Project 996 - Koni Special Active upgrade

[Crhodes64]

Fellow 996 aficionados - My 2001 C2 3.4 sunroof delete narrow body Meridian beauty is about to undergo some tweeks to her suspension and I'm planning cutting some Car Wow style video before and after footage for the benefit of others who may be contemplating the same.

Having owned the car for just over a year and having has the suspension and Geo checked and set-up by Chris at Centre Gravity (in the process having new engine mounts fitted and the usual bits and bobs that were born out/or creaking) I've decided that the car is a keeper but I really want to try to sort out the ride quality for much of what I use the car for which is mainly bumpy B roads around where I lie in Leicestershire.

So the plan is to fit new Koni Special Actives all around - She's done 78K, the original dampers were tested as being OK but I want something a bit less hard on my 55 year old spine - something more GT car, but something that still puts a grin on my face laying into a fast corner.

Since the cash has been splashed quote a bit already - You know the drill - IMS/RMS/Clutch/Radiators/Waterpump/Low temp stat ... .. I'm planning on doing some of the before final check and GEO back with Chris down the road at CG. I'm keeping the existing springs which have settled to a ride height that is already 10mm lower than standard.

Now I've come across some instructions that came with the new Koni's and I need some help.... There is a little diagram with the rear shocks that seems to indicate some spacers being required where the spring sits on the large round washed that slips over the shock body. The purpose of the spacers seems to be to adjust the mounting of the coiled spring such that the flat washer fits to the helical shape of the spring. Problem is that I cannot see anything in the parts manual for the standard car and there is nothing in the Koni box. ?? Anyone any ideas?

First the Koni graphic in the box then the standard image from the parts manual. What and where are the damn spacers that the Koni arrows are pointing too?




Thanks in advance for any tips - will post a link to youtube content before and after the upgrade in due course.

Cheers

Colin

[Paynewright]

Colin,

Where abouts are you in Leicestershire? I’m in Broughton Astley.

I’ve worked on Bilsteins which have several grooves in the shock body which a large circlip fits into. The spring platform / collar fits over this and effectively jams it in place. Looking at the circlip you wouldnt think its strong enough but it works perfectly.

Any circlip like items with it? In a bag or on the shock body?

Ian

[Crhodes64]

Hi Ian

I’m near to Kibworth - small world.

In the bag there is a large round washer that drops down over the suspension leg and it rests squarely on a circlip that sits in a slot cut around the bottom part of the suspension leg. Does the standard spring just sit on this large washer?

It looks like that from the parts manual but what is confusing me is the not very obvious or helpful flyer contained in the box that appears to show some funky fitting that somehow accommodates the spring being a coil with parts of the spring varying in height as it come from bottom to top.

I’m confused about what Koni are tying to tell me.

Cheers

Colin

[Crhodes64]

No idea what the Koni info is trying to tell me. I just looked at the existing rear shock and took a picture - The existing standard spring is resting directly on top of the large flat washer on the Bilstein damper leg as shown in the parts manual. Simple!

So what is that pesky Koni info in the box trying to tell me?

[Wayne95]

This sounds a really interesting project - looking forward to the result

Track lowered suspension is all well and good, but her majesty’s government demands we all drive SUV to save them bothering with repairs .

So I hope the change held us old folk with delicate spines to still enjoy our 996’s. been thinking almost no the same lines myself ( 959 Paris Dakar looking more appropriate than lemans renegade )

[Crhodes64]

HA :-) Very true Wayne95

My theory is that dampers have moved on technically since 2001 - Trying to keep the car as original as possible but just like advances in tyre technology improve car performance why not upgrade the shocks to something better than original 2001.

Quite excited.

[edh]

Very interested to see how you get on with this

The dampers on my 60k mile C2 seem fine when driving quickly, but are not great at slow speeds over rough / broken surfaces. Ohlins seemed like a possible option but might be a bit firm..

[swtcar]

Pic of my konis albeit with Eibach springs. You can see the spring sits on the washer.

[mmcd87]

I looked into these dampers but didn't go ahead after I realised they wouldn't work with lowering springs. Ended up with Koni Sport / H&R Cup kit with the Koni yellow adjustable shocks and H&R springs (still to fit). Will be interesting to see what you think of ride quality over standard Bilstein.

[Crhodes64]

Thanks SWTCAR - Very Helpful.

[swtcar]

@mmcd87 I have teamed the Konis with -30mm Eibach springs and they work absolutely fine. That's both on the terrible condition B roads of Cambridgeshire and on track.