abloor
07-18-2016, 10:59 AM
Felt I should post my recent experience with a Koni shock failure. I built FFR 5809 Roadster with IRS. I chose Gordon Levy's DA Koni setup for my suspension. After 22000 miles my left rear shock failed at the rod connection to the lower shock mount just above the threaded section. I have been at the London Cobra Show for the last six years. The events included the legendary burnouts, some auto crossing, and two days each year on the Mid-Ohio Race track at elevated speeds. Fortunately my shock failed at low speed on an errand run at home. I contacted Gordon for the shock specifics and he sent me to Koni for a possible rebuild. He also suggested that I should try to determine why the shock failed (and I agreed). During the tear-down, I did not, unfortunately, pay particular attention to the setup as I felt that I could refer to my build manual. After sending the shocks to Performance Shock (Koni only recently disbanded their in-shop repair facility) I started my research on the failure.
In reviewing my build manual, I discovered a possible reason for my failure. On page 248 of my MK III build manual the specific instructions for mounting the shock to the lower IRS arms says in the text "10. Fasten the shock to the bottom mount with the fasteners and spacers provided. The longer spacer goes toward the front of the car." However the picture (labeled Lower shock mount) immediately following the text clearly shows the longer spacer mounted toward the rear of the car.
I referenced the pictures that were taken during my build and, indeed, I had followed the photograph provided in the build and NOT the text.
I contacted FFR and asked for clarification and was assured that the longer spacer DOES go toward the front of the car. I am of the opinion that this was at least part of the reason for the shock rod failure.
I am hoping that the word will get out to all of the owners of MK IIIs with IRS who are visual learners like me to check their lower rear shock mountings against the textual directions of the build manual.
In reviewing my build manual, I discovered a possible reason for my failure. On page 248 of my MK III build manual the specific instructions for mounting the shock to the lower IRS arms says in the text "10. Fasten the shock to the bottom mount with the fasteners and spacers provided. The longer spacer goes toward the front of the car." However the picture (labeled Lower shock mount) immediately following the text clearly shows the longer spacer mounted toward the rear of the car.
I referenced the pictures that were taken during my build and, indeed, I had followed the photograph provided in the build and NOT the text.
I contacted FFR and asked for clarification and was assured that the longer spacer DOES go toward the front of the car. I am of the opinion that this was at least part of the reason for the shock rod failure.
I am hoping that the word will get out to all of the owners of MK IIIs with IRS who are visual learners like me to check their lower rear shock mountings against the textual directions of the build manual.