Installation Procedure GR40 S197 SLA Front Suspension System (Does not include Aluminum Spindle and Hub Instructions)

Transcription

1 Installation Procedure GR40 S197 SLA Front Suspension System (Does not include Aluminum Spindle and Hub Instructions) Please take the time and read these instructions first! The GR40 S197 system is designed for installation by experienced mechanics. It is a very simple install if you have experience with serious high performance chassis. It can be done on the floor but is best done on a lift. These instructions are only a list of suggestions that we follow in our shop. They work for us. If you work out better or easier methods, we would be glad to hear from you. But please be careful. If you do not install things properly, following quality standards of skilled mechanical work, you can damage parts, the car, or injure yourself and/or others. Removal: Remove entire front suspension and #1 and #2 cross member. This can be done by completely disassembling one part at a time, or in sub-assemblies. The following steps are for removal in three sub-assemblies. Note: Although not required we remove the front bumper cover and both front fenders to make the installation easier and prevent damage to fenders while installation is performed. 1. Using an engine support cradle, secure engine in place. Caution: You will be underneath the engine with no other support! Be sure to do this properly or serious injury or vehicle damage could result. Fig 1 2. Remove upper radiator retention brackets. 3. Support radiator with straps or bungees. It must be held up in the stock or higher position. Fig 2 4. Remove lower steering shaft from Steering rack. 5. Disconnect anti-roll bar links from struts. 6. Remove brake lines from #1 cross member (Supporting radiator and anti-roll bar) Fig 3 Page 1 of 14

2 7. Remove #1 cross member with anti-roll bar attached. Fig 4,5 8. Remove motor mount bolts. Fig 6 Page 2 of 14

3 9. Disconnect brakes and ABS cables. 10. Drain power steering reservoir and disconnect hoses from steering rack. Fig Support the #2 cross member securely. Fig Remove all #2 cross member retaining nuts and bolts. 13. Remove strut mounting nuts at top of strut towers. Fig Carefully lower #2 cross member with suspension and steering rack attached and remove. Fig 10,11 Caution: Have someone on each side holding each strut while lowering so struts won t flop over and damage the fenders, or cause the assembly to tumble off of support. Page 3 of 14

4 Installation: 1. Position the front cradle into place and install only the four forward mounting bolts (that used to attach #1 cross member and the four rear most lower mounting bolts down low under the floor. Tighten to snug. DO NOT INSTALL THE FOUR UPPER NUTS YET. Fig 16,17 Note: You may want to check the alignment of the K member to the frame, by using plumb bobs. The same method as all other GR40 front ends should be employed. See K member and A-arm install on our website at: HOWEVER, it should be noted that in our experience no s197 cradle has required plumb bob alignment unless the car has been crashed or otherwise heavily abused. 2. Tighten the installed 4 forward cradle mounting nuts and 4 rear bolts to Ford OEM Torque specifications. 3. Prepare for mounting the inboard reinforcement brackets that sit in place on top of the sub frame on each side, inboard of the apron (under hood next to engine). Do this by modifying the tang of the four long #2 upper cradle bolts so that the bolts will fit properly into the brackets. Be careful not to damage the A/C lines. Fig 12 13,14,15 Page 4 of 14

5 4. Install motor mounts on Cradle. If using solid motor mounts, install them now and remove engine cradle and supports. If using rubber mounts, the hole in the engine mount brackets on block may need to be enlarged on some models. Fig Remove rubber grommets from discarded #1 cross member and install them in the radiator support brackets of the cradle. Reinstall the radiator and upper retention brackets, removing radiator support straps or bungees. Page 5 of 14

6 6. Remove the fender liners 7. Remove the brake line hold downs on the side of sub frame and release the wiring harness hold downs so that the harness can be relocated on the aprons to facilitate positioning of towers. Page 6 of 14

7 8. Install towers, be sure left is on left and right on right. Fit them under the wiring as shown. 9. Use the original nuts and tighten to Ford factory OEM specifications. 10. Locate the two upper tower mounting holes You can drill 7/16 holes though the apron using the tower as a drill guide, or you can blind punch thought the holes in the tower and then remove the tower and drill using a roto broach, This take more time but is a cleaner install. (Shown) 11. These holes should line up with the holes in the inboard reinforcement bracket. If not, wallow out the holes in the apron until they align well enough to install the 3/8 bolts. Before final install of these 3/8 bolts, be sure to install the supplied spacers in between the towers and the apron. Install loosely. Page 7 of 14

8 12. Snug all mounting fasteners ands then torque to specificatin on chart. Caution: When drilling, be sure to limit depth of drill so as not to damage A/C lines inboard of apron! 13. Reposition wiring harnesses as shown, reinserting all hold downs possible. Page 8 of 14

9 14. Reposition brake lines to clear tower and upper control arm. If you are installing Griggs 4on4 brakes system, the hoses and fitting supplied will attach to frame to secure lines. If not, we recommend using an Adele clamp on the brake line to hold it in place on side of sub frame. 15. NOTE: This step is a change as of 2014 affecting all 2005 up Installations. Install upper mini tower support bolt and spacer to strut towers. Install all bolts before tightening any. Torque to specifications on chart. (Previously used vertical support bar as seen in other images has been deleted) 16. Reinstall fender liners trimming as required to facilitate wiring relocation and towers. 17. If headers are being installed, now is a good time to do so. There is lots of room. If long tube headers are being used, you may have a problem with the steering shaft clearance since it is relocated inboard. We offer angle mount steering rack bushings to provide additional exhaust to steering shaft clearance. 18. Install rear brake load support aluminum plate. Shim as required for clearance to bell housing bolts. Do not mount to Bell housing unless this is a track only vehicle and the engine and rotation parts have been precision balanced. (Drawing) 19. Install steering rack and assemble and connect hoses. It is advised to use a larger power steering cooler, along with AN fittings and hose. Due to the many varied vehicle usages and applications, these are not supplied by Griggs Racing as these parts usually require a custom installation. Contact our tech line for help if you have trouble finding what you need. 20. Install new steering shaft rack adaptor. Torque as per chart. 21. Install tie rod ends on rack. 22. Install lower control arms. Torque mounting bolts to spec on chart. Note: Outer strut link bolt and strut link jam nuts are supplied finger tight to facilitate installation. After installation be sure to tighten bolt and jam nuts as per chart. Do not allow aluminum tube to turn, this will make setup much more difficult. Page 9 of 14

10 23. Install upper control arms, be sure to install cross-shaft back side spacer washers. Torque mounting nuts to specifications on chart. 24. Install spindles and hubs. Torque ball joint nuts and steering arm bolt to specifications on chart. Be sure to use thread locker on lower ball joint nut and install the cotter pin in the upper joint. Suggestion: Apply a small amount of anti-seize to the taper on the ball joints to facilitate service removal in future. Note: At this point we perform a preliminary alignment. If vehicle is truly level, hold spindle at ride height. (See ride height char). Set camber and caster to initial settings as per chart, and zero the toe. A simple angle finder held against the machined surfaces of the Aluminum spindle will suffice. Be sure steering rack is locked in straight ahead position (centered). Use whatever method works for this. A simple squeeze grip clamp on the steering wheel to a bar across the doors will suffice. 25. Set Bump steer, if desired. Note: The system is designed for use with 18 inch or larger diameter wheels. With wheels smaller than 18 shortening of the Bump steer sleeve may be required and true bump steer cannot be attained. Our recommendations: Just run the car with the supplied aluminum spacers and recommended caster angles. We have found that bump-in seems to work best on this system on current DOT track tires. The exact amount depends on tire make, size, and compound and driver preference. But there is very little difference in vehicle feel or performance from small bump steer settings on turn in, as compared to the strut cars. The supplied spacer should make the bump steer close if not perfect. 26. Install anti-roll bar (ARB) assembly: A) Install jam nuts on 5/8 rod ends and screw into weldments on cradle. They should be set so center of ball is 2.5 inches below rail. Leave jam nuts loose until ARB is final installed. B) Insert bolts and spacers into pivot holes of anti-roll bar arms. Assemble onto rod ends attached to cradle. C) Check spacing between ARB arm and rod end each side. Minimize this distance with appropriate shims before tightening bolts. Torque fasteners and jam nuts to specs on chart. D) Install end links and spacers as shown. Be sure to leave one end link disconnected until after ride height and corner weights are set. Page 10 of 14

11 Note: It is recommended that the rear hole on the control arm and the center hole on the ARB arm be used initially. Almost all cars run in this position and need no further rate adjustment. 27. Assemble coil-over and adjust spring seat to zero free play and then back off one turn. 28. Install coil-overs spring down (upside down). Torque to spec on chart. 29. Install brakes, tie off the brake lines. You may need to be creative re fastening the steel lines to the new radiator core support cross tube on the cradle. We simply use ¼ wide tie wraps with steel tabs. 30. Install brake duct brackets and ABS sensors if used. 31. Tie off brake lines to center of radiator support. ** See supplemental sheet of images in addendum for pluming Griggs Racing Supplied Brakes. 32. Install wheel and tires. 33. Set ride height, scale and align. Recommended initial settings are in alignment chart. 34. Install final anti-roll bar link. With car level and loaded, so that the bar is will not be preloaded, with the car sitting level and wheels straight. 35. Tighten all Jam Nuts with hand wrenches. Use good judgment. Over tightening may cause problems. 36. Lubricate upper control arm grease fittings with synthetic extreme pressure lubricants. We recommend Amsoil or Redline products. Anti-seize works as well. 37. Before driving check that wheels do not contact the tie rods or steering arms at full lock. They need about 3/8 clearance or they may contact at full bump travel while at lock. If they do not have enough clearance, additional steering stops can be added to the race under the boots. We supply them with all the stops necessary for our GR40 Toy series cars, different wheels and purposes may require more stop or perhaps less. 6 mm stops are available from Ford dealers, part number F-N S. Other thicknesses are available however we have not been able to determine a consistent part number for them. If you find out, please let us know. It is recommended that the jam nuts and all other fasteners be checked after the first outing on track. Periodic inspection of all parts and bolt torque is a requirement for safety and longevity of components. Lubricate ball joints and upper control arms every 3000 miles or every track event. We recommend Amsoil or Redline lubricants. Page 11 of 14

12 Fastener Torque Specifications Location or Component Size Grade Torque (Ft-Lbs) Cradle Mounting, Forward 12mm 10.9m 85 Cradle Mounting, Rearward 12mm 10.9m 85 Cradle Mounting, Center 12mm 10.9m 85 Tower (UCA and Shock Mount) 3/8-24 SAE 8 44 Tower Upper Support 3/8-24 SAE 8 44 Lower Control Arm Pivots at Cradle 5/8-18 SAE Lower Control Arm at Ball Joint 1/2-20 SAE 8 85 Upper Control Arm Mount Nuts 7/16-20 SAE 5 55 Upper Control Arm Assy Bolts 7/16-20 SAE 5 55 Steering Rack Mounting Bolts 1/2-20 SAE 8 75 Steering Shaft Upper Pinch Bolt 8mm m 18 Steering Shaft Lower Pinch Bolt 5/16-18 NC 8 18 Ball Joint, Lower, Nut (USE Loctite 242) 3/4-16 SAE Ball Joint, Upper, Nut (Use Cotter pin) 5/8-18 SAE Anti-Roll Bar Mounting Bolts 5/8-18 SAE Anti-Roll Bar Linkage Bolts 7/16-20 SAE 8 55 Steering Shaft to Tie Rod End Bolt 5/8-18 SAE Coil Over Fasteners 1/2-13 NC 3 65 All Jam nuts Use good judgment with hand wrenches. Preliminary Set Up Specifications Note: Ride Height is measured at bottom of front cradle rear mounting flange (the plate the bolts go through, not the lower box gusset). 30 psi in all tires, car level side to side, driver in seat and full of fuel. 48.5% initial cross weight recommended. GR40 ST and TT with 2 drop Aluminum Spindle Track Use Street Use With Hoosier 295/ Diameter With Hoosier 315/ Diameter With Toyo RA1 275/35 R Diameter With Toyo RA1 305/35 R Diameter GR40 ST and TT with Steel Spindle Track Use Street Use With Hoosier 295/ Diameter With Hoosier 315/ Diameter With Toyo RA1 275/35 R Diameter With Toyo RA1 305/35 R Diameter Alignment Track Use Street Use Camber -2.0deg -1.0deg Caster 6.5deg 6.5deg Toe 0 1/16 Total Page 12 of 14

13 Front Brake Plumbing Addendum. These are examples of Griggs Supplied Brakes Installed With Griggs supplied Hoses and adaptors. Page 13 of 14

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