Quick Question on Koni Yellow Install on GTV6 - Alfa Romeo Bulletin Board & Forums
 
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post #1 of 14 (permalink) Old 01-15-2018, 12:12 AM Thread Starter
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Quick Question on Koni Yellow Install on GTV6

Koni provides incomplete and cryptic install instructions with their shocks. I just want to make sure I have the white nylon split-washer, rubber bump stops, and metal washer in the right place. Can someome confirm I have correct placement in the pictures below?

Not sure where that white nylon washer is supposed to go...on top or bottom. In the pic I have it on bottom.

Also, I assume I should use the rubber boot from my old shock to protect the shock piston as in the pic below.

Thanks.
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--Scott
Current: 85 GTV6, 69 Duetto, 17 Giulia, 74 GTV
Past: 65 Giulia Sprint GT, 77 Alfetta, 79 Alfetta, 87 Milano Gold, 74 GTV (Euro)

Last edited by crackie; 01-15-2018 at 10:05 AM.
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post #2 of 14 (permalink) Old 01-15-2018, 09:50 PM
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Hi,
Been 6+ years since I did mine but it looks right. Make sure you adjust to your desired setting before installing. Obviously. Yep reuse of the old boot is the way to go.

Happy installing!

'83 GTV6 - 164 12v 3.0 in!
'99 156 Twin spark - for track time fun! And ferrying the kids around in...
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post #3 of 14 (permalink) Old 01-16-2018, 01:03 AM Thread Starter
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Yeah - I think nylon washer goes on bottom. I just installed that way, so hopefully that is the case!

Thanks for the reply!

--Scott
Current: 85 GTV6, 69 Duetto, 17 Giulia, 74 GTV
Past: 65 Giulia Sprint GT, 77 Alfetta, 79 Alfetta, 87 Milano Gold, 74 GTV (Euro)
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post #4 of 14 (permalink) Old 01-16-2018, 06:48 AM
But Mad North-Northwest
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I’m going from memory here, Crackie, but IIRC the plastic washer is supposed to be up against the body of the shock, and there should be a second metal washer below the two rubber bushings.

The nuts should be tightened until the rubber bushings expand out to be flush with the outside of the washers (that’s what one of the cryptic graphics on the install instructions means. Took me a while to figure that out.)

Tom

1963 Giulia Spider (1750 engine)
1974 GTV
1991 Spider
Former: 1987 Milano Gold
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post #5 of 14 (permalink) Old 01-16-2018, 10:28 AM Thread Starter
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So the only washers that come in the box from Koni is 1 metal washer and 1 nylon split washer. And then the cryptic install schematic doesn't even show the nylon split washer or where it goes, nor does it show another lower washer. So a bit confusing.

So I called Koni tech support. They couldn't tell from their documentation either, so they pulled a shock from the shelf. Here are their instructions after looking at the shock and the parts in the box:

+White split washer goes flush up against the yellow shock body. So it needs to go BELOW the weld mark on the shock piston. (ie to the right in my picture)
+The original Alfa metal washer should be used where I have the white washer in my picture above...between the weld mark and the flush with the lower rubber bushing.

Net-net...what Gubi said. ;-)

Thanks.

--Scott
Current: 85 GTV6, 69 Duetto, 17 Giulia, 74 GTV
Past: 65 Giulia Sprint GT, 77 Alfetta, 79 Alfetta, 87 Milano Gold, 74 GTV (Euro)
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post #6 of 14 (permalink) Old 01-16-2018, 11:06 AM
But Mad North-Northwest
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Yep. Otherwise that plastic washer would be taking all the load of the bottom rubber bushing against the weld, and that's not going to work. I think the plastic washer is just there to prevent the adjustment mechanism from engaging in normal operation (you need to pull it out to adjust the shock, I believe.)

It should've come with two new metal washers. Weird that it didn't.

Tom

1963 Giulia Spider (1750 engine)
1974 GTV
1991 Spider
Former: 1987 Milano Gold
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post #7 of 14 (permalink) Old 01-16-2018, 04:59 PM
Richard Jemison
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Set-up

Actually none of the instructions yey posted seem correct.

The split plastic washer is to prevent bottoming and distroying the adjustmenr mechanism inside. That "weldment" will simply dislodge/crush the plastic and will not stop bottoming.

Commonly Koni shocks use the split plastic inside the metal cover shield on the shaft to have a flat metal contact on both sides to stop the shock travel.

Richard Jemison
RJR Racing

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post #8 of 14 (permalink) Old 01-16-2018, 09:24 PM
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<Thought bubble> Perhaps the plastic washer is to fit inside the open end of the boot to prevent big bits of crud getting in there?? </Thought bubble>

'83 GTV6 - 164 12v 3.0 in!
'99 156 Twin spark - for track time fun! And ferrying the kids around in...
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post #9 of 14 (permalink) Old 01-17-2018, 07:50 AM
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plastic washer goes inside the housing. not outside.
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post #10 of 14 (permalink) Old 01-17-2018, 09:16 AM
But Mad North-Northwest
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Quote:
Originally Posted by barboncino105 View Post
plastic washer goes inside the housing. not outside.
Are you suggesting you need to disassemble the shock to install that washer? Because that sure doesn't sound right.

On the shocks I got, the washer was already installed on the shaft under the weld, up against the body of the shock. I pulled the washer off to be able to push the shaft in far enough to engage the adjustment mechanism, then I put it back on where it had been.

Crackie, I'd listen to what Koni told you. And also that Gubi guy: he's pretty smart

Tom

1963 Giulia Spider (1750 engine)
1974 GTV
1991 Spider
Former: 1987 Milano Gold
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post #11 of 14 (permalink) Old 01-17-2018, 09:52 AM
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Seems to me some pieces are missing. There should be 2 steel washers for the top of the shock shaft. The split plastic washer goes around the shaft and lies directly on the shock body, it keeps the missing snubber from driving swarf into the seal around the shaft at the top of the shock body.
I suggest using one of the old steel washers, instead of the plastic washer, at the top of the shaft.
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post #12 of 14 (permalink) Old 01-17-2018, 02:32 PM Thread Starter
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Here's what I did. After talking to Koni, looking around at other forums, and input here, I believe this to be correct.

Working from top to bottom of installed shock:

--Top--
nut
nut
Koni flat metal washer
rubber bushing/stop
shock tower sheet metal
rubber bushing/stop
OEM Alfa metal washer (inserted in old dust boot to keep boot in place)
Koni nylon split washer (below piston weld, against top of shock body)
OEM Alfa dust boot over the top of it all and slipped over the shock body at the bottom of the boot.
--Bottom--

Some thought that nylon washer would not stop the shock from bottoming out. That may be the case, but it does look designed to slip between the weld and the top of the shock body while not expanding when compressed (i.e. when the shock bottoms out). Whether it actually achieves that end, I will leave to engineers to figure out. ;-)

HTH. Thanks for the input everyone.

--Scott
Current: 85 GTV6, 69 Duetto, 17 Giulia, 74 GTV
Past: 65 Giulia Sprint GT, 77 Alfetta, 79 Alfetta, 87 Milano Gold, 74 GTV (Euro)

Last edited by crackie; 01-19-2018 at 10:08 AM. Reason: Typo
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post #13 of 14 (permalink) Old 01-17-2018, 02:51 PM
But Mad North-Northwest
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That sounds about right. Like I said, tighten the nuts just to the point that the outside of the rubber bushings expands to flush with the outside of the metal washers. There should be a rather cryptic graphic with the shock instructions that shows that.

Tom

1963 Giulia Spider (1750 engine)
1974 GTV
1991 Spider
Former: 1987 Milano Gold
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post #14 of 14 (permalink) Old 01-17-2018, 03:10 PM Thread Starter
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Yeah - that was the only graphic of the bunch I understood. ;-)

--Scott
Current: 85 GTV6, 69 Duetto, 17 Giulia, 74 GTV
Past: 65 Giulia Sprint GT, 77 Alfetta, 79 Alfetta, 87 Milano Gold, 74 GTV (Euro)
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