Koni EVO shock replacement --- use oem washer?

[redbaron73]

I am replacing my sachs front shocks with KONI evo's on my freightliner chassis.

For those that have done this, did you use the OEM metal washers or just the bushings provided by Koni?

I have found that using all 6 bushings is not possible, but I can use the single washer on each end for the bolt.

What I dont like is that there is not much thread showing with this washer.

It appears I dont need the washer, but want to verify before I proceed.

[redbaron73]

I have tightened this as much as possible, and think this is proper. I have about 1.5 threads showing above the nut.

Anyone think this is not good?
This is the top nut.

And the bottom nut:


More threads on the bottom nut. The only way to get even more thread is to remove the washer, which just doesn't seem right to me. I already removed 4 washers, leaving only the top and bottom ones.

[Dutch Star Don]

Red.....I can't tell from your picture, but there are washers that need to be removed and may not be initially noticed. In the pictures below, one is of the washer that has to be pried out and can be missed on both the upper and lower shock mount. One is of all the washers and collar that are at the top of the shock and need to be removed. The last photo is all the parts that should come off the bottom of the shock.

The single washer pictured is used to center the shock and is not needed with the Koni's , they center with their rubber insert.

You should have 2 nuts, 6 metal washers, 1 collar and 4 grommets come off with each shock.

[redbaron73]

Did you reuse any of the washers that came off? I did get all 6 off that you have pictured, but I was attempting to reuse one between the bolt and rubber insert. That is the one I am thinking may not be needed.


Edit: upon rereading it sounds like you did **NOT** use any washer, and instead installed the Nut directly against the Koni rubber grommet. Is that correct?

[Dutch Star Don]

You shouldn't be using any of the old pieces. The Koni's include all the rubber and washers needed. They just do it differently than Sachs.

It was tough to tighten the upper nut. On one, I had to use an allen wrench to hold the shock stud and tighten with an open end wrench, as my air gun just spun the shock stud. The other side, my air gun was able to tighten without spinning the stud.

[Peter M]

Redbaron the washers prevent the rubber bushing from sliding off the internal shock metal bushing.
What torque is recommended for the shock nuts ?
I see plenty of thread exposed in your second post.

[redbaron73]

I didn't have any washer's included with the konis, all I had was the for rubber grommets and the two nuts. I have never installed without a washer so that's what has me is concerned

[Dutch Star Don]

Okay.....The Koni's should have come with four metal (domed) washers per shock. They do package them separate and can get stuck in the box. If you don't have them, using the old (domed) washer like in your photo is fine.

That single washer I showed in the photo above does need to be REMOVED and not reused. Sachs centers the shock using that washer. Koni centers the shock by molding a centering ring on the rubber grommet. The rubber grommets only go in one way, raised ring into the shock mount, to center it. If you look, the raised ring will not fit into that washer that needs to be removed.

[redbaron73]

I appear to still be missing two washer's from my installation then. I only installed one on top and 1 on bottom. I'm going to try to re install it reusing the old washers to see if I get it to squish down enough. I won't use the one you pictured as you said.

[FatChance]

Be aware there are differences between Spartan and Freightliner chassis equipment.

The Koni EVO shocks for my Freightliner XCR IFS chassis did not come with washers, nuts or bolts. I just reused what was installed with the original Bilsteins and everything works great.

[jerry davis]

Getting ready to install the new Koni’s. When I unpacked the two boxes this is what I received. Other than the obvious nut, what am I missing here? Shouldn’t I have two more rubber bushings and 8 metal washers? I checked and rechecked all the packing and this is all I received.

[redbaron73]

Two bushings are in the bag at the bottom. You will need to remove a total 6 washers from the original shock, and only reuse 2 of them.

You will reuse the top and bottom washer, which the new nut will compress against.

When putting the bushings on the shock, pay attention to the indented side. It will form against the shock. The top part of it has a raised portion that will go inside the hole of the frame mount to hold in place.

The top side bushing will be the same, with the exception of there is no indentation, rather a flat surface for the OEM washer.

[redbaron73]

This shows the indentation that goes against the shock.

This is the assembled bushing ready for install on the coach. This view is the top, but the bottom will be the same.


This is what they will look like once installed. Obviously there will be a frame between the two bushings, but you get the idea.


Here is the final installation top view.



And finally the price I paid for doing it wrong the first time :(

[Dutch Star Don]

Jerry.....did you get those from Shock Warehouse? You're missing two rubber grommets, two metal washers, a lock nut and one plastic dust cap.

It seems that the orders coming from Shock Warehouse are short parts. I ordered mine directly from Koni and got all new parts.