Whoa! Not GC mount, Koni Shaft Busted!!!

[JETninja]

How rare is that? I pulled the JL Stealth Box, pulled the Carpet, Looked ok but shaft felt loose. Jacked car.....large washer falls on floor. Get under....hmmm....then grab shock...it's moving all over. Come around to the wheel well, grab shock....shaft is busted! Sheared clean!!!!

This car is driven on the freeway and neighborhood, no racing, no big bumps I try to baby it over bumps. Was fine Friday nite when I took a kid to/from practice. Sat morning taking a kid to a game, go down street from my house slowly as th car is not warmed up, turn left to go down hill and I start hearing the metallic noise that had me make the GC mount post!

The Koni's came on the car, do I have any recourse with Koni or do I just need to pick up one SA?

[POS VETT]

Koni has lifetime warranty. Call them up and explain it. They usually will take your cc number as deposit (they won't charge it) and send you a new shock. If you didn't return the old shock, they will charge your cc. If they determine that the old shock has been improperly used, they will charge your cc. Otherwise, that new shock is free.

[JETninja]

Thanks! Hope they can get one out quick!!!!

[thejlevie]

Hmm, the normal loads on a shock are axial and the shaft should be more than able to deal with those forces unless there was a material defect. However, a broken or loose shock mount or cracked shock towers could subject the shock shaft to repetive bending forces which would concentrate at the shock mount. That could eventually case the shaft to fail.

Might be a good idea to have real good look at the upper shock mount & tower.

[JETninja]

My same thoughts exactly (work in Aerospace) initial brief inspection mount looked ok, when I remove it I'll know better. Doing some home plumbing atm...yeach!

[JETninja]

Ok, removed everything. GC Mount was tight top and bottom. No sign of movement. Use a 1/2 drive from the wheelwell (13mm Socket) to loosen and it was nice a tight. Bottom Bolt (18mm) was also very tight, proper torque.

I snapped some pics of everything. Left a message with Koni NA, hope to hear from them tomorrow.

[JETninja]

And.........

[thejlevie]

The resolution isn't good enough to tell is there were any old cracks. A macro shot of the end of either piece might be informative.

[weenerdog]

Hmm. Maybe that's why a impact wrench is bad! Though, it would be a neat trick to get one in the trunk...

[JETninja]

Impact Wrench? I do not have an air system (not until I get a shed built, and room in my garage) so it's all hand labor. Koni's were part of the Vogtland Clubsport Matched System. Been on the Car for about 2yrs I think.

It sheared right at the point where they turn down the shafts diameter to fit different applications. My neighbor (an old time BMW Parts place dude..Mesa Performance in Costa Mesa) says he's seen lots of shocks do that over the years...even one on a Corolla! LOL!

They are 4mb pics, but I had to resize to 800x600 for the forum.....

[4ZPN]

The ground control RSMs use a urethane mount, which is kinda stiff. This can cause a slight bending on the shock shaft (but I doubt enought to break anything). When I installed my RSM, I lowered the car first and then tightened the top nut that secures the shock shaft to the RSM. This, and a little grease, prevents preloading and keeps things quiet.

[Furious]

oh wow, you werent kidding clean off .. hope you get a replacement asap

[JETninja]

Ok, both Koni (thanks Lee...a member here, owns a '97 M) and GC were very helpful. Lifetime warranty on both is only to the original buyer, but they did sell me one at 1/2 price.

Looking at the guide GC sent me I see two possible things that could have led to this, one the Bottom bushing on the GC mount was in the Race position (compared to Street / flipped position) and I have no idea how tight the upper nut was. It's only supposed to be at 10lbs, GC has a good writeup since its hard to get a Tq wrench on it. Overly tight would add stress to the upper shaft.

I'll be removing the other side and flipping its bushing over, need the shock out anyway so I can match valve setting.

[cozmo kraemer]

Wow...That is pretty crazy!

Should have called me up. I would have talked to Koni to get you your free shock, since I was the original buyer. Good thing it didn't happen at a critical moment. I can't imagine having no damping force entering a corner on a race track.

JET...On, a second note, I still think you are crazy for thinking that car rides stiff ! I always thought it rode like a luxury car

[maq]

JETninja,

Can you tell me the username of the Koni rep on this board? My left rear shock has developed a noise and I'm looking into getting warranty replacement. I sent you a PM. Many thanks.