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Hi folks
I've rebuilt the front suspension on my 2.4L Mk 2 this week with a 420 subframe, complete with power steering box. Quite a task, but I have two remaining problems.

1. I have not fitted the shock absorbers yet, as I only have one spacer ring for the top mount in the turret (one was rusty and fell apart on dismantling, the 'new' subframe did not have any). Anyone have an idea whether these are important, or whether I can leave them out?

2. The Mk 2 service manual says that there must be a packing piece and eight shims between the outer ends of the upper wishbone levers and the top ball joint. There were only five shims and a packing piece on each side when I dismantled the old suspension. How critical is it to have all eight shims? The bolts would not be long enough if I crammed eight shims in.

Any advice gratefully received.

Best wishes, David

Hi David,

The spacer is there so that you get the correct 'crush' on the two rubber bushes at the top of the damper, mine are also missing and I just guess it!

The spacer and shims again are to make sure the two inner faces of the top arms are parallel, as they are cast they can be broken. If someone has replaced the spacer with something else the number of shims will vary. Parallel faces is the important bit.

We are usually told to count and remember how many shims are each side of the top knuckle joint to ensure we have the correct caster and camber angle. This is critical to the handling of the car.

Brian

Thanks Brian.
I was concerned that the top shock mount may move from side to side if the spacer is not fitted? Presumably you have not had this problem.
I've replaced all the shims/spacers exactly as I found them on the top ball joint and on the upper wishbone spindle. I'm assuming that I will have to adjust camber and castor angles anyway as the 'new' subframe had no wishbones and I transferred the ones from my old subframe. The missing three spacers at the top ball joint would add 3/16" to the distance between the wishbones, but there is not enough length on the bolts to accommodate this increase and still have one thread protruding from the nut.
Best wishes, David