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Unread 08-08-2011, 10:26 PM   #16
dykaar
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My body guy, Ben, did the rears without having the wheels, so that was a mistake on my part. Be aware that the left rear wheel is most likely 1/2" further outboard than the right. Ben was also of the opinion that steel would be much stronger than cutting off the quarters and "stapling" on fiberglass or carbon flares. The quarters were laid on top of the cut off originals to gain about 2.5 " across the top. Also be careful with clearance along the front edge of the wheel opening. Thats where the 335 tire caught the sheet metal, but that was before I discovered the exrtra 1/2" of outboard spacing.

Best of luck, and post your progress. We all have better chances to succeed if we all post.

Regards,

doug

86 951 (http://www.pcaucr.org/visuals/photos...egory&catid=61)
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94 855 turbo Wagon (sold in 09)
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83 944 (sold in 86)
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Unread 08-08-2011, 11:15 PM   #17
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Quote:
Originally Posted by dykaar View Post
Be aware that the left rear wheel is most likely 1/2" further outboard than the right.
This seems to be right on, from what I've seen of my two cars thus far. Is this from bushing wear? Alignment drift? Global warming? I'm due for an alignment before I put the car back on track (UCR in September at Mosport) but I'll try to avoid aligning the body panels to the wheels, in any case!

Sorry to drag your thread off-topic.
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Unread 08-09-2011, 12:02 AM   #18
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Actually, I think the culprit is this eccentric mounting hole for the spring plate cover on the driver's side. The hole is circular on the passenger side. I think the spring plate ends up at the outside of the eccentric.

Regards,

doug

86 951 (http://www.pcaucr.org/visuals/photos...egory&catid=61)
01 E320 (W210) 4matic Wagon (http://www.benzworld.org/forums/w210...body-do-2.html)
00 540i-6 (http://forums.bimmerforums.com/forum...hp?albumid=976)
94 855 turbo Wagon (sold in 09)
85 535i-5 (sold in 07)
76 300D (sold in 92)
83 944 (sold in 86)
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Unread 08-09-2011, 10:31 AM   #19
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Okay, noted.
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Unread 09-18-2011, 04:34 PM   #20
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Update here. No torsion bars inside so I can check clearance. I had to position the chassis bolt exactly where the old torsion tube had been (as seen by the outline of the washer in the undercoating) in order for the spring plate to rotate freely. Go figure.

Regards,

doug

86 951 (http://www.pcaucr.org/visuals/photos...egory&catid=61)
01 E320 (W210) 4matic Wagon (http://www.benzworld.org/forums/w210...body-do-2.html)
00 540i-6 (http://forums.bimmerforums.com/forum...hp?albumid=976)
94 855 turbo Wagon (sold in 09)
85 535i-5 (sold in 07)
76 300D (sold in 92)
83 944 (sold in 86)
I apparently only buy cars designated by numbers
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Unread 09-22-2011, 09:30 PM   #21
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Update here. I installed the loaded swingarm (neww ball bearing and spherical end bearing). Unfortunately, the hub plate with studs doesn't wanna slip into the bearing, so I'm gonna have to use the stub axle and nut to pull it together, which means more car wrestling. Feh. At least it looks mahvelous. Doesn't it lookj mahvelous? I think it looks mahvelous.

Regards,

doug

86 951 (http://www.pcaucr.org/visuals/photos...egory&catid=61)
01 E320 (W210) 4matic Wagon (http://www.benzworld.org/forums/w210...body-do-2.html)
00 540i-6 (http://forums.bimmerforums.com/forum...hp?albumid=976)
94 855 turbo Wagon (sold in 09)
85 535i-5 (sold in 07)
76 300D (sold in 92)
83 944 (sold in 86)
I apparently only buy cars designated by numbers
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Unread 09-23-2011, 11:16 AM   #22
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Very nice. I had an alignment done last week, and the guy who did it (Courtney at EU Autowerks in Toronto) thinks I have a slightly bent control arm, but my mechanic friend thinks that it's more likely that slop in the eccentric mounting hole you mentioned above is to blame.
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Unread 09-23-2011, 03:00 PM   #23
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Charlie,

I now have had two different torsion bar carriers in the car, and they were both offset to the very outside of the eccentric hole.

The location in the eccentric hole in the frame shouldn't necessarily result in an alignment error if everything else is straight. Did you get a printout of the results? It would be very useful to see exactly which measurement was off.

I had bent the mounting ears on the torsion bar carrier where the end of the swing arm pivots. The result was that they couldn't get the rear toe in spec.

My front control arm bad bushings. My 86 had the original ginormous rubber rear bushing on the front control arm and it had cracked/split allowing so much distortion under braking it felt like I had major toe-out.

Regards,

doug

86 951 (http://www.pcaucr.org/visuals/photos...egory&catid=61)
01 E320 (W210) 4matic Wagon (http://www.benzworld.org/forums/w210...body-do-2.html)
00 540i-6 (http://forums.bimmerforums.com/forum...hp?albumid=976)
94 855 turbo Wagon (sold in 09)
85 535i-5 (sold in 07)
76 300D (sold in 92)
83 944 (sold in 86)
I apparently only buy cars designated by numbers
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Unread 09-25-2011, 08:27 PM   #24
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Update here.

The picture has the wheel/brake disk on and the swingarm raised until the tire just starts to rub. What is supposed to limit the suspension travel? Is it the swingarm hitting the chassis, or does the shock bottom out? Anybody know?


Regards,

doug

86 951 (http://www.pcaucr.org/visuals/photos...egory&catid=61)
01 E320 (W210) 4matic Wagon (http://www.benzworld.org/forums/w210...body-do-2.html)
00 540i-6 (http://forums.bimmerforums.com/forum...hp?albumid=976)
94 855 turbo Wagon (sold in 09)
85 535i-5 (sold in 07)
76 300D (sold in 92)
83 944 (sold in 86)
I apparently only buy cars designated by numbers
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Unread 10-17-2011, 04:26 PM   #25
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Update: I'm now trying to drop the torsion bar carrier again, and I'm having the same issue: the clips on the carrier are hanging up on the corresponding clips on the torque tube. Picture here. It doesn't seem like it was designed to drop straight down. Or has my whole drive train moved forward slightly? Uh oh.

Regards,

doug

86 951 (http://www.pcaucr.org/visuals/photos...egory&catid=61)
01 E320 (W210) 4matic Wagon (http://www.benzworld.org/forums/w210...body-do-2.html)
00 540i-6 (http://forums.bimmerforums.com/forum...hp?albumid=976)
94 855 turbo Wagon (sold in 09)
85 535i-5 (sold in 07)
76 300D (sold in 92)
83 944 (sold in 86)
I apparently only buy cars designated by numbers

Last edited by dykaar; 10-17-2011 at 04:49 PM.
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Unread 10-17-2011, 06:46 PM   #26
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OK, this is just redicky-donkey. To get the torsion bar carrier to drop, I had to lever it as far as it would go to passenger side. Is that right? I'm beginning to think that the reason the eccentric hole is on the driver's side is because the torsion bar carrier was speced 1/2" too long by the factory.

Next is doing a better job of mounting the elephant bushing inner races, then final assembly mit torsion bars.

Regards,

doug

86 951 (http://www.pcaucr.org/visuals/photos...egory&catid=61)
01 E320 (W210) 4matic Wagon (http://www.benzworld.org/forums/w210...body-do-2.html)
00 540i-6 (http://forums.bimmerforums.com/forum...hp?albumid=976)
94 855 turbo Wagon (sold in 09)
85 535i-5 (sold in 07)
76 300D (sold in 92)
83 944 (sold in 86)
I apparently only buy cars designated by numbers
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Unread 10-18-2011, 12:57 PM   #27
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I don't know why, but I'm surprised that you're putting torsion bars in. Then again, maybe the advice I've heard to ditch them in favour of coilovers is motivated by not knowing how to do what you're doing...

Which bars are you putting in?
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Unread 10-18-2011, 01:17 PM   #28
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Charlie,

I have the straight cup setup, coil-overs and torsion bars (23.5 mm). I'm thinking of larger bars. I'm concerned about removing the bars altogether. The lower shock mount supposedly isn't designed to carry the entire load. I know there is a conversion kit to a beefier lower mount, but that would be more money (presumably) than bigger torsion bars. This project is already over budget and late. Very late. I wrecked in 2001. Family happened in between. My kids are now teenagers and I need a hobby again.

My other concern is that stiffening the rear will make the car looser, and that's what may have contributed to the wreck. OK, that and the front sway bar bracket breaking.

I'm looking for nice well behaved setup that won't bite me.

Regards,

doug

86 951 (http://www.pcaucr.org/visuals/photos...egory&catid=61)
01 E320 (W210) 4matic Wagon (http://www.benzworld.org/forums/w210...body-do-2.html)
00 540i-6 (http://forums.bimmerforums.com/forum...hp?albumid=976)
94 855 turbo Wagon (sold in 09)
85 535i-5 (sold in 07)
76 300D (sold in 92)
83 944 (sold in 86)
I apparently only buy cars designated by numbers
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Unread 10-18-2011, 05:32 PM   #29
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I have a pair of 25.5mm bars that have been staring back at me from the corner of my shop for over a year. If I don't decide to use them, I'll let you know.
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Unread 12-03-2011, 04:13 PM   #30
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Update: It occurs to me that I should be able to easily remove the 1/2 shafts. Picture here. They are detached from the swingarms, which are off the car. On my other cars, the splined shafts are just "pushed" into the diff, and held in by a circlip. On my 540, I had one pop out and I had to mash it back it with a mallet. My favorite repair of all time.

The factory manual seems to skip this part, and the how tos suggest taking all the bolts out.

So do the splined drive shafts just get pried out of the diff, or am I missing something?

Regards,

doug

86 951 (http://www.pcaucr.org/visuals/photos...egory&catid=61)
01 E320 (W210) 4matic Wagon (http://www.benzworld.org/forums/w210...body-do-2.html)
00 540i-6 (http://forums.bimmerforums.com/forum...hp?albumid=976)
94 855 turbo Wagon (sold in 09)
85 535i-5 (sold in 07)
76 300D (sold in 92)
83 944 (sold in 86)
I apparently only buy cars designated by numbers
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