Upgrading to AE86
struts in a KE2# Corolla
Here's a way to upgrade to a strut with 9" disks in your ke20, ke25
or ke26. The same conversion ideas could be used for struts out of a T powered
corolla ie TE27, TE37, TE71 etc and many early Celicas, Carinas and Coronas that share the
85mm steering arm bolt pattern. For this upgrade i am using AE85 struts.
The strut itself being identical to an ae86, except has differences in spring
rates, the vented disk, different caliper and backing plate which i plan to change to at a
later stage. I am doing this particular upgrade on the cheap and used whatever was
available at the time
To remove struts
First step: crack the wheel nuts, then jack the car up and put the front end on axle
stands. this is for your own safety!
Next.. undo wheels and unbolt the complete ke2 struts by undoing the three 12mm nuts at
the top and the two 17mm bolts at the bottom.
If you have slotted the brake hose mount then unbolt the caliper + hose and put it off to
the side. If not, then you'll need to undo the brake hose (messy).
The strut can then be removed. You may like to keep a nut on at the top to take the
weight whilst the bottom is pulled out. I find it easiest to step on the end of the
steering arm to split it away from the strut... then twist the strut over the other
locating pin and out away from the car. To remove steering arms, pull out
split pins, undo the nuts and use an appropriate puller tool to make removal easier.
If you have to bash things, try use a soft face hammer and put a nut on any bolt
threads for protection.
Steering arms
The problem here is the ball joint in the ke2# has a smaller pin than the T
powered corolla or any of the later corolla's. So one of their steering arms are not
going to seat on it. The options here is to use a steering arm that bolts in (te27), find a ball joint that will match
the steering arm to be used, change to a different lower arm that suits or buy some
RCA's that adapt from 80mm to 85mm (may have to be custom made) and keep the ke2 steering
arm. Or get some custom steering arms made to the correct size. The cheap and nasty way is using a 1mm shim wrapped around the
ke2# ball joint pin to increase it's size. This has to be exactly 1mm or an ae86 steering arm
wont seat against the b/j boot.
NZ model ke2# have a steering arm 110mm long center-to-center with an 80mm bolt spacing to
the strut. To keep the same turning circle and turning response, a similar length
steering arm should be used. TE2# have the same length 110mm arm and 85mm bolt
spacing and the smaller ke2 ball joint pin hole so is a perfect part to use (if you can source some!). next shortest is the AE85/86 at 115mm or
135mm long depending on power-steer or not but need to adapt the ball joint size to suit. These are the shortest ones to my
knowledge. Late ke70 wagon 130mm long and ta22 130mm. TE7# arms are much too long at 138mm. measure anything you look at buying as theres so many variations found in each market!
Shocks/Springs
Here i am using lowering King Springs #ktfl-28 and a Tokico AE92 GT gas shock. Due
to the sporty nature of the spring i needed to have at least 1.3/4" shorter stroke
than factory to keep them captive. The well known AE92 GT shock conversion can give
between 2" and 3.1/2" shorter stroke (from my measurements) depending on where
the shock body is positioned. The body itself is 45mm shorter than an ae86 shock so
spacers will need to be used inside the strut to keep it contained. This setup may
not be the best but so long as the shock is sufficiently supported and theres enough
suspension travel for safe driving then there shouldn't be a problem. Or ultimately
the strut body can be shortened which will give extra travel at a low ride height.
Overall the ae92 GT shock length is about 90mm shorter than the ae86 one.
Otherwise the ae8# shocks could be shortened or aftermarket short stroke items ordered
etc.
This is an area where theres plenty more options... so a simple sport spring upgrade may
suffice or up to the ultimate coilover setup... a standard shock up to fully
adjustable dampening short stroke shock etc.
Fitting
Before assembly the parts were degreased, and where applicable, wiped with grease
n wax remover then painted satin black.
The shock retaining nuts from the ae92 unfortunately had a different thread to screw into
the ae85 strut. The ae92 shock has a smaller body near the top so a locating collar
needs to be made when using the ae85 retaining nut to hold it central. I didnt have
any material available for this so decided to turn the new ae92 nuts into collars.
see pic.
With the shock nicely secured at the top, a 45mm spacer was turned to locate it at the
bottom as i wanted the shock to sit at the top of the strut for maximum stroke.
The ke2# sponge type bump stop tends to crumble after 30 years. So the rubber ae85
bump stop was used, but I cut the dust cover off as the ke2 top spring cap has a dust
cover attached already which i wanted to use to keep the spring fit snugly.
Last thing before assembly... just under the top hat, there should be a dust cover
to protect the bearing.. these usually have crumbled and dropped out by now so is a good
idea to replace it. I used some high density sponge cut to shape. It'll be
interesting to see how long that lasts. Spring compressors are required to fit the
spring cap and top hat on if your springs are infact captive! which make it soo much
easier to locate the cap on the top of the shock.
materials/costs: (NZ dollars)
AE85 struts
$50.00 (trademe)
AE85 p/s steering arms $24.00 (pick-a-part)
king springs 2nd hand $100.00
Tokico AE92GT gas shocks $218.00 (S.A.S)
aerosol degreaser $2.50
(supercheap)
Satin Black aerosol nz$4.20
"
wheel bearing grease
words/pics by Mark
Tech
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