Maintenance Safety
Posted: Thu Nov 06, 2008 6:43 pm
Today I drove out to Icon Dynamics to have my right coilover rebuilt after busting it at BorregoFest. I brought all my tools, including jack, jackstands, blocks, airtools, (Powertank 
)etc. What normally should have been a 10 minute shock removal become 30. I could not understand why the strut was placing so much pressure on the lower control arm mount even when I had completely released all tension on the spring by backing out the upper spanner ring completely. I finally used a crowbar to pry the lower strut from the lower control arm and when it popped out the strut literally exploded. The entire lower arm shot downward while oil and shrapnel blew everywhere, mostly on me 
. I was very lucky that nothing but oil entered my eyes. There were pieces of the destroyed piston, retaining ring and nut scattered all around me. Most of the metal shot down with the strut and the oil fanned outward. Much of the aluminum piston was already shredded to bits but there were some thumb sized chunks here and there.
I had considered going into the shop and asking them to take a look before I pried the strut outward but I was sure it would release with just a nudge. Neither Adrian nor Jeremy had ever had to release the nitrogen charge in order to remove a strut so they both said they probably would have done the same and just pried it out. If we would have known the strut was separated and had no retaining ring or nut in place they could have manually released the charge and that would have prevented the explosion. I was wearing gloves at the time but not safety glasses. Next time something seems to be resisting I'll resort to the safety glasses.
As usual the Icon Dynamics crew including Jeremy and Adrian were a great help. Adrian basically built a new shock using the spring and caps of my old shock with a new strut, piston and cylinder. I had the new coilover back on in minutes, made some adjustments and it felt great on the way home. Those guys over at Icon always amaze me with their positive attitude and helpful manner. They also left me a hat, stickers, etc. These guys hands down offer the best customer service in the suspension product arena or anywhere for that matter.
P.S. Dylan and his wife are having a baby today, he or she could be born by now?
)etc. What normally should have been a 10 minute shock removal become 30. I could not understand why the strut was placing so much pressure on the lower control arm mount even when I had completely released all tension on the spring by backing out the upper spanner ring completely. I finally used a crowbar to pry the lower strut from the lower control arm and when it popped out the strut literally exploded. The entire lower arm shot downward while oil and shrapnel blew everywhere, mostly on me . I was very lucky that nothing but oil entered my eyes. There were pieces of the destroyed piston, retaining ring and nut scattered all around me. Most of the metal shot down with the strut and the oil fanned outward. Much of the aluminum piston was already shredded to bits but there were some thumb sized chunks here and there. I had considered going into the shop and asking them to take a look before I pried the strut outward but I was sure it would release with just a nudge. Neither Adrian nor Jeremy had ever had to release the nitrogen charge in order to remove a strut so they both said they probably would have done the same and just pried it out. If we would have known the strut was separated and had no retaining ring or nut in place they could have manually released the charge and that would have prevented the explosion. I was wearing gloves at the time but not safety glasses. Next time something seems to be resisting I'll resort to the safety glasses.
As usual the Icon Dynamics crew including Jeremy and Adrian were a great help. Adrian basically built a new shock using the spring and caps of my old shock with a new strut, piston and cylinder. I had the new coilover back on in minutes, made some adjustments and it felt great on the way home. Those guys over at Icon always amaze me with their positive attitude and helpful manner. They also left me a hat, stickers, etc. These guys hands down offer the best customer service in the suspension product arena or anywhere for that matter.
P.S. Dylan and his wife are having a baby today, he or she could be born by now?
