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Old 11-04-2005, 02:52 AM   #1
sjscooby
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Default 02 struts on 04, washer size?

I've been searching with no luck, can someone tell me how big of a washer i need for my tokicos on my 04 setup? Planning on installing soon and hopefully a quick run to the hardware store is all i will need. TIA

Just to be sure, the washer goes under the tophat or above? I've read posts where people have said one or the other. I thought it being under the tophat between the shaft and top hat made more sense but i may be wrong.
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Old 11-04-2005, 07:53 AM   #2
yobtah
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Quote:
Originally Posted by sjscooby
I've been searching with no luck, can someone tell me how big of a washer i need for my tokicos on my 04 setup? Planning on installing soon and hopefully a quick run to the hardware store is all i will need. TIA

Just to be sure, the washer goes under the tophat or above? I've read posts where people have said one or the other. I thought it being under the tophat between the shaft and top hat made more sense but i may be wrong.
I have Koni inserts intended for '02-'03 struts installed with '04-style rear tophats and springs. I can't remember the washer size right now, but I plan to take them apart today or tomorrow anyway, so I can tell you soon.

I did manage to find some hardened steel washers at Home Depot or Lowe's, but it was harder than I thought. Finding hardened steel washers with a large enough inside diameter and a small enough outside diameter was difficult.

You're right, by the way... the washers go on the top of the strut rod. They end up under (and inside) the tophat. Their purpose is to make the top of the strut rod larger... to allow it to seat inside the tophat correctly. I used three or four washers in a small stack to get very close to the height of the newer style strut rod's "shoulders".
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Old 11-04-2005, 02:01 PM   #3
sjscooby
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cool, keep me updated yoktah, thanks.
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Old 11-04-2005, 04:53 PM   #4
ralliharri
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I was just gonna go to the hardware store myself for these, thought a 15mm hole diameter and around 22mm outside dia and stacked about 9mm high would be good?
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Old 11-05-2005, 07:34 PM   #5
yobtah
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Okay... so I took apart and reassembled my suspension today (again... what a pain in the a**). The washers are 9/16" inside diameter and 1-1/8" outside diameter.

When I removed them from the rear struts, I was able to match them up with an unopened package on my workbench. The package says:

Hillman 9/16" SAE Flat Washers Hardened
UPC code (barcode) is: 0 08236 70652 9
H# 880260 (I'm guessing this is Hillman's product number)

The outside diameter of these is really close to the inside diameter of the '04 style rear strut tops. I think this is good because it prevented them from sliding on each other. They fit tight enough inside the strut tops that it was necessary to lube them with some grease and tap them with a screwdriver to remove them. Nothing like that was necessary when I installed them... I simply kept everything aligned while I tighted the top nuts. That pulled the washers into the strut tops. I suppose you could lube them a bit during installation also.

The washers are between 1/16" and 1/8" thick (around 3/32"). I used two washers stacked inside each rear strut top. That provided enough thickness to tighten the top nuts on the Konis. It's definitely possible to use more... and it may be necessary with a different amount of threads on a different rear strut top. I think you want to use as few washers as possible, however.

I hope this makes sense... and I hope it helps. Let me know if you have more questions.
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Old 11-06-2005, 01:50 PM   #6
sjscooby
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thanks yobtah, that was very helpful . Hopefully i can find the same ones locally.
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Old 03-23-2006, 12:09 AM   #7
mcdrama
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Quote:
Originally Posted by sjscooby
thanks yobtah, that was very helpful . Hopefully i can find the same ones locally.
I assume you are in San Jose, CA? I am too and am having major issues finding the washers I need. I tried OSH and Winchester auto but no luck. I bought some 5/8 ID washers, but the OD was too big. so I put my strut back together, and tomorrow I begin my search again.
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Old 03-23-2006, 02:02 PM   #8
sjscooby
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yup from san jose, i found them at OSH. I think you're the one i sold the fujimoto valve to. I ended up not using the washers, i'm getting an occasional clunk at the right rear which is weird because i don't know if its the top hat or something else.
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Old 03-23-2006, 03:15 PM   #9
Mann Engineering
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Quote:
Originally Posted by sjscooby
yup from san jose, i found them at OSH. I think you're the one i sold the fujimoto valve to. I ended up not using the washers, i'm getting an occasional clunk at the right rear which is weird because i don't know if its the top hat or something else.
Contact Adam at LIC Motorsports and he will be able to help you on the exact spacers. I know he has done a few MY04 conversions for my customers who had 02s but wanted to run 04 springs.

www.licmotorsports.com

Regards,
Gary
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Old 03-23-2006, 03:27 PM   #10
Scooby921
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PM me with an email address and I'll send you the drawing I created for a spacer. I had a couple made when I did my D-specs last summer. If you want, I can have a couple more made and ship them to you.
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Old 03-24-2006, 02:51 PM   #11
mcdrama
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forgot to subscribe to this thread!

I ended up going to a fastener shop and picked up some 9/16 inner diameter, 1-1/4 outer diameter. But I had to buy $10 worth so I have enough washers to do another 2 cars, if anyone needs a set and doesn't want to do the hunting just PM me.
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Old 10-06-2006, 07:27 PM   #12
DomozitoLK
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Quote:
Originally Posted by mcdrama View Post
forgot to subscribe to this thread!

I ended up going to a fastener shop and picked up some 9/16 inner diameter, 1-1/4 outer diameter. But I had to buy $10 worth so I have enough washers to do another 2 cars, if anyone needs a set and doesn't want to do the hunting just PM me.

Sorry to resurrect this thread...but do you still have extras you want to sell? I'm in San Jose too.

Thanks!



Rob
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Old 10-06-2006, 07:31 PM   #13
mcdrama
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yeah, I still have some. though if you have the 04 rear top mounts, you should grind the inside lip to reduce strut compression.
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Old 08-02-2007, 07:27 PM   #14
davisw999
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Can anyone answer a couple of related questions for me? I have an '03 WRX wagon and just installed some Tokico D-spec struts with Tanabe GF210 springs. I bought these used and they are '02-03 model struts with '04 model springs (with the corresponding '04 top hats). The previous owner had them on his '02.
-They installed fine, but my camber went from ~-1.5 all around to ~-.4? I would have thought it would go more neg, not less. Any thoughts?
-Can anyone confirm the torque specs on the lower 2 nuts? The factory manual I was looking at listed ~120 ft-lbs for the front and ~160 for the rear (I'm going by memory at the moment). After I stripped one of the front nuts before reaching 120 I stopped at 100 on all the rest...
-OK, a bonus question: how do you torque the rear nuts? The rear CV joints seem to be in the way to put a socket on them so I had to just wing it with a box-end wrench. Do you use a crow's foot wrench (closed I assume since the torque is so high)?
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Old 08-02-2007, 07:45 PM   #15
TurbojonLS
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1 - You're using sedan struts on a wagon. The geometry is different, and when doing this your camber is ~0.9* more positive.
2 & 3 - I just do all these nuts & bolts damn tight.

What are you doing to adapt the rear struts to the tophats? Hopefully using the Scooby921 adapter from Turn in Concepts...

Last edited by TurbojonLS; 08-03-2007 at 04:07 PM. Reason: Springs, struts - what the difference?
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Old 08-03-2007, 04:04 PM   #16
davisw999
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Thanks for the reply. I guess I'll sell these springs and buy wagon ones, presumably '03 and use my original tophats. In what way is the geometry different for the wagons? I can't even picture how the spring would cause this camber change... I would think that the geometry would be set by the strut. Tanabe doesn't make different springs for the sedan vs. wagon, but I see that Eibach does?? hmmm...
www . tanabe-usa . com/springs/spring_applications.asp?id=3 (note added spaces)

The TiC adapters were not used by the struts' previous owner. If I take them apart for some reason but stick with the '04 hats, I'll buy some.
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Old 08-03-2007, 04:07 PM   #17
TurbojonLS
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Quote:
Originally Posted by davisw999 View Post
Thanks for the reply. I guess I'll sell these springs and buy wagon ones, presumably '03 and use my original tophats. In what way is the geometry different for the wagons? I can't even picture how the spring would cause this camber change... I would think that the geometry would be set by the strut. Tanabe doesn't make different springs for the sedan vs. wagon, but I see that Eibach does?? hmmm...
www . tanabe-usa . com/springs/spring_applications.asp?id=3 (note added spaces)

The TiC adapters were not used by the struts' previous owner. If I take them apart for some reason but stick with the '04 hats, I'll buy some.
Well, I actually screwed up when typing. I meant to say its you using sedan STRUTS that's causing the difference.

I ate up a rear tophat by not using the adapter - I'd order the adapters as soon as you can. It won't change anything alignment-wise in the rear, so it'll just be a quick R&R.
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Old 08-03-2007, 04:20 PM   #18
davisw999
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Really? Tokico specs the same DSP-10 for both sedan and wagon, and websites that sell them list the same too... (I had checked their app charts before I bought these.) The potential effect on the geometry makes sense though.

As you can tell by my join date, I'm a Scooby rookie (got the car last week). I'm still confused about all the similarities/changes between the models/years... Thanks for your patience!
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