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Old 11-30-2004, 11:16 AM   #76
gotsol
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I don't think you'd have to, I was able to wiggle the strut top to where the ID hole went over the middle step. the problem was where the top of the step sits higher then the nut seat (that sounds strange).

So if you have a washer large enough to fit over the top of the step, the washers and nuts will keep it all tight.

But yes, I'm sure you could machine the v7 if you wanted to do it that way.
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Old 12-16-2004, 11:25 PM   #77
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anyone know the exact diameter of the middle step on the AGXs? mine started clunking after 4 months of almost no clunk. i dont' want to take the struts out of the car and measure them since it'll throw my alignment all out of whack.

the diameter is def. more than 16mm for that middle step. i guess if noone responds by tomorrow afternoon, i'll just get some 18mm ID by 30mm ODwashers, some 19mm ID by 30mm OD washers etc. till one of them fits. also, how thick do the washers need to be stacked? 10mm?

btw, can we sticky this thread? it has some invaluable information in it.

Last edited by MRF582; 12-17-2004 at 12:12 AM.
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Old 12-17-2004, 07:42 AM   #78
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did you use any washers when you first set it up?
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Old 12-17-2004, 09:33 AM   #79
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no i didn't add any washers.
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Old 12-17-2004, 11:22 AM   #80
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wooHOO!!!!! the left rear clunking is gone. i ended up using a 16mm ID washer. actually it was a lock washer which kind of looks like it's part of a coil with a cut in the middle and one 'end' raised above the other slightly.

anyway, i think a regular flat washer would've worked too. i only needed one washer for now. i couldn't get grade 8 hardened washer in a size that fit b/c the OD was too big for the hole in the strut mount. otherwise i would've went with a 5/8" grade 8 washer. instead i had to go with the metric 16mm washer which is equivalent in hardness to a grade 5 SAE washer.

chances are that in time this washer will get crushed to the point where it'll start making the noise again and i'll add another washer then and that should be the end of that. the right rear hasn't clunked yet but i'm sure it will. however this time i'm ready for it armed with washers and a cordless impact.

unfortunately, ALL of the rear suspension noise isn't gone. welcome to the land of imprezas eh? there's still a squeaking type that seems to happen when both tires go over a speed bump simultaneously. the sound isn't nearly as bad when only one tire goes over a speed bump. i'm thinking it might be the swaybar bushings which i did not lube when i put my 22mm adjustable helix RSB in.

the squeaking and stuff i can deal with but it's the hard clunking that you can sometimes feel through the chassis as you're driving is what is really annoying.

another source of squeaking creaking in the rear might be b/c of the geometry of the rear suspension. after reading a LOT of posts on here about it, it seems the shaft of the strut is rubbing against the spring during certain situations. oh well, that's for another day.

cliff notes :

if you are using 04 tophats/strutmounts with 04 springs with 02/03 KYB AGXs, just a 5/8" grade 8 washer or a 16mm washer. you can use a lock washer if you want but i don't really think it matters. if clunking is not gone, use at the most 2 washers. assuming the washers themselves are about 2mm thick.

thank you for all the input people have put in this thread. it's threads like these that make NASIOC what it is. none of that OT bs. good luck to all future readers of this thread.
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Old 12-17-2004, 12:52 PM   #81
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Great news! Keep us updated throughout the months. Glad this info could help.
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Old 12-17-2004, 01:10 PM   #82
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well, after generously spraying the bushings and sway bar endlinks down with silicone lubricant and secruing the spare tire, the squeaking, clunking, noise is ALL GONE. i'm sure the silicone lubricant will wear out soon but i just wanted to see if lubing it will help. i didn't take the sway bar mounts to get grease between the swaybar and bushings but one day i'll do that.

i'm so happy!!! no squeaks just a nice 'hiss' sound...music to my ears
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Old 12-17-2004, 01:35 PM   #83
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On poly bushings I use Marine Grease. It holds up the best against water and grime. Don't use lithium grease it absorbs water and gets all puffy and falls off.
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Old 12-18-2004, 02:23 PM   #84
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All, I installed the 02/03 konis on my MY04 wrx wagon w/Tein H-Tech springs. I had no issues with fit. I did not use washers/spacers or anything. Used the stock tophats and everything worked fine.

No clunks or any problems.
I have 10-15k miles on it since then and still all is great. Just an update....
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Old 12-18-2004, 11:53 PM   #85
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That's great to hear. I figure, its a YMMV type situation. Some folks get lucky, some don't, but at least we have a good idea what the cause may be if the dreaded knock rears its ugly head.
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Old 12-30-2004, 12:36 PM   #86
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Just thinking out loud- what about a thin nut (jam) that was rounded to approximate the shape of the v8 run all the way down on the v7 strut

This would take up the slack, have correct shape and hopefully still have enough engagement on the piston for the top nut??????????

Had another thought- would machining the piston on the v7 to match the v8 cause too much heat where the gas inside the strut might be a concern- I'm not real familiar what kind of heat a lathe cutting the piston would produce????

Big Sky
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Old 12-30-2004, 02:13 PM   #87
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Quote:
Originally Posted by BIGSKYWRX
Just thinking out loud- what about a thin nut (jam) that was rounded to approximate the shape of the v8 run all the way down on the v7 strut

This would take up the slack, have correct shape and hopefully still have enough engagement on the piston for the top nut??????????
i'm having trouble differentiating this from a washer. the washer that i have in mine, goes around the V7 thicker part of the threaded piston top and 'raises' the floor so it fills the gap from the bottom of the threaded nut and the piston.
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Old 12-30-2004, 02:55 PM   #88
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Quote:
Originally Posted by MRF582
i'm having trouble differentiating this from a washer. the washer that i have in mine, goes around the V7 thicker part of the threaded piston top and 'raises' the floor so it fills the gap from the bottom of the threaded nut and the piston.
I guess I've mis-envisioned where folks were putting the washer- it's going around the thicker portion- not the threaded shaft itself.

What about something that slipped over the threaded portion, a sleeve of sorts that could be rounded to mimic the v8 and fill the voided space? Or a couple of washers to fill the void and the rounded sleeve used in conjunction w/ it?
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Old 12-31-2004, 01:44 AM   #89
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Quote:
Originally Posted by BIGSKYWRX
Or a couple of washers to fill the void and the rounded sleeve used in conjunction w/ it?
that would work. although i don't know how beneficial it would be. as of now my rear suspension is not making noises. well almost. there is a very very very slight noise which seems to be b/c the v7 strut is not chamfered. but i don't think i'll bother with it.
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Old 12-31-2004, 08:44 PM   #90
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Yeah, mine seems to be fine once I threw some washers on it. The only thing is they tend to stick to the top hat after a few thousand miles. The only way I could get the top hat off to put on my STi Pinks was to just take off the top nut without any spring compressors, and the spring popped off the top hat that way.
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Old 02-01-2005, 11:22 AM   #91
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Does anyone know what the OD of the "middle" step on the 02 strut shaft is?

Thanks,
Jon.
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Old 02-01-2005, 05:54 PM   #92
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My setup: v8 Jdm pinks/Tokico D-spec strut/GroupN tophats 03 WRX

Ok, I installed the v8 pinks onto a v7 design strut (tokico d-spec) mainly because the vendor sent me the wrong springs and the v7 were difficult to find in stock. And I like the v8 pinks spring rate a little bit better.

I'm hearing a dull thud type of noise from the rear on small sharp bumps (ie like small potholes as opposed to the usual cracks in the road). What could be causing this? I've checked the top bolts and they are tight (couldn't move them at all)
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Old 02-01-2005, 06:33 PM   #93
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gogitawrx - It could be the ill fitment of the 04/05 top hat to the 02/03 designed strut. See the beginning of the thread for more detailed info.

Jon - I'm afraid I don't have access to my stock 02/03 struts but I'll keep you in mind with my measuring calipers at the ready next time I mess with a strut install (probably this or the following weekend).
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Old 02-01-2005, 07:27 PM   #94
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Too bad you didn't post a couple of days earlier- I had all versions of struts disassembled
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Old 02-01-2005, 07:38 PM   #95
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Arnie, I will be checking the rears this weekend. It feels and sounds like going over a expansion joint when going from a smooth to rough surface back to smooth again.

I may be just over-reacting, over-cautious with the much stiffer suspension (this is the first time I've had this stiff of suspension).
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Old 02-01-2005, 07:50 PM   #96
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Well there is certainly an increase in NVH to be expected from the Group N tops going over certain types of road surfaces. So that may be it. If its solid knocking coming from the rear, it may be the hat/strut compatibility.
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Old 02-01-2005, 08:27 PM   #97
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Thanks Arnie. Very helpful.

The streets around here are not the greatest and it actually takes alot for the car to make it loud enough to be heard. And its not solid (though I do feel more of the road surface which I know is normal) just when hitting really rough spots.
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Old 02-01-2005, 08:29 PM   #98
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Quote:
Originally Posted by gogitawrx
Thanks Arnie. Very helpful.

The streets around here are not the greatest and it actually takes alot for the car to make it loud enough to be heard. And its not solid (though I do feel more of the road surface which I know is normal) just when hitting really rough spots.
Keep us informed on your setup. I'm sure there are lots of 04 owners curious (I included) with your setup since there aren't any adjustable struts for 04s on the market, except for STi. How do you like the D-specs?
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Old 02-01-2005, 08:44 PM   #99
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Are you using a washer? Even if the top nut is tight there can still be slack w/o the use of a washer- if there is slack, there will be a thunk.
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Old 02-01-2005, 09:20 PM   #100
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Big Sky: I have one grade 8 washer underneath. I will be checking this on Sunday. I may need another underneath there. May just be me.

Zuffy: So far I like them, but I have some "playing" to do to find the right combo for the damping (way too much adjustibility). The only thing that I don't like is I will have to remove the rear seat to be able to adjust the rear damping.
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