Tech, Repairs, Upgrades > Brakes/Suspension/Tires/Wheels

Total Suspension Rebuild

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EShepherd:
Howdy, guys. So, I'm getting to the point where it's time to start refreshing the entirety of my '91 XR2's suspension. I need help tracking down some parts. I'd also like some first hand accounts of how different setups feel.


So I'll probably be sticking with the stock wheels. I MIGHT go up to a 15" someday, simply for more tire options. However, there is the Toyo R888R's out there in the OEM size, so I'm not really in any rush. Keeping in mind that, my goals are twofold. Everything is factory, so old and tired. Old, squishy rubber. Old, leaky shocks. You get the idea. I'd also like to stiffen the thing up, if at all possible. Chassis bracing seems hard to come by, so obviously options are limited there. Here's what I'm looking to replace:

-ALL of the control arm bushings
-Ball joints
-Swaybar endlinks & bushings  (front and rear)
-Inner & outer tie-rods
-Either coilovers, or stiffer shocks and either lowering springs OR I'll just cut the OEM ones shorter
-Shock mounts
-Engine mounts
-All the bushings for the rear (I haven't looked back there, but I'm assuming there are trailing arms and/or control arms
-The alignment eccentric bolts or jam-nuts or whatever is in the back (mine are totally seized on)

If I'm missing anything, let me know. I'm also debating running some wheel spacers to widen out the track width slightly, both front and rear. I don't want to lower it a crazy amount, but it definitely sits too high as it is. Maybe around an inch or so. Another idea I've been playing with is staggering tire sizes. Something slightly wider out front to increase the contact patch.


What I want to hear is, what modifications have you guys done to your suspensions? What has worked for you, and what was a mistake? Where will I see the most improvement? I'd love to find a nice set of coilovers, just for the freedom of adjusting height and damping depending on track conditions.

greywolf27030:
You'll probably have to make your own coil overs.

EShepherd:

--- Quote from: greywolf27030 on April 19, 2021, 09:07:37 AM ---You'll probably have to make your own coil overs.

--- End quote ---

That sounds not fun. At all. Perhaps there is a vehicle with similar suspension pickup points, and I could just modify those coilovers to fit? I wouldn't even know how to go about making my own set lol.

greywolf27030:
There are threads on Festiva.com and maybe here that gives the whole deal.

Rocketman:
You should have a dive into the Clubprotege forums. There's an absolute goldmine of BF suspension info archived there. http://www.clubprotege.com/forum/forumdisplay.php?194-Suspension-Brakes-BF-Chassis

My hot take:

Coilovers should be super easy to piece together for the Capri. Some proper size adjuster sleeves, 2.5" springs can be had from Summit, and the spring tops should be easily found/modified. I made DIY coilovers on the rear of my 95 pontiac grand prix, and it was fairly easy
There are/were Ground-Control brand coilovers for the 323 that fit but they aren't a perfect solution, most folks buy them just to lower their capri. I worked on one with them and I was not happy with the front springs

Performance struts don't exist anymore, you will need to DIY a solution for that. There is some info on the clubprotege board on using strut cartridges in the OE strut bodies. Or have an OE style body welded to take whatever good insert/cartridge you can find. I think someone used VW stuff.

There used to be performance control arm bushings, I'm not sure they are available anymore. There's a sticky thread here with part numbers.

Rear lateral links might be tricky, I think you can order them for the 323 but the Capri uses an adjustable one for rear toe, I don't think the 323 had that. I believe that style is NLA. The rear bolts that run thru the subframe and knuckles are a mofo, any amount of age/rust seizes them solid.

Trailing arms can be had I think, which are needed many times after removing rear struts. The lower strut bolt seizes into the bushing and tears it up on removal.

Spacers I would stay away from, as well as large wheels, as it tends to aggressively eat front wheel bearings.

Front strut bar & polyurethane front control arm bushings made the biggest difference for me

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