Dangerous Koni Problem

[Wendigo]

Just a quick question/statement. I had some strange noices coming from my front end and got up under there to check it out and found what I think is a serious problem.

Has anyone who installed the inserts had the retaining bolt back out and concave washer fall off? I couldnt get right under the strut to inspect if it had backed out or actually broke off. I installed to all Koni specifications, and this seems rather dangerous. Can anyone tell me if they had this problem? Anyone know where to get replacement washer and bolt? Tried to contact Koni and havent had any success.

I havent even used the car for any autocrossing! Needless to say I am babying the car now. And I just got the LPM and 80mm MAF, so this is even harder to do doh

 

[SHOck]

I have heard of one other person that had one become loose. I'd suggest using the red locktite thread sealant on both sides.

You can simply remove the bolt on the other side and take it to a local supply house to find a match. The washer will not be as simple, but to be honest, you could just use a thick washer in place of it. The boss on the bottom of the koni cartride seats against the bottom of the oem strut, so it's not like you're going to bend the 1/8" thick steel that makes up the bottom of the oem strut.

Keep calling and complaining to Koni until they send you replacement parts. Mention that you've heard of several other people having this problem, and wonder if there's a design fault.

Oh, yeah, do not bother with the lock-washer they provide. It breaks when you torque the bolts to a proper torque anyway (50lbs is what I did, IIRC).

 

[svtsho]

This is not uncommon. I had a simple tack weld done on mine. One bolt to washer and then one washer to housing.

The welds will be easy to grind off if the insert needs to be removed.

Bill

 

[Todd TCE]

Some of you are going to bitch about this statement, but if the housings are cut too short as I've stated before the insert can rock in the housing. Thus the insert may wiggle loose on you. I did a couple of dozen complete car sets years ago and never had one person call back about the bolt coming loose. Perhaps they just didn't want to tell me.

 

[Lance Cheney]

I would tend to agree with Todd. I've never had any problems with mine in 7 years and three sets (I have gripes about the reliability of the insert itself, but I've never had anything like this fail). If they are installed properly there should be very little force on the bolt -- it's holding the strut in the housing, which is only going to be pulled when the strut is being pushed back out by the spring (after being compressed). And they don't send you cheap bolts. The inserts should be tight enough in the housing that they require substantial force to get them out. Not having appropriate tools (eg. a press), I screw the bolt partway into the bottom of the insert and drop the whole strut assembly on the pavement, forcing the insert out. If you can remove the insert easily then you've got a problem.

Or you might have gotten a bum bolt.

-Lance

 

[SHOspazz92]

TOKIKO's are looking real nice right now

 

[Wendigo]

Well, after speaking to a very helpful Koni rep, I was informed that this is in fact a very common problem. This is the resulting newer design that I, unfortunately dont have. I didn't ask just exactly what the new design entailed, but it is a different style retaining bolt and washer combo.

Also, the information I recieved with the inserts did not state the same amount of torque to be applied as the rep told me. He did recommend using nothing short of the red Loctite or locknut with the equivalent PSI rating, as I did tell him I used blue on the first install.

However, if I didnt put as much torque on them as he stated was necessary, that they would easily back out over time, even if the housings were cut to the proper length. They were more than happy to overnight several sets of new hardware at no cost.

Oh yeah and the rep told me to apply 64ft/lbs of torque minimum.

I have no doubt that the state of the roads in the middle TN area helped to contribute to the speed with which the bolt backed out, if you drove on them, you would know what I mean.

 

[Lance Cheney]

Hmm. I'm glad you got ahold of Koni and they're making it right. This is interesting, and will make me go home and check mine to make sure they're still tight.

The last replacement I got came with a socket-head cap screw instead of the hex-head bolt that usually comes with them. The washer was still the same. I'm not sure if that's what he meant.

-Lance