cusco zero-2 maintenance

[dyslexik]

Anyone know where in Melb I can get my cusco zero-2 coils rebuilt? There is still a bit of noise on the front left and its suspected that something is worn inside the struts itself. It has been tested on a suspension machine and also can be heard slightly on the road. Also, there is no more noise from the pillow ball mounts and camber plate as they have been replaced with new ones already.

[SuperDave]

I'd be interested to find out if they can be rebuilt, but as far as I know Cusco's idea of rebuilding them is to buy new inserts and swap the upper and lower mounts and other bits they stick on. They don't cost that much money; postage will be a killer though. I'll ask around for you though.

[dyslexik]

I'd be interested to find out if they can be rebuilt, but as far as I know Cusco's idea of rebuilding them is to buy new inserts and swap the upper and lower mounts and other bits they stick on. They don't cost that much money; postage will be a killer though. I'll ask around for you though.

I just looked over the Cusco zero2 scanned PDF guide you had quoted in the workshop and also an info sheet of the zero2's from the Cusco website. I'm hoping that the noise problem is simply due to a worn 6mm rubber seat used in the coils to reduce spring contact noise or the specifically designed bump rubber.

Thanks for your help SD, look forward to hearing from you soon.

[SuperDave]

You could try contacting this mob http://www.shockreco.com.au/reco.htm

Only downside is they are in Brisbane, but I'm sure they could let you know if it is possible and who local to you can do the work.

[dyslexik]

You could try contacting this mob http://www.shockreco.com.au/reco.htm

Only downside is they are in Brisbane, but I'm sure they could let you know if it is possible and who local to you can do the work.

Ahh TSR...was looking at their website this morning. why must everything be in QLD lol. Cheers SD.

This one is in Melb http://www.advancedjapautoimports.com.au/suspensions_coilovers.html as well as a couple of others in the west side. --> Just got off the phone with these guys, they don't do rebuilds =(

Still waiting for callback from TSR.

Received callback from Chaser Motorworks and they referred me to their contact whom they get their suspension work done there. http://www.centrelinesuspension.com.au/ Hopefully, these guys will be familiar with Cusco zero series as they live about 15 mins drive from my house too. --> Just spoke to Chris and he suspects the noise may be due to a worn rubber seat and the spring may have gone through the seat itself knocking on the pillow ball mount. He also mentioned the noise may be coming from the front strut or even worn bushes from experience.

Only problem is that, he wouldn’t be able to get Cusco parts and doesn't have the tools to re-gas/oil the coil itself back together. They specialise in Koni, Pedders and Bilstein suspension.

I will book my car in on my next rdo to get the noise problem diagnosed. Worse case scenario is, if they can't get replacement parts and fix it, I will need to ship the front left coil to TSR, if they are able to rebuild it.

Edited June 23, 2010 by dyslexik

[dyslexik]

I've contacted a Cusco distributor in QLD http://www.cusco.co.jp/en/distributor/ --> http://www.999automotive.com.au/index.html and spoke to Geraldine. She said they too also don't have the tools to take apart the Cusco strut itself. The best thing is to have my front left coil posted to them and have the old strut replaced with a new one from Japan. She will also have the mechanics put in a new 6mm rubber seat and bump stopper for free.

They also use TSR for all their sports motoring suspension work, but with Bilstein suspension setups only.

Total cost is approx $700 or less delivered back to my door.

Breakdown of cost:

$510 new strut

$190 Labour + Delivery

$Nil 6mm rubber seat & bump stopper

mmm...what to do, what to do????

[SuperDave]

I'd hope all struts were replaced as there is a high chance of them being unmatched; hence why struts are always sold in pairs.

[dyslexik]

I'd hope all struts were replaced as there is a high chance of them being unmatched; hence why struts are always sold in pairs.

That is correct SD.

My decision on this topic can be found on post #37 http://au.toyotaownersclub.com/forums/index.php?showtopic=27747