Suspension Rebuild, New Torsions and 2" Drop[56k beware]

Forum for the Xterra, Frontier and Hardbody, the smaller workhorses of the Nissan lineup!
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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

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I have been having suspension trouble pretty much since I bought my truck. Well I wouldn't say trouble, just less than stellar performance and not-so-right alignment. I replaced all the steering compenents two years ago. I have upgraded the shocks and have added poly sway bar bushings. I have added a rear sway bar and plus sized my rolling stock from 195/75r14 (14x6) to 205/60r15(15x7). The handling is decent. Sumitomo HTR tires are fun. The rear sway bar does a good job planting the rear end and shedding 50lbs by removing the rear bumper has really made the handling come alive.

So back to the story: 16 year old bushings can be blamed for the trouble I am having keeping the truck aligned. I have the truck aligned every Spring whether it needs it or not but last year I had to go back 3 times to have it "fine tuned"...and it's still squirrelly and chewing up tires on the outside edge. The suspension has settled over the years so even when it's 'in spec' on the rack it's still not correct when on the road. It's time to update! Since October 2010 I have been collecting parts for a more major suspension overhaul.

On the list: replacing every bushing, every ball joint, changing bump stops, replacing the OEM torsion bars with Sway A Way which are close to 4mm thicker and finally lowering the front by about 2". The hope is to have a better than new suspension with a few added perks. New nuts and bolts too! As much stainless as I can source.

Today I began tearing down the passenger front suspension and here's a few random pics in no kind of order.

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Still trying to figure out the cleanest way to get the lower control arm bushing out. I have a feeling I will probably have to torch it but I'd like to experiment a little bit first. The lowering blocks come with cheap grade 5 'rust in one week' u-bolts so I ordered a custom set built to dimension by a spring shop in Rochester NY. They should be in my mailbox by Tuesday, just in time for when I hope to begin rebuilding the rear leaf springs. The next few days will be getting the front in good order. By good order I mean, every part cleaned and painted too. I want the work I do it to last years.


PhillyHardbody
Posts: 26
Joined: Thu May 05, 2011 8:12 pm
Car: 1994 Hardbody

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This is exactly what I'm trying to acquire all the parts to do right now, I've already amassed the steering components, minus a gearbox, now I'm working on finding ball joints, control arm bushing and some drop shocks since mine are shot lol.

Good luck with your project I know how annoying it can get with rusted bolts everywhere on these older cars.

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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

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Actually I have lucked out so far, no rust. Currently I am building a home made bushing press based on some info I found on youtube. That's where I am hung up right now, that lower control arm bushing is not friendly at all. Burning it is out of the question, it will burn and damage the truck. Hoping to resume this project on Monday.

mrecoolgar
Posts: 362
Joined: Wed May 28, 2008 5:34 pm
Car: 1990 Hardbody Reg Cab 2WD 2.4 5SP

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Nice.
Makes me want to do the same to my Mazda.
Several months ago I purchased a 1988 RX7 convertible to drop a SHO engine into.

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Amays U G37S
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Car: shoes
Location: Cabin

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Lookin good Rev! Nice shop area you've got there. And I am loving the frontier in the pics with the hardbody, hahaha.

Gotcha some time to mess around with the d21 I see!

PhillyHardbody
Posts: 26
Joined: Thu May 05, 2011 8:12 pm
Car: 1994 Hardbody

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Hey Rev, if you haven't had any luck figuring out a way to press the bushing out just say the word, I know a trick using two sockets, some washers and a long threaded bolt and nut. I've used it a couple different times and it always seems to go smoothly.

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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

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That's pretty much what I tried only I used a 2" pipe nipple with a cap and a stack of washers. I hooked it all together with some 3/8" threaded rod and the whole thing exploded. I got pretty lucky it didn't hit me. One of the pieces is still missing, it shot out like a bullet.

So here's what I have been up to. I have drilled out most of the bushing which has made the center shaft very easy to move. I still have to press it out but I believe it's going to be a whole lot easier with most of the rubber gone.

PhillyHardbody
Posts: 26
Joined: Thu May 05, 2011 8:12 pm
Car: 1994 Hardbody

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Really?! Wow I've always used a setup similar to that and never had any issues, good to hear you're ok though.
Usually I use one socket with an ID larger than the bushing and another socket with an OD approx the same as the bushing, threaded rod, nut and washers. Use the large socket as a receiver, small socket as a press, threaded rod/nut as through the center, impact gun on the nut and out pops the bushing.

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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

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That sounds like the same idea. Mine must be in there really good. It doesn't want to pop out at all. I'll keep torturing it tomorrow.

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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

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Spent some twilight hours drilling the rubber out of the bushing. The center sleeve hasn't popped out yet but I imagine it will today when i am done with it. This whole debacle has been holding me up for two days.

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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

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OK the sleeve is out! Repeat: The sleeve is out. And might I add how much this part of the project has sucked. Now I have a rubbery mess that only wants to be burned out. Problem is it's in a bad spot where I could end up catching the truck on fire. If one can't burn out a bushing what's available to them? This project is already taking twice as long as I expected so a few extra hours won't hurt me. What do you think?

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Bushings suck BTW!!

ib4200
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Joined: Sun May 15, 2011 9:31 pm
Car: 93 hardbody
95 Camaro

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bushings do suck! keep on working at it, you'll get it eventually. More pics too please

Novajoe
Posts: 59
Joined: Wed May 18, 2011 4:48 pm
Car: 97 hardbody xe king cab
08 lancer evolution gsr

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I think you should just torch it. I don't see anything really hazardous in the way. Just use a small, controlled flame. Feel free to pick up some scrap metal to use as a shield though if you're worried about it.

Another option is a dremel. though you're still going to need to get the metal bushing casing out.

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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

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Nope, casing has to stay for the poly bushings. I got it out and wire-wheeled the remains out so now it's ready for action.

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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

Post

PROGRESS MADE with lots of pics! If you don't want to burn a bushing you need to press the remains out followed by a lot of wire brushing. Pics are in no kind of order.

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Home made press, as seen on youtube.
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Number 1 thing to remember when putting poly bushings in....lube them good with the tacky stuff ES supplies with them. I noticed a squeak on the upper control arm just moving it by hand, lubed it up better and the noise went away. LUBE LUBE LUBE!!

PhillyHardbody
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Joined: Thu May 05, 2011 8:12 pm
Car: 1994 Hardbody

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Wow it looks like you really made some progress! This thing is going to be tight like it was new, good to see someone putting the time in to make things right.

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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

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More pics from today in random order. One of these days I'll have time to make a coherent thread out of all this.

Ok here's what I have for today. Both control arms are now installed, ball joints/knuckle installed and greased, painted the tension rod with Rustoleum and reinstalled the steering arm and the tie rod end. I also made a short list of items I still need to get, small s*** like cotterpins and such. On to the pics.



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Novajoe
Posts: 59
Joined: Wed May 18, 2011 4:48 pm
Car: 97 hardbody xe king cab
08 lancer evolution gsr

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passenger side looks great!! Are you going to do the alignment yourself?

StephenG
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Joined: Tue Jul 27, 2010 4:50 pm
Car: 93 Nissan Hardbody 2wd KA24E 5spd
87 Nissan 200sx CA20E 5spd

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Nice work Rev. Bet you're itching for that first drive.

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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

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Yeh, that's the big goal in mind. I still have the driver side to do which I am not looking forward to. I also have the rear springs to rebush and 2" lowering blocks to install. After that I imagine getting the suspension to settle for a good alignment will take a while. No hurry though, I am enjoying the garage time with my tools.

Not sure if I am doing the alignment or someone else is. I guess I'll know more when I get there.

Novajoe
Posts: 59
Joined: Wed May 18, 2011 4:48 pm
Car: 97 hardbody xe king cab
08 lancer evolution gsr

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sounds like you have your work cut out for you. good luck and I hope everything goes smoothly (like that ever happens lol).

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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

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Thanks man, hoping to be done with the entire suspension project by next Tuesday, like that's going to happen!

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longtooth
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Looks good. Glad its going back together for you. With the polyurathane busings I have found outboard blue lube works great.

ib4200
Posts: 21
Joined: Sun May 15, 2011 9:31 pm
Car: 93 hardbody
95 Camaro

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is This in spirit of the It trucks? are those the torsen bars talked about in the It truck thread? I just made almost the same bushing tool today to use on my buddys Bimmer and on only the second one the 1/2 inch threaded rod sheared off, how is yours working?

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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

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Inspired by is the best way to put it.

My press is working well. I made another one just using threaded rod, washers and nuts for pressing the bushings back in. So far so good I guess. My first attempt resulted in a sheared rod that turned into a bullet. Still haven't found one of the ends. After that I noticed it's all in the nuts, the grade 8 nuts that is. Cheap nuts didn't hold up well so I switched everything to grade 8. Nothing broke after that.

ib4200
Posts: 21
Joined: Sun May 15, 2011 9:31 pm
Car: 93 hardbody
95 Camaro

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wow, you've got me itching to do something like this now. what do you think the lower grade nuts had to do with the threaded rod shearing?

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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

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Grade 8 bolts are rated something insane like 150000lb tensile strength, correct me if I am wrong. I noticed the corners of the cheap nuts rounded off while the grade 8s corners didn't.

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Rev_D21
Posts: 5946
Joined: Sun Jan 12, 2003 9:49 pm
Car: 1986.5 D21 LB HD 2WD V6 5Speed
1991 D21 Reg 2WD Auto
1995 D21 Reg 2WD 5Spd
1996 D21 Reg 4WD 5Spd
2012 Versa 1.6S 5-Speed
Location: Somwhere in Western NY
Contact:

Post

Right side done! Time to take a 2 minute breather then start the other side. Here's some pics from today.

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And now a question to other members running this setup. Does the rear transmission bracket need to be modified to clear the wider diameter torsion bar? The bar seems to be sitting on the bracket even with tension on it. I am wondering if this will change once the truck is back on the ground. Here's pics of what I am talking about...

Note where the paint has begun to rub off.
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Any ideas?

Novajoe
Posts: 59
Joined: Wed May 18, 2011 4:48 pm
Car: 97 hardbody xe king cab
08 lancer evolution gsr

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dunno. I would wait to see how it sits when the suspension is loaded. As long as it doesn't rattle the only downside I can see to it being that way is the fact that it rubs a little bit of paint, other than that it can only make it better for the torsion bar to rest against a chassis piece like that. Maybe throw a small sheet of rubber in between the two to keep it from rubbing/vibrating too bad.

PhillyHardbody
Posts: 26
Joined: Thu May 05, 2011 8:12 pm
Car: 1994 Hardbody

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If your bolts arent rusted too bad it wouldn't be a bad idea to spend the 15 minutes to pull the crossmember down a bit and try to pound it out a bit with a hammer to give you some clearance.

Other than that GREAT progress Rev! Keep it up!


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