How to install inverted inserts – Flatout Suspension Inc

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How to install inverted inserts

This post is in reference to installing our universal 40mm inverted shock inserts but can be used universally with some minor differences.

The first thing you want to do after removing your suspension is remove the top mount and spring so you are only left with a strut assembly.

Step 1: Drill a small hole in the very center of the bottom of the OEM shock. This will allow the gas and oil to escape and serve as a pilot hole later in the process.

Step 2: Push and pull the shock rod up and down to drain as much oil as possible.

Step 3: Use a pipe cutter to cut the top of the shock off, usually between 5-10mm total. Trim as little as possible and cut more as needed. If you have a beveled edge inside, be sure to leave about 7mm of material above that as it will secure the bushing used later.

Step 4: Pull the innards of the shock out so you are left with a hollow housing.

Step 5: At the bottom of the housing, enlarge the hole to 1/2” to allow the threads at the base of the shock to pass through.

Your OEM shock housing is now prepped and ready for the insert.

Step 1: Insert the supplied (or use your own) cartridge alignment shim. It's the longer tube with a beveled edge.

Step 2: Gently tap the edges of the shock body to "crimp" the shim into place. You might find you need to use a tool such as a flathead screwdriver to get a good crimp. Tap in a few areas to hold it firmly in place.

Step 3: Install the top/ finishing cap. After test fitting, you may want to run a bead of glue on the inner wall where it touches the sides of the shock body. If it fits in place firmly don't use glue as it will be easier to service.

Step 4: Apply a liberal amount of waterproof grease (something like CV axle grease) to reduce friction and to allow the insert to move freely. This is easy to service as it only requires pulling the insert to re-grease.

Step 5: Slowly slide the insert into the shock body. Be sure and guide the bottom through the hole so as not to damage the knob. It shouldn't take any force to slide in. It will slide in with very little to no resistance.

Step 6: Install the 19mm nut on the bottom to secure the insert into place. If you use an electric impact, go until the first click (or ugga dugga).

Step 7: Install the adjustment knob finishing cap and secure with the 3mm set screw on the side.

That's it! All that's left is to reassemble with springs and tops and install on your vehicle!

This is a universal part, your steps may vary, you may need different sized alignment inserts and top cap, but we supply a base so you can reference what you need. We can't guarantee fitment on anything. Our procedure was done using a new Subaru Global shock (new Forester, Outback, etc.).

 

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