Front Suspension Rebuild - ZR-1 Net Registry Forums

XfireZ51 · 02-20-2012

Spring Updatng season has come early this year. with 40d+ weather here in Chicagoland, its possible to throw open the garage door and do some needed maintenance work on the front end. Last year I decided to get a wheel alignment prior to BG. I was told they couldn't do it due to the condition of the lower ball joints. I bought some Moog ball joints last fall planning on installing them this spring. I also got a poly bushing kit for the front end. Well this weekend marked the beginning of maintenance season and I started with replacing the D/S rear hub bearing. Bought a Timken unit for that. And yesterday I started tearing into the front end.
The Brembos were the biggest obstacle due to how they were installed.
Also went ahead and order upper ball joints after getting a closer look at them. Here's some pics of the devastation:

You can see the Brembos use a 2 piece disc. The bracket mounting bolts were too long to allow removal of the caliper which in turn would not allow removal of the disc. My suspicion is that the outer disc was installed in the caliper, then the center hub portion of the disc was bolted to the outer ring once the caliper mounting bolts were torqued. Otherwise, no way to remove disc without cutting the bolts which is what I did.
Passenger side gets disassembled later today.

02-20-2012	#1
XfireZ51 Join Date: May 2007 Location: Chicagoland, IL Posts: 9,683	Front Suspension Rebuild Spring Updatng season has come early this year. with 40d+ weather here in Chicagoland, its possible to throw open the garage door and do some needed maintenance work on the front end. Last year I decided to get a wheel alignment prior to BG. I was told they couldn't do it due to the condition of the lower ball joints. I bought some Moog ball joints last fall planning on installing them this spring. I also got a poly bushing kit for the front end. Well this weekend marked the beginning of maintenance season and I started with replacing the D/S rear hub bearing. Bought a Timken unit for that. And yesterday I started tearing into the front end. The Brembos were the biggest obstacle due to how they were installed. Also went ahead and order upper ball joints after getting a closer look at them. Here's some pics of the devastation: You can see the Brembos use a 2 piece disc. The bracket mounting bolts were too long to allow removal of the caliper which in turn would not allow removal of the disc. My suspicion is that the outer disc was installed in the caliper, then the center hub portion of the disc was bolted to the outer ring once the caliper mounting bolts were torqued. Otherwise, no way to remove disc without cutting the bolts which is what I did. Passenger side gets disassembled later today.