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For the rears, I decided not to mount the reservoirs in the plastic trim along the sides of the wagon trunk. I guess it depends on what you carry back there but I wouldn't want to risk them getting damaged or knocked around. Instead, I have them wrapped in towels under the side floor panels. They're still perfectly accessible but are protected. You might even be able to install them using the supplied brackets under the panels actually into the metal.

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Very much icing on the cake at this point. A shift boot made from pieces of and R seat. 

OK so, Had the rear seal replaced on the angle gear as well as the fluid changed out. No longer leaks on the hot exhaust making the terrible terrible stench. Started in on wrapping the exhaust and g

Alright I should see there return early next week but the kind people at Performance Shock Inc were gracious enough to provide me with some pictures of the rebuild and testing process. 

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Getting the rear pads in and cleaning off some goo. Alot easier and faster when it's not on the car.
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The assembly of these brakes is so much nicer than the standard setup. I always hated pressing the pad with the clip into the piston. Here i can use a hammer. (we miss you clarkson)
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OOOO New
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So large!
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Aftermath
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Nice cleanup! Now you're set for 50-60K on those pads :)

They do fill the wheels nicely too..

I REALLY like how nice they come together. Not just from a looks standpoint but the construction of the pin/retainer/backing plate.

I also may have learned there's a cotter pin that holds the larger retaining pin in by smashing the first one out with the punch/framing hammer. I'm sure a parts or hardware store will have a decent replacement.

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Got a chance to install the intercooler. 
Not easy and not hard just time consuming getting everything lined up straight. Everything is as expected, tighter upon refitting. 
The fan had to kind of be shoved into place to fit past the plenum. 
Arranging the Ac/intercooler/rad is a paint as well. My do88 unit did not have a perfect 90* angle on one side so it cause some headaches getting the bolts in through all 3 pieces. However the previous radiator replacement on this wagon l;ed some one to drill holes in the headlight support and allowed for much greater access. 
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Good mix of coolant and Atf
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Many curse words later 
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Obligatory side by side picture. 
Pictured as well the Milwaukee m18 fuel impact gun excellent tool if your looking for a electric impact gun.
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on the advice of VS i put washers to space the intercooler from the radiator and get less surface contact.
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Gaff tape to keep them in place for the install
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Four hours later
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The rebuilt front shocks are a sight to be seen. Really happy with their performance so far. Noticeable difference from 1-4 and especially at the 7-8 setting. Bumps are no doubt felt with more force and I can report more once the new tires are on all four corners. Dry rot /  Ozone sucks. 
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Experiences in the past week have been mixed as well. The back end of the car is rather low and any suggestions for getting a little more height would help as i've already had a few nicks to the undercarriage adjusting to the dropped chassis. 


Control arms in the back sit almost parallel to the ground compared to their sprung state they previously had.
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Have to love those heat shield fasteners too. I hope to get a good solution for keeping it up there soon. 

 

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Not sure if i should stay with b&w or go with a colored one 
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More gratuitous shots. Profile is normally the best view of these cars
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Sadly 10 years in the box seemed to get the better of the one rear Ohlins Shock.
Seeing what can be done with warranty from overseas as its weeping fluid. 
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Mini project I dont think i can get done by carlisle.

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Also didn't realise they have a plastic hinge on the 99 cars but metal on the 98 so the gap should be a little different. 

As is ALWAYS my luck the day i wash and wax the car there is heavy rain. O well. 
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Edited by apeacock
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I suspect an installation error caused the damage to your Öhlins. On the picture it looks like the braided line has a cut, that might have been caused by the cover plate for the strut tower. There is a foam sleeve on the braided line meant to prevent it from getting in contact with anything.

As for the heat shields: Simply use a big washer to get around the problem of rusted mounts.

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That defiantly looks like a cut. 10 years in the box, that stainless still looks new, stainless does not rust or break down, this is damaged else wise. 

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I suspect an installation error caused the damage to your Öhlins. On the picture it looks like the braided line has a cut, that might have been caused by the cover plate for the strut tower. There is a foam sleeve on the braided line meant to prevent it from getting in contact with anything.

As for the heat shields: Simply use a big washer to get around the problem of rusted mounts.

​I will go that route for the heat shield.
tough to say on the lines really. If it did happen then It was an accident on my mechanics part, though he says that it had a break in it to start with when it was installed and I do tend to trust him with that kind of thing. 
I only installed the shields loosely this past weekend and the car has otherwise driven without them. The tube doesn't contact the edge though and it was definitely cut prior to putting any sort of miles on the car. Maybe there was a defect to start with I didn't see when in the box? 

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Hmm...

Braided lines like this don't just fail for no reason. So if it was damaged before, the line has either been kinked (bending angle was to sharp) or cut. However you said you installed the shields loosely and I can't see the foam sleeve. Might have been an unfortunate coincidence that caused the failure. I'm not blaming your mechanic, some things just happen without anyone being really at fault.

Warranty - good luck with that. Not sure if I would give or honor a warranty on 10 year old dampers that were sold abroad. *looks around* Want to buy some replacements?

Edited by Blockpartie
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Hmm...

Braided lines like this don't just fail for no reason. So if it was damaged before, the line has either been kinked (bending angle was to sharp) or cut. However you said you installed the shields loosely and I can't see the foam sleeve. Might have been an unfortunate coincidence that caused the failure. I'm not blaming your mechanic, some things just happen without anyone being really at fault.

Warranty - good luck with that. Not sure if I would give or honor a warranty on 10 year old dampers that were sold abroad. *looks around* Want to buy some replacements?

​If it comes to it and your have some I would consider it. However they were sold with a warranty and so I would imagine if there is another set and they can honor it then something can be worked out. 
Tough to tell what I can do, would just like to be able to use them as they were not easy to get and who knows if they are replaceable. 

 

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Instead of dicking around with warranty and shipping them out to an Ohlins service center, I'd just have a local hydraulic line shop replace that section of line.  It'd be cheaper and quicker to deal with a local shop.  I know Omni Services can typically turn that stuff around in a day or two - there's one not far from you in Buffalo at 3187 Eggert Road Tonawanda, NY

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