Suspension Modifications

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My GT-Four is fitted with Bilstein shocks all around. Bilstein do not make shocks off the shelf so customisation is required.

 

For the front I purchased stock ST162 struts to use as a basis for the conversion. I cut the spring platforms off and welded adjustable platforms in place for 2-1/2" race springs. Toyota Levin Bilstein inserts were used, these had the stroke reduced and were re-valved to suit the GT-Four.

 

I was fortunate to buy rear shocks which had once been on a Toyota Team Italia rally car. This saved me the hassle of modifying the rear struts to take inserts. They are Bilstein competition units and were actually intended for a Group N Peugeot 205 GTI!! The knuckle mounts were all cut off and new ones (out of 5mm sheet steel) welded in place. They have been revalved slightly for a rally spec GT-Four, and I have since revalved them again for the street. I have fitted adjustable platforms.

 

    ST165 stock settings:

Springs

Front:    2.4 kg/mm - 134 lb/in
Rear:     2.5 kg/mm - 140 lb/in

Shocks

Front:    100/35
Rear:     120/55
    ST165 TRD settings:

Springs

Front:    4.0 kg/mm - 224 lb/in
Rear:     3.6 kg/mm - 202 lb/in

Shocks

Front:    225/100
Rear:     225/100
      ST165 my settings:

Springs

Front:    250 lb/in
Rear:     200 lb/in

Shocks

Front:    375/100
Rear:     231/120

 

    ST185 TTE tarmac settings:

Springs

Front:    80 Nm - 706 lb/in
Rear:     75 Nm - 662 lb/in

Shocks

Front:    430/200
Rear:     280/220
    ST185 TTE gravel settings:

Springs

Front:    75 Nm - 662 lb/in
Rear:     40 Nm - 353 lb/in

Shocks

Front:    400/220
Rear:     260/240

I have also replaced all the suspension bushes with Urethane because the original ones were getting pretty worn.  The front bushes are available off the shelf (same as ST162). The rear bushings are not so easy.  There is a total of 14 bushings for the suspension arms and roll bar at the rear.  Of these,  12 were custom made.  Custom bushings allowed replacement of the worn hub balljoints.

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