I recently purchased a pair of KYB front strut assemblies for my 99 Honda Civic DX. KYB catalog indicates that two different parts are required: SR4040 (right) and SR4041 (left).

I ordered and received both units. SR4041 (left) mounted perfectly. However, SR4040 (right) did not mount. The angle between the top mount (two bolts) and the bottom mount (notch) is too shallow. In other words, SR4040 appears to have been twisted to make a shallower angle between the two mount points. No matter what I tried SR4040 would not mount on the right front strut holder.

I returned SR4040 and was refunded without issue. However, after receiving a replacement SR4040 I see exactly the same problem as before: SR4040 mount point angle is shallower than the SR4041 mount point angle.

Pictures make the problem obvious. First, lay both units on a flat surface with their notched lower mount points pointing up:



Next, view each unit along its axis from the top mount point:


I expect the angles made by the top mounting bolts to be equal and opposite for each unit. They are opposite, but not equal.

Has anybody successfully used the SR4040 and SR4041 strut assembly pair from KYB before? If so, did they have the same difference I'm seeing here? If so, what am I missing?

 

The tophats can be adjusted, you do know that right?

 

Yes, just twist the top part as necessary until the bolts will line up, and install. The top is designed to rotate relative to the bottom, in fact when installed on the car they have to rotate every time you turn the steering wheel.

It should go without saying, but since you seem to be new at this, NEVER loosen that nut on the top of the strut rod. The unit will fly apart from spring pressure with enough force to potentially cause injury or death.

 

oh yes....bust an ankle...

 

That's good news. How is it done?

I can grab the top hat and twist the bottom mount point (where the strut fork attaches). It does not budge. This applies to both SR4040 and SR4041.

That seems to contradict observations and the FSM. I have tried twisting the bottom relative to the top and vice versa. No amount of torque I can apply with my body will change the angle between the top mount and bottom.

Also, the strut fork does not appear to rotate when the front wheels turn. The FSM doesn't give any great pictures here, but consider this one:


As you can see, the strut fork does not rotate. It's prevented from doing so by the lower arm. So as far as I can tell, the angle between top strut mount bolts and the strut fork never changes when the front wheels turn.

What am I missing?

 

Wrong - only struts do this and this is a shock absorber.
Yes the tophat can be moved to line up
I have these Shocks on my 2000 EX and they both fit fine with out having to move it.

 

Put the shock fork on the shock, mount the assembly, stick a long bar in the shock fork and turn it so the fork will line up with the LCA. That's all I ever did. You will need a long bar though.

 

Contacted the manufacturer (KYB). The angle I'm referring to is "clock angle." It's not set correctly in SR4040 and should not be adjusted by the customer. Company tells me they are looking into the problem and that I should return the assembly for a refund in the meantime.

 

LOL..not adjusted by customers? So If someone wants to put lowering springs on there who is suppose to do it? What if the customer wants to do it themselves, which is the norm these days.

 

I don't know that I've ever bought a set of pre-assembled shocks that didn't need some adjustment in that regard. In any case I would simply disregard KYB's advice and adjust as necessary.

 

To close the loop, I broke down and bought the KYB SR4040 from a local auto parts store. Its clock angle was exactly as expected. Installed the unit without issue. Still no word back from KYB.

FWIW, the service manual notes that the expected clock angle, as measured with alignment tabs facing inward, is 59 degrees: