512BBI:Rear Shocks/Brake Hose Replacement

Just after FCA Nationals this year while driving my 82' BBI back to Chicago from Toronto a fairly loud knocking sound could be heard in the left rear when hitting a road bump. At first I thought it was a loose rear deck lid catch but that proved not to be correct. After arriving home, using an automotive stethoscope while an assistant rocked the rear suspension, the problem was traced to an internal issue with the left rear/forward shock absorber. During the summer I ordered (4) new Koni 82-1984SP6 rear shocks (current replacements for BBI's), and since Koni supplies the shocks less bushings (4) 100809, and (4) 100810 upper & lower shock bushings will also be fitted. While replacing the rear shocks all (8) 101393 & 101392 front & rear brake hoses will be replaced which were just received from T-Rutlands. The rotors, pads, can be inspected and renewed if necessary. If brake pads require replacement, I may decide to just go ahead and replace the caliper seals.

Since I took the day off and we received our first light snow this morning, it was a good day to get started on this winter project in my garage. The plan is to remove all four shocks then take them over to an auto shop to install the original springs to the new shocks. While there, I'll use his hydraulic press to install the new upper and lower shock bushings. Since I used this shop's spring compressor before to do my BBI's front shocks last year, it may be awhile before I further report progress to this thread depending on his shop schedule. His spring compressor is mounted securely to an alignment machine's post and works well (and safely) on coil-over type shocks.

To begin the project, the battery is disconnected, all wheels are removed and the car is blocked under the frame. Since my BBI is stored on a Bend-Pak four post lift, I'll utilize it for this project allowing me to position the car's height to a convenient position. All springs are marked for position with tags.

1) All shock mounting hardware is loosened (photo 1). The first to be removed is the forward shock. Wood shims are placed under the suspension "A" arm for support. The top bolt is pulled out of it's mount, the top of the shock tilted outward and removed from the lower mounting stud (photo 2).

2) The rear/rear shock requires the ATE caliper to be removed for clearance. The caliper pistons/pads are retracted.
Using my special "brake maintenance buddy" (a turkey baster fitted with a short length of rubber hose), brake fluid is removed from the master reservoir (photo 3). Since Thanksgiving is around the corner, this turkey baster will be well hidden from my wife. Brake fluid on turkey does not make a good seasoning.

3) The rear caliper brake lines are cracked open (photo 4) using 11mm and 17mm fitting wrenches. Use a disposable catch pan to catch any fluid in the lines. While the fluid drains, the caliper mounting bolts can be removed. Disconnect the brake lines from the hoses. The caliper can now be removed (photo 5). I have an assortment of plastic caps which came in handy to cap the fittings to keep out debris and or moisture.

4) The top mount of the rear/rear shock can now be tilted outward and removed from the lower mounting stud (photo 6).

5) There are minor, but noticeable visual differences between the new Koni shocks and the OEM originals (photo 7). The new Koni is on the right and is not extended. New spring retainers and split collars are included with the new shocks as original. Koni's logo has changed and the top mounting eyelet is now plated instead of painted. I have gone to great lengths to keep this car as original as I can so I secured some original triangular logo stickers by request from Koni NA. I'm not sure about the upper eyelet. I suppose I should be anal and paint them the correct color over the chrome plate!

6) I will be using the factory adjustment setting for the new shocks. I replaced my 308 GTSQV shocks a few years ago as well as the BBI's fronts last year and found I like the ride as is. An extra note, Koni recommends never to extend their shocks while in a horizontal position. Extending should always be done in a vertical position.

I will add this to the BB Repair thread when completed.

Dave
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