Koni - Adjustable inserts into a Mighty Boy Koni special Part No 86-2400
Check bottom of strut, if there is already a bolt head you are a winner. Strut mod already completed. If not, the strut is standard. in photo left strut has koni inserts, right is standard.
I am not a mechanic, the following is what I did to install the inserts using Koni instructions and some trial and error. Use this post for general overview and if your not confident maybe take it to a suspension expert.
Use spring compressors if needed to take pressure off the top of strut to allow you to undo top bolt. If the spring is still under tension and your nut is at the top of the tread fully engaged,you will need a spring compressor. I didn't need to as king springs KSFL-12 had zero compression when fully extended.
Place all the parts in order on the table.
Wrap strut with a thick rag and place in vice upside down. GENTLY hold strut in jaws, do not crush the tube. Centre punch bottom of strut
Put on safety glasses especially if you have a gas strut. Mine was oil only so not too exciting. Drill a 4mm hole through the bottom.
Drain oil into bucket, open and close strut a heap of times and shake to get most out.
Next cut the strut tube just under the top seam weld. Use a hacksaw, angle grinder or metal band saw. You only need to cut the strut tube not the central shaft which is hardened steel. Its only about 2mm thick and pretty easy, cut as straight as you can but can clean up after with an angle grinder.
Once cut, pull out the old shock, pour remainder oil into bucket and put a rag in the cut end.
Turn upside down and drill the 4mm hole on the bottom of strut into a 13 – 14mm hole. Koni asks for 14mm but 13mm is fine if your hole is pretty central. Tidy up hole and the cut tube with a file Paint hole and cut to stop rust
Slide Koni strut into strut tube and push in.
Last edited by cam on Tue Aug 20, 2019 6:23 pm, edited 1 time in total.
Gently tap with a soft hammer until insert touches or nearly touches bottom of strut.
Insert bolt with washer and serrated washer into bottom hole and do up (85Nm)
flip over strut Adjust shock to desired settings using Koni instructions. Koni website http://www.koni.com/en-US/Cars/Technology/Adjustment-Guides/
Adjustment Procedure 76, 80, 82, 86, 87, 88, 90, 8040, 8240 Series Rebound Adjustment Procedures
Remove the shock absorber from the vehicle and hold it vertically with the lower eye or pin attached in a vise. Use clamp plates to prevent damage.
Fully collapse the shock absorber, at the same time turning the dust cap or piston rod slowly to the left (counterclockwise), until it is felt that the cams of the adjustment nut engage in the recesses of the foot valve assembly.
Some shock absorbers include a bump rubber concealed under the dust cover and it must be removed prior to adjusting.
The damper may have already been adjusted. Therefore check whether the shock absorber is in the adjustment position or not by keeping it collapsed and gently turning it further to the left counting at the same time the half turns until a stop is felt. Stop turning then and do not use force.
Keeping the shock absorber collapsed, make 1 half turn (180 degrees) to the right (clockwise). In case of prior adjustment add the number of half the turns previously found. The total range is about 5 half turns.
Pull the shock absorber out vertically without turning for at least 1 cm to disengage the adjusting mechanism. The dust cap or piston rod may now be turned freely.
Extend and compress the shock fully a number of times to purge it ready for use. Install Koni dust cover over the strut which covers your cut area
Rebuild strut Drop on Koni white plastic washer, onto strut. Compress spring if needed and drop onto fully extended strut. To hold the strut fully extended, I used some narrow vice grips with jaws wrapped in a rag . Access the shaft through the spring at the bottom of the shaft. Pull shock out to max and very lightly lock vice grips with soft jaws
Drop on bump stop, spring, spring inner dust cover, spring to mount, shock “bearing”, bearing dust seal, cover plate then strut top.
Do up Top strut bolt until its tight and you cant hold the strut top from spinning.
You can torque up to 80Nm after its installed. stick on your koni sticker to let the next person know whats the go.
Re install into car
torque up top bolt to 80Nm
Job done for another 34 years It was harder making this post and trying to attach photos that installing the Koni inserts
Last edited by cam on Tue Aug 20, 2019 7:00 pm, edited 1 time in total.
Thanks for the write-up mate, and sorry the forum made it difficult to create.
I'm rebuilding the website at the moment, so create a DIY guide out of the info.
Did you write the details straight into the forum, or did you copy/paste it from another document?
.Do you have the insert dimensions (open/closed/diameter) so that I can check other suppliers?