How to install a Cusco rear strut brace.

1)Remove the rear seat base by removing the two retaining bolts with a 12mm socket, then sliding forward.
http://www.btinternet.com/~john.fels...ace/strut1.JPG
2)Remove the rear seat backrest by removing the three retaining bolts and lifting the backrest up over the retainers.
http://www.btinternet.com/~john.fels...ace/strut2.JPG
3)Remove the soundproofing by prising out the three plastic clips on the edge of the rear parcel shelf.
http://www.btinternet.com/~john.fels...ace/strut3.JPG
4)Remove the lower strut bar by removing the two retaining bolts
http://www.btinternet.com/~john.fels...ace/strut4.JPG
5)Remove the rear seat/boot area plastic separator by removing the two retaining clips.
http://www.btinternet.com/~john.fels...ace/strut5.JPG
6)Remove the rear seatbelt units using a 14mm socket and long extension; the bolts have retaining washers so they will not fall out of the seatbelt unit. With the bolt undone pull the seatbelt unit forward slightly to disengage the locating bracket, then push rearward and sideways and extract the unit. This allows easy access to the 3 strut top mount retaining nuts.
http://www.btinternet.com/~john.fels...ace/strut8.JPG
7)Remove the three nuts on the rear top mounts; make sure the cars weight is on the wheels, this way the strut will not move when you undo the 3 nuts.
http://www.btinternet.com/~john.fels...ace/strut9.JPG
8)Remove any excess joint compound from the top of the strut area where the strut brace bracket will mount, this ensures the strut brace bracket lies flat and clamps properly.
9)Strip the strut brace into its components then insert the top mount bracket through the sound deadening hole into the boot area, then place over the three studs from the top mount. Refit the three nuts onto the studs and tighten down so there is still some play to allow the bracket to move, yet it is located properly.
http://www.btinternet.com/~john.fels...ce/strut10.JPG
10)Insert the alloy spacer into the top mount bracket, locate the strut brace onto the top mount bracket, insert the long bolt through the bracket and brace, place the washer on the nut side of the bolt, tighten the nut to the point that all slack is taken up but there is still some slight play.
http://www.btinternet.com/~john.fels...ce/strut11.JPG
11)Centralise the strut brace and then tighten up the top mount nuts to the correct torque
12)Tighten the strut brace bolts to the correct torque.
http://www.btinternet.com/~john.fels...ce/strut12.JPG
13)Reinstall the seatbelt units, ensuring the locating brackets slide into the hole in the body. There are two, use the top hole. Torque the seatbelt unit retaining bolts.
14)Reinstall the seat in the reverse order of disassembly. The rear seatback locates over three retaining clips; ensure these are located before bolting up the three retaining bolts.
http://www.btinternet.com/~john.fels...ce/strut13.JPG
http://www.btinternet.com/~john.fels...ce/strut14.JPG

Only items 7-14 on a wagon :D

Richard

hmmmm, STi5 TypeRA V-Ltd or wagon????

Yep, i'll stick with having to do 1-6 too. :D

JF,
Nice:D

I have simalar instructions round here somewhere (never got round to posting them!)

*Note* UK cars (excluding RB5) do not require steps 4+5:)

Iain.

John,

Points 11 + 12, whats the correct torque settings?

cheers,
dela

PS - Wagons rule! :)

John,
This is like a dejà vu!!! I installed my front and rear Cuscos last Thursday!! While checking your guide, it looks like I didn't do any mistakes during the installation. GREAT GUIDE!! I found it particularly difficult to put the left 'blue' strut-plate in place with all the cables in my way! So far I am super happy with them! (Thanks again to Jamie @ JW-RACING!!)

would you have to have the geometry re-checked after fitting ?

anyone ?

Yes, it would be a good idea to get the geometry setup after fitting a strut brace. If you had the geometry setup and then added a brace, I doubt it would knock it out. AFAIK, the point of the brace is to stop excess chassis movement so should help maintain the geometry rather than upset it.

Stefan

cheers ozzy, may just buy one now, didn't want another geometry setup to pay for.

Oh no....Where's the bloody pictures gone too ?

Thanks Phill

WAGON & SEDAN (OLD)
JIM