RRE's 3G Koni Insert Install Pics and Price Info

Koni sells an insert intended for the front of the 90-94 Mitsubishi Eclipse. The strut tube inner dimensions and upper threaded rod of the 1G Eclipse is exactly the same as the 2000-2002 Eclipse. This means that the Koni insert is a direct swap into the 3G front strut housing. This swap on a 1G Eclipse or a 3G Eclipse requires a fair amount of mechanical ability. You need to be able to cut open the stock strut tube and drill large holes in addition to being able to remove and install the springs with out hurting your self. This page is intended to show you what is involved so that you can make an informed decision when it comes to purchasing and installing these inserts. We have pricing information on both the parts involved and our shop labor at the bottom of the page.

Note 4/25/02 Modifying Konis for additional travel:
Some people have been putting the custom modified shortened Koni front struts on cars that are too low and/or with too big tire and wheel combos. When you ask for additional travel out of your front suspension, you will get exactly that...additional travel. Because of the complaints regarding this modification we performed, we are no longer offering this service for mail order customers. If you are local and we are able to make sure that the application and install are correct, we will still do this modification. Mike W

Koni's Instructions
	Here, Koni is asking you to make alignment marks on the bearing plate, the upper spring perch and the lower spring perch. The spring perches are offset to clear the strut tower. If not aligned properly, the spring and perches will contact the body when you turn the steering wheel. The standard spring removal and install steps and precautions apply here. Many big chains will loan you a spring compressor for free or they can be purchased for $25-$50. Air tools are a HUGE help here but not necessary.
	Center punching the center of the bottom of the strut housing.
	Drill a starter hole in the bottom of the strut housing. 1/8" hole is fine. This will bleed off any residual pressure from the strut. Here Koni is having you put a piece of tape over the hole to not make a big mess with oil everywhere.
	About 1 3/4" below the top of the strut, use a hack saw to cut through the tube. Keep going around in a circle until the tube is cut through. You dont need to cut all the way through the strut rod, just the outer tube. About 1/16" deep, or a little more. Knock the upper part out of the strut tube.
	With the strut rod in a vise, tap down on the strut body. The stock insert will come out. It will be an oily mess. Have a drain pan ready. Dump what ever oil remains in the housing into the drain pan. Dispose of the oil like you would motor oil.
	Now, using the starter hole you made earlier, drill a larger 9/16" hole in the bottom of the tube. If you cant come up with a drill that big, use a 1/2" drill and file it 1/16" bigger.
	Check the inside of the strut tube for any burrs or protrusions. Remove them if necessary.
	Place the rubber sleeve over the end of the strut tube. Slide the Koni insert into the strut tube.
	Use the supplied bolt, concave washer and lock washer to draw the Koni insert down into the strut tube. Torque the bolt to 60-65 foot pounds. It is a good idea to check the torque on this bolt one month later and also one year later. Roll the rubber sleeve up to cover the joint where the insert meets the strut body.
	Place the white flat plastic washer on top of the strut insert over the rod. Reinstall the spring assembly. Take note of your alignment marks. Dont forget to install the bump stops and accordion dust boots.
	Torque the top nut to 37 foot pounds. Do not use an impact wrench. With an impact wrench, you risk breaking off the upper tip of the rod (it is hollow) and you risk damaging the adjuster tab.
	Adjustment knob placed onto the adjuster tab.
Additional pics
	Spring compressor clamping down on the spring.
	Using a Big Ol' drill press to drill the bottom hole. A hand drill works fine too.
	Starter hole drilled. We blow a bigger 1/4" hole in the bottom.
	Lets us drain all the oil out. You need to pump it some to get all the oil out of the valving.
	We cheat when it comes to cutting the top of the tube off.
	We use a chop saw and make a big smokey mess.
	Here it is with the inner strut guts just poking out.
	All the guts out.
	Empty tube.

We currently have the Koni Sport front inserts in stock. They are $145 each.

If you are local, us installing everything:

You need to make an appointment to bring the car in. We are usually able to get the car in with in a week. You will need to drop the car off for an entire day. We are not able to do it "while you wait".

The cost to remove and install the pair of front strut assemblies from the car is $40.

The cost to remove and reinstall the springs is $20 for the pair.

Once the springs are removed, the cost is $50 to cut the pair open, take out the stock inserts, clean the housings and install the Koni inserts into the strut housings the way that Koni recommends. This gives you the same amount of suspension travel as stock.

Add $40 to install rear shocks and or lowering springs on the rear at the same time as installing the fronts.

E-mail Tony to set up an appointment for the install.

Local, but us modding the struts only:

If you are local, you remove the strut assemblies your self but are unable to deal with removing and reinstalling the springs. You bring in just a complete spring/strut assembly:

The cost to remove and reinstall the springs from the struts is $20 for the pair if you bring them in with the springs still installed..

An appointment is not necessary, we will need the struts left here for an entire day.

You are far away and we will be shipping you installed inserts for exchange:

If you are far away and we are going to ship you struts already made up for you to install. You send us your old dead struts back with in 2 weeks:

If you are a frequent repeat customer, you pay $40 additional for the core/exchange deal.

If you are a new customer, we will charge you a $170 core charge. When we get your old front struts back (valving can be dead, strut bodies must be straight) we will refund you $130. We are keeping $40 of the core money to go towards buying core exchange parts.

If you wish to keep your old struts, you just pay the full $170, let us know your plans at the time you place your order.

The cost is $50 to cut the pair open, take out the stock inserts, clean the housings and install the Koni inserts into the strut housings the way that Koni recommends. This gives you the same amount of suspension travel as stock.

To sum it up:

Frequent Customer, Core Exchange Availability subject to other guys returning their cores in a timely fashion
Part/Service	Quantity	Price Ea	Price
Koni Sport Insert	2	$145	$290
Labor, Install Inserts	1	$50	$50
Core Fee	1	$40	$40
Total			$380
If Cores are not returned to RRE With in 4 weeks of invoice date			$130 Additional

New/Infrequent Customer, Core Exchange Availability subject to other guys returning their cores in a timely fashion
Part/Service	Quantity	Price Ea	Price
Koni Sport Insert	2	$145	$290
Labor, Install Inserts	1	$50	$50
Core Charge	1	$170	$170
Total Charged to Your Credit Card at Time of Purchase			$510
Refund Amount When Usable cores are returned to RRE			$130
Total Cost Once Cores are Returned			$380 Standard

No Core Exchange, No Wait, You Keep Your Old Struts:
Part/Service	Quantity	Price Ea	Price
Koni Sport Insert	2	$145	$290
Labor, Install Inserts	1	$50	$50
New Factory Mitsu Struts	2	$85	$170
Total Charged to Your Credit Card			$510
No need to return your old stuff.

Who and When I'll try to keep this list current to with in a day or two just to help everyone know where they stand. Please install them and get your cores back to us ASAP, there are others waiting. Guys that are buying the struts outright and not doing the exchange will get done with in 3-4 days since we don't have to wait for a pair to be returned. Your credit card is not charged until the struts actually ship out to you. We are currently running 4 pairs in circulation for the exchange program (4/02)
Who	What	Order received	Parts in/ Cores Avail	Building Parts	Shipped	Cores Returned
Ryan Saghir	Short	3/19	Yes	5/17	5/20	Ryan didn't listen and used the US Mail to return his :-P
Brian Sewell	Short	3/20	Yes	5/17	5/22	No Exchange
Alex Meredeth	Short	4/9	Yes	4/19	4/24	No Exchange
John Tmmerman	Std Length	4/11	Yes	6/11	6/14	Received
Joe DeNave	Std Length	4/15	Yes	6/11	6/14	Received
Lyndell Carrion	Std Length	4/25	Yes	7/2	7/3	Received
Angelo Kapsimalis	Std Length	5/15	Waiting For Cores	7/14	7/17	Received
Edgar Martinez	Short	5/21	Yes	8/9	8/12
Bruce Ponkivar	Std Length	5/22	Yes	7/13	7/10	No Exchange
Mathew Booth	Std Length	6/04	Yes	8/9	8/12
George Dushensky	Std	6/18	Yes	7/2	7/3	No Exchange
Andrew Go	Std Length	7/15	Yes	~7/22	7/19	No Exchange
Chris Ryniker	Std Length	7/18	Yes	7/22	~7/26	No Exchange
Tyler Morant	Std Length	7/22	Yes	8/22	~8/23
J Bachleda	Std Length	8/5	Yes		~8/23	No Exchange
Thomas Borja	Std Length	8/14	Yes
Michael Moore	Std Length	8/19	Yes	8/22	~8/23	No Exchange
Thomas Wozniak	Std Length	8/20	Waiting For Cores

Contact Road///Race Engineering
13022 La Dana Ct. Santa Fe Springs, Ca 90670
Tel (562) 777-1522 Fax (562) 777-1562
This page created and maintained by ArtOfWeb.com last updated 8/7/02mw

RRE 3G Koni Front Insert Install Info

Additional pics

We currently have the Koni Sport front inserts in stock. They are $145 each.

If you are local, us installing everything:

Local, but us modding the struts only:

You are far away and we will be shipping you installed inserts for exchange:

What Rear Shocks to get?

Who and When