Shock Inspection Procedure
 
The following will step through a shock inspection on FFR Roadsters, Type 65 Coupe’s, Spyder GT’s, and Challenge Cars.
 

Bilstein shock assembly and part names.
 
First:    Ensure correct assembly of suspension parts.

Properly secure the spring hat to the spring to prevent the spring from not fully seating on the spring hat.  This connection is commonly made with zip ties, or safety wire and can be observed in the photo below.
 

Zip tie installation. NOTE: Washers are also installed.
 
The photo below shows the spring incorrectly riding on the spring hat.
 

Shock installed incorrectly. Misaligned spring and spring hat.
 
Second:

Install an extra thick grade eight 7/16” SAE washer (15/32" ID, 59/64" OD, 0.119" thickness) between the shock jam nut and spring hat in the order shown below.
 

Installation sequence position (NOTE: Heavy duty washer should lie flush to the spring hat.)
 
Third:

Carefully check suspension components for clearance or damage.  Below are some areas we are highlighting for inspection, but you should carefully inspect ALL parts of the suspension:

FRONT SUSPENSION
1.
2.

3.
4.
5.
6.

7.

8.
9.

 Check to see that the shock part number is correct, the front shock is:  A273 T0.
All front shocks should be mounted with the body at the top, shaft at bottom (closest to road). This position makes the shock look "upside-down," but is correct.
Check front lower control arm to shock and spring seat clearance.
Check front upper control arm to spring clearance.
Check front upper shock to shock mount clearance.
Check front spring to threaded sleeve.  (acceptable light wear will usually be found here due to    normal spring deflection).
Check to make sure that the threaded sleeve is covering the snap ring on the shock body, the sleeve is recessed at one end for this purpose.
Check for evidence of misalignment between spring and spring hat.
Be sure that the total combination of spacers between the spring hat and the jam nut measures no longer than 0.50”. 
Note: This is shorter than the spacers that were supplied with the arms for use with Pro shocks.  If you are using other aftermarket front lower control arms, check with the manufacturer for clearance and shock travel concerns.  The earlier and current FFR arms can be seen in the picture below.
 

First generation FFR front lower control arm with Bilstein, 1⅞” spring and 0.50” (max length) spacer installed
 
10. If using 450lb or 500lb springs, please check the diameter of the spring wire, if the wire measures 0.462” or larger  the springs can not be used with this combination .  If you can not measure the diameter of the wire count the number of coils.  Use the picture below as a reference of where and how to count the coils.  Using 450lb or 500lb springs, if you have 12 or more coils, the springs can not be used with this combination.  New smaller wire diameter springs with a  spacer combination no longer than 0.50” would eliminate any problems.
 

Spring shown with 12.5 coils
 
11. If you have determined that you are using the springs with the larger wire diameter, measure the height of the ends of the wire (just below the start arrow in the picture above).  If the height of the end of the wire is 0.25” please call Factory Five Racing.
 

Left: first generation FFR front lower control arm.    Right: current Rev FFR front lower control arm
 
SOLID REAR AXLE
1.
2.
3.

4.

5.
6.
7.

 Check to see that the shock part number is correct, the rear coil-over shock is:  A274 T0.
Verify solid axle shocks should be mounted with the body at the bottom.
Check solid axle springs to threaded sleeve. (acceptable light wear will usually be found here due to normal spring deflection).
Check to make sure that the threaded sleeve is covering the snap ring on the shock body, the sleeve is recessed at one end for this purpose.
(3-link only) Check solid axle driver side spring to pan hard bar frame mount.
Check for evidence of misalignment between spring and spring hat.
If using the traction lock brackets that wrap around the shock mount, make sure that the thin spacer (looks like a washer) provided is installed between the shock and the back of the traction lock bracket.
 

New traction lock bracket with wrap around the shock mount.  Driver side shown.
 

Spacer and shock order.
 
INDEPENDENT REAR SUSPENSION
1.
2.
3.
4.

5.

6.
7.


8.

 Check to see that the shock part number is correct, the IRS shock is:  A273 T0.
IRS shocks should be mounted with the body at the top.
Check IRS shock and lower control arm clearance.
Check IRS spring to threaded sleeve. (acceptable light wear will usually be found here due to  normal spring deflection).
Check to make sure that the threaded sleeve is covering the snap ring on the shock body, the sleeve is recessed at one end for this purpose.
Evidence of misalignment between spring and spring hat.
If the IRS kit uses Pro shocks, or 2.5” springs, then the spacers provided with the FFR kit must be in place to make sure the spring and spring hat clear the IRS lower control arms. The spacer goes between the jam nut and the spring hat just as in the front suspension section above.
If the IRS is using 450# or 500# springs, please check the diameter of the spring wire, if the wire measures 0.462” or larger please call Factory Five Racing.  If you can not measure the diameter of the wire count the number of coils.  Use the picture below as a reference of where and how to count the coils.  Using 450# or 500# springs, if you have 12 or more coils please call Factory Five Racing.
 

Spring shown with 12.5 coils
 
If damage is found with any shock, spring hat, threaded sleeve, or spring seat, it must be replaced.  If you are in doubt, replace it.  These may be purchased from Factory Five upon the return of damaged parts.  Factory Five will inspect these parts and destroy them

If you have any question at all, please contact Factory Five Racing at 508-291-3443.