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Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

Fitting the Terrafirma Extreme 12 inch travel mega sport kit

So our TD5 90 had an unknown set of springs and shocks on it when we collected it almost 10 months ago, we knew it had uprated springs and dampers and some D44 kit, but we were not sure of what it exactly was.

So as we worked the car hard on our off road school course, we soon realised the shocks were tired, despite having a good range of travel.

Then back in September on our extreme cross axle section, we managed to break the front off side shock absorber.

So we decided to order the full Terrafirma extreme suspension kit, which was duly delivered at end of September.

The reason we chose this solution,,was that we had it our our previous V8 CSW 90, and it was a revelation in terms of performance and comfort.

So after months of the rattling shock, we finally decided enough was enough and set about fitted the off side set today.

The next posts will be all the pictures, sorry they are only iPhone versions, meant to use my Nikon dslr but got side tracked.

3rd Jan 2019 10:21pm

Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

First job.

As always with what seems like a simple job, it was time to get the air tools on the top shock mount.

As usual, despite lots of WD40 the top shock bolt was not for coming off.

So in the end we decided to just row the whole shock tower off.

Click image to enlarge

3rd Jan 2019 10:24pm

Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

Or what it seems!

So we had been told our car had a two inch lift, but it now seems it was not the case.

On pulling the D44 shock tower and shock itself off, together with the spring we now realised it was only about a 1 inch lift with a spacer.

Click image to enlarge

3rd Jan 2019 10:28pm

Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

Mounting the extreme shock tower.

Next job was getting the shock tower in place.

It took some cutting and bending of the inner wing to get it in place.

Click image to enlarge

But after a bit of cutting and bending it went in quite easily.

3rd Jan 2019 10:30pm

Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

Spring and dislocation cone mounting.

Next job was to get the spring and dislocation cone in place.

A bigger challenge than you realise, as the +2 inch springs need the axle to be almost of the floor and the chassis as high as it can get.

Click image to enlarge

3rd Jan 2019 10:34pm

Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

Shock mounting.

Next part, the big one, getting the shock in position.

If you’ve never seen one of these shocks before, it’s hard to believe just how big they are!

Click image to enlarge

3rd Jan 2019 10:38pm

Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

Shock trial fit.

Now the next challenge, getting the huge shock in the right position.

The issue of course, is one, where to put the remote reservoir, and two where to angle the output of the hydraulic pipe to feed in the right location, without fouling all th rest of the stuff in the local area!

Click image to enlarge

3rd Jan 2019 10:41pm

Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

Dropping the shock in place.

So top down, or bottoms up to get the shock in.,

We went for top down.

Click image to enlarge

3rd Jan 2019 10:43pm

L110CDL

Member Since: 31 Oct 2015
Location: Devon
Posts: 10540

Good phone pic's

Good progress there, once you have done the first one, the others should be a bit easier to do

1996 Golf Blue 300Tdi 110 Pick up. Keeper.

Clayton.

3rd Jan 2019 10:45pm

Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

Offering all the parts up for a full trial fit.

On to the semi final part.

Offering the whole assembly into position.

Click image to enlarge

3rd Jan 2019 10:47pm

Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

Remote reservoir location?

As you can see we chose to put the remote reservoir inside the outside part of the wing.

Only reason for this was space under the bonnet was limited. And we did it like this last time.

Any other suggestions before we finally fix it in place?

Click image to enlarge

3rd Jan 2019 10:50pm

Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

So, it’s much higher than the previous set up.

Now it’s all in place we know it’s much higher than the previous installl.

These pictures might not show it, but the whole car, once settled back on it’s whewls and jacks and stands off is 3.5 inches higher on the off side than the near side.

Click image to enlarge

3rd Jan 2019 10:53pm

Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

L110CDL wrote:
Good phone pic's

Good progress there, once you have done the first one, the others should be a bit easier to do

Cheers Clayton!

Yep,we hope so!

We had put it off for months, but in reality even with the seiezed bolts the whole off side took less than 2 hours from start to Finish!

3rd Jan 2019 10:55pm

Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

Finally finished off the rest of the front suspension

Mounted the hydraulic bumpstop and the remote reservoir too.

Click image to enlarge

18th Jan 2019 11:28am

Nigelpugh7

Member Since: 18 May 2018
Location: Solihull
Posts: 115

More updstes pictures of the whole install.

A member contacted me to say that he wanted to know about the rear suspension install..

Sorry but for some reason I only update the other thread with the rest of the photos.

Here’s the rest now.

Click image to enlarge

26th Jan 2019 10:10am

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