Front strut suspension washer failure                     

A common problem is the failure of the front strut shock washer which sits on top of the

shock rod against a small collar. Lotus made the washer a bigger diameter than std to reduce the

flex in the rubber above it, stiffening up the suspension. Unfortunately the washer thickness was the

same as standard, but the forces from the shock rod would literally punch right through the washer.

Some owners have experienced severe brake judder as a result. One of the things on my list of jobs

was brought forward recently by the findings of another club member (thanks David Franczak;-) 

, so I thought I may aswell take a look at mine. I've not really suffered any brake judder that I can 

remember, so was not expecting my washers to be punched through.............

 

The suspension leg is easy to remove, you may need to remove the top caliper securing bolt as this

fouls the lower leg through bolt. I undid the anti-roll bar drop link at the roll bar end. Undo the nut on

top of the strut rod sticking up from the suspension turret and the whole assy can be withdrawn.

With spring compressors in place and clamped, the nut holding the rubber swivel

bush can be undone.

The hole in the top plate should be opposite to the lower shock body bolts, mine was

slightly out.

 

 

At this point it would be a good idea to mark the orientation of the rubber mount in relation to the 

way it was removed, an old mount will have been distorted and so needs to go back in the same way 

it came out. (Not shown here as I used new mounts.)

Well why should mine be any different to anyone else's ?, the damage is quite obvious !

The replacement washer is about 5mm thick in the area that failed for the OE washer, I need to

buy some new rubber bushes, this gives me time to get the washers zinc plated.

Thanks Andy Bullock for supplying these new washers, for future ref, contact Dave Kember.

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