>93 480 rear suspension- spring cap removal, and bumpstop

VanDerGraaf · Post by **VanDerGraaf** » Sun May 28, 2006 10:03 am

NOTE: This thread started as inquiry into the differences in changing rear springs on 480s from 1993 onwards, which have a different setup to earlier cars. Turned out to be very useful!

Original text follows below.

Quick Q for those in the know- what methods do you use to remove the rear bumpstops easily (on a >93 car)?
Can you chop the top of them when lowering or only at the base where they fit back on?

Rohan

martinholmesuk · Post by **martinholmesuk** » Sun May 28, 2006 10:36 am

lever the bottom up a little and there held on by a clip or something which is pressed across to hold it. (from what i remember)

warning! They can break due to and then you need to get axle off and then the snapped bit welded back on.

warning! I could be talking shit again as I think the bump stops are from the top facing down.

The thing that needs welding is the spring holder!

JohnTurbo · Post by **JohnTurbo** » Sun May 28, 2006 10:42 am

Cattus showed me the light on this one....think he cut the tops off with a breadknife, when the car was jacked up. I used a hacksaw (through the spring). 2 min job.

VanDerGraaf · Post by **VanDerGraaf** » Sun May 28, 2006 11:23 am

Cool! I'll just cut the tops off then! Nice and easy.

Got to be done as i don't fancy getting bashed around whilst driving over bumps etc

Thanks guys.

Rohan

VanDerGraaf · Post by **VanDerGraaf** » Sun May 28, 2006 10:50 pm

martinholmesuk wrote:lever the bottom up a little and there held on by a clip or something which is pressed across to hold it. (from what i remember)

warning! They can break due to and then you need to get axle off and then the snapped bit welded back on.

Martin/anyone, how do you remove the plastic spring cap- Groomus told me it has a pin that needs hammered out. Is this the plastic pin in the middle as i don't see how you can hammer it?!?

To avoid any confusion, i mean this bit:

feeling stupid now (everything else was easy though

)

Rohan

JohnTurbo · Post by **JohnTurbo** » Sun May 28, 2006 11:45 pm

easy peasy mate....you get a self tapping screw...screw it into the hole in the pin a turn or so, and lever the fucker out with a pinch bar, or failing that any other suitable metal implement.

Bing bang bosh.

jerlab · Post by **jerlab** » Mon May 29, 2006 5:27 pm

I changed my springs a few weekes ago, and I spent lot of time on this "pin" (don't know the world for "goupille"...)

But I found the solution, and it's very easy

You just have to take a screw, scew it into the the pin, continue to screw and it will get out out very easily, but you have to be patient, it takes a little time

To put the pin in, keep the srew in the pin and hammer it
The screw you need is a 8x70 one

Sometimes the pin is dead, it's harder, then you cabn make one with a bolt and a mettalic tube :

Hope my english is clear

catgroom · Post by **catgroom** » Mon May 29, 2006 7:19 pm

WOW!

Han youre honoured,you had stereophonic replies!One from France and one from England!

jerlab · Post by **jerlab** » Mon May 29, 2006 8:05 pm

But French reply has pictures

Murf · Post by **Murf** » Mon May 29, 2006 9:02 pm

Hmm, think it might be too late!
'Han's cars sitting up on stands at the mo with a broken spring retaining cap lying underneath it.
Never mind bud, thats what the spares car is for

VanDerGraaf · Post by **VanDerGraaf** » Mon May 29, 2006 9:42 pm

WOW! Jerlab-

Thanks for your pictorial explanation! Your English is fine too.

Those pics are cool!

I had bust it already when i posted the other night....

A new one is.....Â£16.45 from Volvo!

Ah well, you live and learn.
One of the few times i wished i had an early car.

Rohan

martinholmesuk · Post by **martinholmesuk** » Mon May 29, 2006 10:39 pm

looking good on pi 40mm drop!

VanDerGraaf · Post by **VanDerGraaf** » Mon May 29, 2006 10:47 pm

See you didn't cut your bumpstops mate!

martinholmesuk · Post by **martinholmesuk** » Mon May 29, 2006 11:32 pm

Why would I ?

JohnTurbo · Post by **JohnTurbo** » Mon May 29, 2006 11:47 pm

Cus if its lowered on pi -40mm the rear of the car sits on them. That means the rear of the car is over sprung, under damped and..corners like shite.

VanDerGraaf · Post by **VanDerGraaf** » Tue May 30, 2006 1:06 pm

What he said.

At least Mart, it only takes 2 mins with a stanley knife (apparently Groomus uses a breadknife, but he would have to be different

).

catgroom · Post by **catgroom** » Tue May 30, 2006 7:35 pm

Mart!

I drove for about 80k on them PIs without the bump stops cut down at all!
If you dont beleive me,just ask my lower back!!!!!

I cut two notches off and the back of the car actually bounced a little and was way more comfy!

I guess that if it was riding (ooer) on the bump stops then it was fully compressed at all times.On hard cornering,I mean fucking hard,then the potential for the back end to slide out would be higherthan if they werent cut down.

As Rich always says,hope this make sense!

ReVolvoLution · Post by **ReVolvoLution** » Tue May 30, 2006 8:14 pm

STICKY!!!!

If this thread had only been posted sooner it might have saved this......

.... the owld rot had fairly taken hold and they still would have needed repair but its handy having a guide for anyone about to tackle their own arse end (ooh errr missus!)

As for cutting the bump stops down, even on a 20mm drop they could do with having a bit shaved off imho. With my newly fabricated Bump Stop Holders and Spring Retainers i've got the bump stop held in place with a counter-sunk bolt so there easily taken out and modified

(more pics to follow when i get back under there to do the brakes!)

VanDerGraaf · Post by **VanDerGraaf** » Tue May 30, 2006 8:33 pm

Yeah, this really has turned into a useful thread! First time as far as i can see that the retaining pin thing has been explained properly.
Should supercede those old threads telling people to prise the spring cap off with a screwdriver!

Fantastic

JohnTurbo · Post by **JohnTurbo** » Tue May 30, 2006 8:50 pm

VanDerGraaf wrote:Yeah, this really has turned into a useful thread! First time as far as i can see that the retaining pin thing has been explained properly.
Should supercede those old threads telling people to prise the spring cap off with a screwdriver!

Fantastic

This does tend to work actually, though i'd never do it on my own car.