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How to: e28 Suspension Install

E28 technical advice asked and given! Troubleshooting, modifications and more.
pstl_pete
Posts: 112
Joined: Oct 11, 2011 4:54 PM
Location: Toronto / Windsor, ON

How to: e28 Suspension Install

Post by pstl_pete »

Hey guys,

I didn't know where to place this but I recently tackled the job of replacing my shocks and springs so I figured there's gotta be someone else doing this that could pick up some tips on how to do it.

I picked up all my parts from BavAuto.com, from a gentleman named Jon Broome. He was super helpful with everything and all my parts arrived in a timely manner. Would definitely use them again.

Here's all that I ordered:

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A full set of Bilstein Sport Shocks, I wasn't about to use the stock shocks with the lowering springs.

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Bav Auto Lowering springs, I decided that these would lower the car just enough to rid some of that wheel gap but not so much that it would affect ride quality. I drive this car everyday so I don't want a stupid low car.

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I also got the shock installation kit since I knew my old hardware would be worn out and with this all being apart it only makes sense to change these items out at the same time.

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The Bav Auto front and rear camber kits were also a must have just in case I want to play with the suspension when I get my wheels on this car. Plus, I knew that the old front strut mounts were in need of replacement so why not upgrade them right?

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I figure if you're going to be doing this job then you'll at least have some type of mechanical experience so I don't need to show how to remove the front strut assembly.

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A spring compressor tool set will be needed to get the assembly apart. I had one but they can be rented at your local auto parts store.

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Take the suspension apart and you'll be left with something like this.

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Here's where I made my first mistake. Instead of trying to loosen the collar nut with the suspension on the car, not knowing better I removed the spring and top hat then decided to have a go at the nut.

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This is a good shot showing how rusted this piece was on my car.

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With a set of massive pliers and a bit of heat I was able to finally crack the collar. For those of you in the rust belt, I suggest first trying to loosen the collar while the suspension is on the car. It will provide you much better leverage than with it out.

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Good thing I bought some new shocks because those look to be well past their prime.

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I was worried that I'd have to reuse the old collar but the front Bilstein Sport shocks come with their own and a nice dust boot as well.

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With the new shock in place I used the same set of large pliers to tighten the collar nut. Technically you should use a special key for this but I'll argue that the pliers do as good a job.

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I slide the plastic collar over the strut assembly as it will be the piece that holds the rubber boot in place.

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Next up, the clean vibrant blue rubber boot is installed.

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Thankfully, I purchased all new shock hardware because my old rubber pieces were falling apart.

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Bav Auto spring goes on.

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Before you put the adjustable shock mounts on, you have to reuse the old spring plate in between. In hindsight I should have bought this new as well since mine was all rusted looking. With the top mount in place use an allen key and wrench to tighten it all up. Do NOT use an impact gun on here. I've seen people sheer the tops off by using an impact gun or similar on this piece.

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All done! Repeat for the other side.

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Reinstall the entire assembly back onto the car...

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At which point you can choose to adjust your top mount to the spec of your choice. I set it up so both caster and camber are zero'd for the time being. I'll go get an alignment after and then spec is some more.

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Moving to the back, the rear shocks are a bit simpler to remove as they require only one lower bolt and three top bolts to free up.

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They still make you to work for it though. The top three bolts holding the shock in place are tucked far back inside the trunk making them hard to get to. Patience was a virtue here.

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On went the spring compressor and off came the top hat.

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This is where I was really happy I'd ordered all those new shock parts, check out that foam bump stop, or should I say lack there of.

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The rear Bilstein's come with a metal ring that sits on the shock body and will hold the spring in place. I noticed the shock is notched so that this ring can be placed lower. At first I thought maybe I should move it but common sense quickly intervened and I left it at the factory spot.

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I slid the new bumpstop and plastic cover onto the shock.

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Then came the fresh rubber spring tenders followed by the Bav Auto springs themselves.

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I should note that when you're taking apart the suspension to keep track of how its all arranged. There are washers that must be reused in the same order as they came off.

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On went the top mount and the same technique as up front was used to secure the nut in place.

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That looks much better than what came off the car doesn't it!

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Bolt that bad boy in place and do the same on the opposite side and you're done!

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I was hoping to replace the rear trailing arm bushings with the Bav Auto adjustable ones. That way I could have some camber adjustment in the rear.

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It was not meant to be though. First of all, I didn't have a press to do it but secondly, after assessing the rust damage on the brake line fittings and other bolts I knew that if I dove into this job it would turn into a very long and potentially agonizing experience so I passed on it. This job will be left to a shop.

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I still had one more thing to attend to though. My brakes were in dire shape so now was better a time than ever to replace the pads and rotors.

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I picked a set of Stoptech Street Performance pads up along with some PowerSlot rotors. The pads are supposed to be more aggressive than OEM and dust less. Plus they can endure a light track day or autocross.

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And here's what the before and after images look like. I'm super happy with the drop, even though its minimal. I like to call it gentleman low :)

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My initial test drive blew me away at how comfortable the ride felt. I was expecting it to be way stiffer and more rough but the car soaks up bumps much like it did before minus all the floating. It's much more crisp and precise. Body roll is noticeably less and the car feels more planted. I can't wait to add a bit of negative camber up front and a slight caster adjustment. It should really make it turn in well.
AlpinaE24
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Post by AlpinaE24 »

Nice write up :alright:
Mark 88/M5 Houston
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Post by Mark 88/M5 Houston »

AlpinaE24 wrote:Nice write up :alright:
+1
Frybrid 524td
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Post by Frybrid 524td »

Nice write up. Too bad you used Bav Auto springs though.
demetk
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Post by demetk »

Very nice. Is this going in the magazine?
528elover
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Location: Tucson, Arizona

Post by 528elover »

Thanks for the write-up and the pics. There's nothing like putting fresh, new hardware on the car, and experiencing what it was like to drive afterward.
Cactus
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Joined: Jun 06, 2010 4:13 AM
Location: Dayton, OH

Post by Cactus »

Little known secret. If you remove the rear seat, either displace or remove the rear shelf and poke through the sound deadening, you have access holes which will allow you to put a socket on the rear upper shock mount nuts. You'll be wrenching blind, but that's far preferable to wrenching like a contortionist.

My write up involves giving up just before you start so that you can make yourself a cocktail. Then you either continue the suspension job, or your train of thought can't stop thinking about how badly you wanted coilovers. And more drinks.
Excerpt from Cactus's Cocktails for Blithering Fools and Less than Adequate Men wrote:
Beer:
Serve one beer, neat.
When finished, try another

Bourbon Mixer:
Take some bourbon and mix 'er.

Vodka Martini:
Reach into your private stash of single malt scotch, and pour a big glass of whichever one kept you from making your mortgage payment on time.
Vodka is for those who don't actually like to drink, but just enjoy being plastered. You're better than that, try Laphroig. Some say it tastes like motor oil, but if they can't appreciate the taste of peat, then their opinion matters as much as the people who put a bunch of bullshit on MTV that wasn't music videos.
vinceg101
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Location: Los Angeles, CA

Post by vinceg101 »

Very nice. Thanks for the detailed write-up.
John in VA
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Location: Leesburg, VA

Post by John in VA »

I'd think this belongs in the Tech Talk or Tech FAQ subforum.
L_N_Love
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Location: VA

Post by L_N_Love »

Good job. Do something with those wheels next.
MLastovo
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Location: San Diego, CA AKA The Best Coast

Post by MLastovo »

Frybrid 524td wrote:Nice write up. Too bad you used Bav Auto springs though.
Please explain why is this a bad thing.
D.
1st 5er
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Post by 1st 5er »

I like clean new parts.
Nebraska_e28
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Post by Nebraska_e28 »

Nicely done! :clap:
leadphut
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Location: Portland, OR

Post by leadphut »

John in VA wrote:I'd think this belongs in the Tech Talk or Tech FAQ subforum.
agreed.
Squire68
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Joined: Apr 07, 2008 11:23 PM
Location: Lompoc CA

Post by Squire68 »

leadphut wrote:
John in VA wrote:I'd think this belongs in the Tech Talk or Tech FAQ subforum.
agreed.
I vote Sticky! :D
pstl_pete
Posts: 112
Joined: Oct 11, 2011 4:54 PM
Location: Toronto / Windsor, ON

Post by pstl_pete »

Thanks for the great comments.

I hope to do the same with my euro conversion.

And I plan to have my wheels on very shortly so I'll be sure to post pictures then.
shagrath
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Location: pLace

Post by shagrath »

Here's a hint: your springs are upside down. The print on the bavauto springs is upside down. Look at your springs with the car on the ground. You will see coils bunched up the bottom. If not they are installed right. :up:

Also for future reference, the spring compressor is not needed. Out of the car, the springs are not under that much compression. I just put my foot on the springs (front) and zip off the nut with an impact. They pop just a little enough to pop the cap/bearing off but not shoot off violently. I have done this with most e28's with no issue.

Good write up though!
M. Holtmeier
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Joined: Mar 11, 2007 3:06 AM
Location: Josephine, Texas

Post by M. Holtmeier »

shagrath wrote: Also for future reference, the spring compressor is not needed. Out of the car, the springs are not under that much compression. I just put my foot on the springs (front) and zip off the nut with an impact. They pop just a little enough to pop the cap/bearing off but not shoot off violently. I have done this with most e28's with no issue.

Good write up though!
LOL, Matt! Let's not put other people in harms way as they may not have the e28 "touch" like you do.
Brad D.
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Post by Brad D. »

Moved to Tech Talk. Nice writeup BTW.
shagrath
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Location: pLace

Post by shagrath »

M. Holtmeier wrote:
shagrath wrote: Also for future reference, the spring compressor is not needed. Out of the car, the springs are not under that much compression. I just put my foot on the springs (front) and zip off the nut with an impact. They pop just a little enough to pop the cap/bearing off but not shoot off violently. I have done this with most e28's with no issue.

Good write up though!
LOL, Matt! Let's not put other people in harms way as they may not have the e28 "touch" like you do.
:laugh: It's not bad at all. It a very gentle process with these cars.
pstl_pete
Posts: 112
Joined: Oct 11, 2011 4:54 PM
Location: Toronto / Windsor, ON

Post by pstl_pete »

shagrath wrote:Here's a hint: your springs are upside down. The print on the bavauto springs is upside down. Look at your springs with the car on the ground. You will see coils bunched up the bottom. If not they are installed right. :up:

Also for future reference, the spring compressor is not needed. Out of the car, the springs are not under that much compression. I just put my foot on the springs (front) and zip off the nut with an impact. They pop just a little enough to pop the cap/bearing off but not shoot off violently. I have done this with most e28's with no issue.

Good write up though!
Haha, I tend to caution on the safe side and use the spring compressor.

My front and rear springs are mounted with the Bav Auto writing right side up, have a look at the photo of the rear spring to see what I mean. I also think the rears are tapered so you can't install them upside down but I'll double check the fronts just to be sure.
Frybrid 524td
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Post by Frybrid 524td »

MLastovo wrote:
Frybrid 524td wrote:Nice write up. Too bad you used Bav Auto springs though.
Please explain why is this a bad thing.
D.
They'll start to sag over time.
BuzzBomb
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Location: SoCal

Re: How to: e28 Suspension Install

Post by BuzzBomb »

pstl_pete wrote: 1-Technically you should use a special key for this but I'll argue that the pliers do as good a job. Wrong
2-Bolt that bad boy in place and do the same on the opposite side and you're done! Wrong
Correct procedures are:
1 No, pliers aren't used for that. Use the right tool.
2 The lower securing bolt is tightened once the car is resting on it's tires, preferably weighted down with someone in the car. Otherwise the rubber bushings will be stressed and will stretch and crack in a relatively short time.
shagrath
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Location: pLace

Post by shagrath »

You can install the rears upside down. Ive done it.the fronts are writing stamp up. go look at your car an youll see.
chevale
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Post by chevale »

Nice write-up. One thought though: if I remember correct, the sport shocks have build-in bump stops, so use of external bump stops in not necessary.
MLastovo
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Post by MLastovo »

Frybrid 524td wrote:
MLastovo wrote:
Frybrid 524td wrote:Nice write up. Too bad you used Bav Auto springs though.
Please explain why is this a bad thing.
D.
They'll start to sag over time.
Agreed. Please note that all springs under load will sag over time.

Do you have any historical data on BAS spring performance?

If so, do you have same/similar data to compare to other brands and/or stock springs?
r/
D.
shagrath
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Post by shagrath »

chevale wrote:Nice write-up. One thought though: if I remember correct, the sport shocks have build-in bump stops, so use of external bump stops in not necessary.
This. Bavauto notes this too.
Frybrid 524td
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Post by Frybrid 524td »

MLastovo wrote:
Frybrid 524td wrote:
MLastovo wrote:
Frybrid 524td wrote:Nice write up. Too bad you used Bav Auto springs though.
Please explain why is this a bad thing.
D.
They'll start to sag over time.
Agreed. Please note that all springs under load will sag over time.

Do you have any historical data on BAS spring performance?

If so, do you have same/similar data to compare to other brands and/or stock springs?
r/
D.
Of course all springs under load will sag with time but based on anecdotal evidence shared numerous times here on the forum, BavAuto springs tend to sag prematurely.
MLastovo
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Joined: Feb 12, 2006 12:00 PM
Location: San Diego, CA AKA The Best Coast

Post by MLastovo »

Frybrid 524td wrote:
MLastovo wrote:
Frybrid 524td wrote:
MLastovo wrote:
Frybrid 524td wrote:Nice write up. Too bad you used Bav Auto springs though.
Please explain why is this a bad thing.
D.
They'll start to sag over time.
Agreed. Please note that all springs under load will sag over time.

Do you have any historical data on BAS spring performance?

If so, do you have same/similar data to compare to other brands and/or stock springs?
r/
D.
Of course all springs under load will sag with time but based on anecdotal evidence shared numerous times here on the forum, BavAuto springs tend to sag prematurely.
Any chance you have the posts indexed?
I've been around since before Roachfly and don't recall ever reading any posts but I may have missed one.
r/
D.
BuzzBomb
Posts: 1672
Joined: Aug 21, 2011 12:14 AM
Location: SoCal

Post by BuzzBomb »

MLastovo wrote:
Frybrid 524td wrote:
MLastovo wrote:
Frybrid 524td wrote:
MLastovo wrote:Please explain why is this a bad thing.
D.
They'll start to sag over time.
Agreed. Please note that all springs under load will sag over time.

Do you have any historical data on BAS spring performance?

If so, do you have same/similar data to compare to other brands and/or stock springs?
r/
D.
Of course all springs under load will sag with time but based on anecdotal evidence shared numerous times here on the forum, BavAuto springs tend to sag prematurely.
Any chance you have the posts indexed?
I've been around since before Roachfly and don't recall ever reading any posts but I may have missed one.
r/
D.
:duel:
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