One of the big problems with the 2G DSM is that the shock fitment it uses is specific to the 2G and nothing else. Accordingly, you don't have much choice when it comes to sourcing aftermarket shocks. You either build your own or you buy Koni Yellows.
Koni Yellows aren't a bad shock but Koni designs them to work with the OEM springs and the OEM upper mount, which just doesn't cut it from a performance perspective.
What you need is a coilover - with a proper coaxial upper spring hat.
Lots of people make reasonable coilover sleeves for Konis, but nobody makes a proper spherical bearing upper shock mount.
There is a commonly availible aftermarket upper mount, but the spring rests dirrectly on the underside of the mount plate, and that is a HUGE no-no. The spring needs to be able to pivot to be able to remain coaxial to the shock shaft without bending, like so:
So then, here is how you build a proper Koni based 2G shock setup:
You need:
- A set of Koni Yellow shocks. They will need to be dynoed, and they need additional snap ring grooves cut into them (Koni North America should be able to do this, or any decent machine shop)
- 4 x Hypercoil springs, in 2.25" x 8". Use the Suspension Dynamics Worksheet to work out your rates.
- 4 x Hypercoil 2.25" "helper springs". These are flat springs with minimal rate; they are designed to collapse as soon as any weight is placed on them. They keep the main springs from rattling around.
- 4 x 2.25 ID Torrington bearings, with races (you need 8 x races)
- 4 x Koni coilover sleeves with low-profile hats, part number 80.0000.1
- 4 x Aurora PNB-12T spherical bearings
- 4 x Upper mount plates. You are going to have to have these made yourself.
Here is the drawing - 4 x Upper Standoff. You are going to have to have these made yourself.
Here is the drawing - 4 x Lower Standoff. You are going to have to have these made yourself.
Here is the drawing - 4 x inside snap ring
- 10 x M10x1.5 socket head screws, with nuts and washers (3 each on the front, 2 each on the rear)
- Access to a small hydraulic press
The spherical bearing is press-fit into the upper mount plate and then retained with the snap ring. Be careful pressing it in, and be sure to use lots of lube, because if it gets cocked in the bore, it'll ruin the upper plate. Slide the coilover sleeve over the shock, then add the Torrington bearing, the helper spring, and the main spring. The spring hat fits over the top of the spring, then the lower standoff, the upper mount plate, and finally the upper standoff.
