Procedure for removing 512TR spring/shock units

I removed all six units without much trouble or surprises. Here is a procedure that worked and required minimal collateral disassembly.

This is best done with each end in the air or the whole car on a lift. Doing both sides of one end at the same time allows the wishbones on both sides to drop together thus obviating the need to detach the anti-roll bar.

This procedure requires loosening wishbone inner pivots to allow the wishbones to drop and provide sufficient clearance for shock removal. On my car that loosening torque required use of a 24" socket handle to break loose the corresponding nuts which did so with a quite loud "crack". After that the nut was still tight enough that it was extremely helpful to have an assistant hold the bolt head still while the nut was further loosened.

Regarding reassembly, be prepared to tighten the inner wishbone fasteners with the suspension in its loaded position. I'm unsure whether this can be done with the wheels mounted.

At the rear:

1. Remove two 13mm hex nuts from the vertical studs at the top of all four shocks.
2. Remove one 19 mm hex nut from the horizontal stud at the bottom of all four shocks.
3. Loosen a turn or so but do not remove the nuts retaining the wishbone inner pivots (19 mm hex above, 22 mm hex below). Make sure the bolt will then rotate with reasonable force.
4. Push down on the end of the upper wishbone until the center stud at the top of the shock is fully clear of the corresponding hole in the frame.
5. Pivot the top of the shock toward you and slide the bottom of the shock off the its lower mounting stud, removing the spring/shock unit downwards.

At the front:

1. Open the trunk lid and lift up the carpet where it lies over the top of the shock mounting locations.
2. Remove three 13mm hex nuts from vertical studs at the top of both shocks. On the driver side you will likely need a u-joint due to one stud's close proximity to the underside of the brake booster.
3. Remove the horizontal bolt and nut (19 mm hex) retaining the bottom of the shock. This will likely require light tapping out of the bolt with a punch.
4. Remove two 13 mm hex nuts retaining the upper wishbone to the ball joint below it. It may require light prying to separate the upper wishbone from the top of the ball joint.
5. Loosen a turn or so but do not remove the nuts (19 mm hex) retaining the upper wishbone inner pivots. Make sure the bolt will rotate with reasonable force. The lower wishbone need not be loosened.
6. Swing the upper wishbone all the way up (to nearly vertical) and extract the spring/shock unit out the top.

 

Forgot to mention: in step 6 at the front, be ready to tie the upper ball joint to one of the inner wishbone pivots to prevent the brake line from being strained when the bearing carrier is free of the wishbone.