Front Suspension System: Removal & Installation Honda S2000 AP1

Lower Arm Removal/Installation

Special Tools Required

1. Ball joint thread protector, 14 mm 071AF-S3VA000
2. Ball joint remover, 28 mm 07MAC-SL0A202

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1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-221314-S10900723812006022400000) ).
2. Remove the front wheel.
3. Remove the flange nut (A) while holding the joint pin (B) with a hex wrench (C), and disconnect the stabilizer link (D) from the lower arm (E). NOTE: Use the new flange nut during reassembly.
4. Remove the flange bolt (A), and disconnect the damper (B) from the lower arm (C). NOTE: Use the new flange bolt during reassembly.
5. Remove the cotter pin (A) from the lower arm ball joint, then remove the castle nut (B). NOTE: During installation, install the new cotter pin after tightening the castle nut, and bend its end as shown.
6. Disconnect the lower arm ball joint from the lower arm using the ball joint thread protector and the ball joint remover (see «BALL JOINT REMOVAL»(ref-221354-S20922790902006022400000) ). NOTE: Be careful not to damage the ball joint boot when installing the remover. Do not force or hammer on the lower arm, or pry between the lower arm and the knuckle. You could damage the ball joint.
7. Remove the flange bolt (A), the self-locking cam nut (B), and the adjusting cam collar (C). NOTE: Use the flange bolt and a new self locking cam nut during reassembly.
8. Remove the self-locking nut (D), the adjusting cam plate (E), the adjusting bolt (F), and the lower arm (G). NOTE: Use a new self-locking nut and a new adjusting bolt during reassembly.
9. Install the lower arm in the reverse order of removal, and note these items: First install all of the components, and lightly tighten the bolts and the nuts, then raise the suspension to load it with the vehicle's weight before fully tightening to the specified torque values. Be careful not to damage the ball joint boot when connecting the knuckle. Before connecting the ball joint to the knuckle, degrease the threaded section and tapered portion of the ball joint pin, the ball joint connecting hole, the threaded section, and the mating surfaces of the castle nut. Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. Before installing the wheel, clean the mating surfaces of the brake disc and the inside of the wheel.
10. Check the wheel alignment, and adjust it if necessary (see «WHEEL ALIGNMENT»(ref-221354-S33629121472006022400000) ).

Upper Arm Replacement

Special Tools Required

1. Ball joint thread protector, 12 mm 07AAF-SDAA100
2. Ball joint remover, 28 mm 07MAC-SL0A202

Scheme 48

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1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-221314-S10900723812006022400000) ).
2. Remove the front wheel.
3. Remove the flange bolts (A) and the wheel speed sensor harness (B) from the upper arm (C).
4. Remove the lock pin (A) from the upper arm ball joint, then remove the castle nut (B). NOTE: During installation, install the lock pin as shown after tightening the castle nut.
5. Disconnect the upper arm ball joint from the knuckle using the ball joint thread protector and the ball joint remover (see «BALL JOINT REMOVAL»(ref-221354-S20922790902006022400000) ).
6. Remove the flange bolts (A), and remove the upper arm. NOTE: Use new flange bolts during reassembly.
7. Install the upper arm in the reverse order of removal, and note these items: First install all of the components, and lightly tighten the bolts and the nuts, then raise the suspension to load it with the vehicle's weight before fully tightening to the specified torque values. Be careful not to damage the ball joint boot when connecting the knuckle. Before connecting the ball joint to the knuckle, degrease the threaded section and tapered portion of the ball joint pin, the ball joint connecting hole, the threaded section, and the mating surfaces of the castle nut. Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. Before installing the wheel, clean the mating surfaces of the brake disc and the inside of the wheel.
8. Check the wheel alignment, and adjust it if necessary (see «WHEEL ALIGNMENT»(ref-221354-S33629121472006022400000) ).

Damper/Spring Removal and Installation

Special Tools Required

1. Ball joint thread protector, 14 mm 071AF-S3VA000
2. Ball joint remover, 28 mm 07MAC-SL0A202

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Scheme 54

1. Raise the front of the vehicle, and support it with safety stands in the proper locations (see «SAFETY STANDS»(ref-221314-S10900723812006022400000) ).
2. Remove the front wheel.
3. Remove the flange bolt (A) and brake hose mounting bracket (B) from the damper.
4. Remove the cotter pin (A) from the lower arm ball joint, then remove the castle nut (B).
5. Disconnect the lower arm ball joint from the lower arm using the ball joint thread protector and the ball joint remover (see «BALL JOINT REMOVAL»(ref-221354-S20922790902006022400000) ).
6. Remove the flange nuts (A) from the top of the damper.
7. Remove the flange bolt (A) at the bottom of the damper.
8. Lower the lower arm, and remove the damper/ spring (A).

Note. Be careful not to damage the body.

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1. Lower the lower arm, and position the damper/ spring (A) in the body. NOTE: Be careful not to damage the body.
2. Loosely install the new flange nuts (A) onto the top of the damper studs.
3. Position the bottom of the damper on the lower arm (A), and connect the lower arm and the lower ball joint (B).
4. Install the new flange bolt (C), and lightly tighten.
5. Raise the suspension until the vehicle just lifts off the safety stand.
6. Install the castle nut (A) onto the lower arm ball joint pin, and tighten it to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it.
7. Install a new cotter pin (B) after tightening the castle nut, and bend its end as shown.
8. Tighten the flange bolt connecting the damper bottom to the lower arm to the specified torque value.
9. Tighten the flange nuts on the top of the damper to the specified torque value.
10. Install the brake hose mounting bracket (A) and the flange bolt (B) to the damper, and tighten the bolt to the specified torque value.
11. Clean the mating surfaces of the brake disc and the inside of the wheel, then install the front wheel.
12. Check the wheel alignment, and adjust it if necessary (see «WHEEL ALIGNMENT»(ref-221354-S33629121472006022400000) ).

Scheme 61

Note. When compressing the damper spring, use a commercially available strut spring compressor (Branick MST-580A or Model 7200, or equivalent) according to the manufacturer's instructions.

Scheme 62

1. Compress the damper spring, then remove the self-locking nut (A) while holding the damper shaft (B) with a hex wrench. Do not compress the spring more than necessary to remove the nut.
2. Release the pressure from the strut spring compressor, then disassemble the damper as shown in the Exploded View.