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**gavin** · 11-3-05, 4:00

Now, youll need a few items to get this all done..

-purchace Koni inserts
- Factory service manual
-Spring compressor(these can be rented at most auto stores)
-A jack and jack stands(a lift would be ideal)
-Assorted hand tools(ratchects, breaker bars, sockets, etc.)
-Air tools(this is a maybe, but it makes life a lot easier)
-dremell, grinders, cutoff wheels
-pipe cutter, hacksaw
-drill, metal cutting drill bits

Ration out some time to do this project. A weekend will be more than enough, but a bit of prep time will be necessary leading up the installation.

Hey…while you are down there, how are your control arms doing? Boots in good shape? What about the steering tie rods? Might as well make a project of it.

There are 3 possible Koni inserts to be used in this project. For the most part the installation process will be the same.

Koni Specials (reds)

Part numbers: 86-2413(front), 86-2414(rear)

These are readily available and will cost about $130-140. They are internally adjustable for rebound only (http://www.koni-na.com/comp.cfm) and less aggressively valved than the “sport”(yellows).

Koni Sport (yellows)

(A)The 1st gen application is no longer made, but if any still exist and you are lucky to find a set (Good luck on this as I may have the last of the NOS inserts).
Part number: 8641-1183 (front), 8641-1184(rear)

(B)The next best thing(and more available) is the European 2nd gen application
Part number: 8610-1305(front), 8610-1306(rear)

They will be @ $160-170 (minus importing)and can be imported through places like shox.com.

They are externally (rebound only) adjustable. They are also 2” shorter in front and 1” shorter in the rear compared to the stock struts. Because of this some adjustments will have to be made to have them fit acceptably. These will be the items we will be focusing on in this install.

All koni shocks are rebuildable, revalvable and upgradable(IE custom revalves, strut shortening, conversion of internal to external adjustment…for a price of course)

Finally, Koni has a lifetime warrantee on their products against defects and workmanship if the car is street legal and the shock is the correct application. For us this means the specials are covered but not the imported 2nd gen sport inserts(Koni will work on the shocks, but they wont be fully covered as they were not a US application)

And here are the differences in measurements for the two types of Konis.

................. 1st gen 2nd gen
Front
shaft length: 18.3cm 15.9cm
shaft diameter: 22mm 22mm
body length: 31.7cm 29.1cm
body diameter: 44mm 45mm

Rear
shaft length: 20.8cm 18.2cm
shaft diameter: 22mm 22mm
body length: 37.6cm 36.3cm
body diameter: 44mm 45mm

The shaft lengths were measured from the base of the body to the bottom of the threads. The body lengths were measured incuding the bottom mounting nipple.

Ok here we go

11-3-05, 4:00	#2 (permalink)
gavin Join Date: Jan 2001 Location: santa cruz.ca iTrader: (1)	Now, youll need a few items to get this all done.. -purchace Koni inserts - Factory service manual -Spring compressor(these can be rented at most auto stores) -A jack and jack stands(a lift would be ideal) -Assorted hand tools(ratchects, breaker bars, sockets, etc.) -Air tools(this is a maybe, but it makes life a lot easier) -dremell, grinders, cutoff wheels -pipe cutter, hacksaw -drill, metal cutting drill bits Ration out some time to do this project. A weekend will be more than enough, but a bit of prep time will be necessary leading up the installation. Hey…while you are down there, how are your control arms doing? Boots in good shape? What about the steering tie rods? Might as well make a project of it. There are 3 possible Koni inserts to be used in this project. For the most part the installation process will be the same. Koni Specials (reds) Part numbers: 86-2413(front), 86-2414(rear) These are readily available and will cost about $130-140. They are internally adjustable for rebound only (http://www.koni-na.com/comp.cfm) and less aggressively valved than the “sport”(yellows). Koni Sport (yellows) (A)The 1st gen application is no longer made, but if any still exist and you are lucky to find a set (Good luck on this as I may have the last of the NOS inserts). Part number: 8641-1183 (front), 8641-1184(rear) (B)The next best thing(and more available) is the European 2nd gen application Part number: 8610-1305(front), 8610-1306(rear) They will be @ $160-170 (minus importing)and can be imported through places like shox.com. They are externally (rebound only) adjustable. They are also 2” shorter in front and 1” shorter in the rear compared to the stock struts. Because of this some adjustments will have to be made to have them fit acceptably. These will be the items we will be focusing on in this install. All koni shocks are rebuildable, revalvable and upgradable(IE custom revalves, strut shortening, conversion of internal to external adjustment…for a price of course) Finally, Koni has a lifetime warrantee on their products against defects and workmanship if the car is street legal and the shock is the correct application. For us this means the specials are covered but not the imported 2nd gen sport inserts(Koni will work on the shocks, but they wont be fully covered as they were not a US application) And here are the differences in measurements for the two types of Konis. ................. 1st gen 2nd gen Front shaft length: 18.3cm 15.9cm shaft diameter: 22mm 22mm body length: 31.7cm 29.1cm body diameter: 44mm 45mm Rear shaft length: 20.8cm 18.2cm shaft diameter: 22mm 22mm body length: 37.6cm 36.3cm body diameter: 44mm 45mm The shaft lengths were measured from the base of the body to the bottom of the threads. The body lengths were measured incuding the bottom mounting nipple. Ok here we go Last edited by gavin : 7-24-07 at 13:26.