. Someone mentioned a place around here (Detroit area) that will beadblast and powdercoat for only $200 for the entire set. I'd probably have gone that route if I knew of the place before hand.
 
#24 ·
Will the vogtland springs fit on a 96 avy? I search everywhere and can't find a answer.
I wish i could help you on that you make be able to cross reference it with camry springs honestly its hard finding any info or aftermarket springs for the 1st gens it took me a month of googling the crap out of suspension parts for my 99 to come up with what i wanted...... Best of luck