jelanier

I have seen several videos of suspension failures on various track cars that could certainly ruin your day. I was starting to wonder about my 2004 S2000. I do a track day about once a month. Are there any known failures (the dangerous kind) that any of you may know of that I can look for? I would hate to have a suspension failure in a high speed turn or have a wheel fall off My S has lots of miles on it now and I just want to be safe. 181,000 miles so far. It is just starting to break-in good

Thanks in advance

Jim

captain_pants

On the front suspension, weld the upper rear control arm mount to the body. The factory spot welds can fail once subjected to track abuse. There's a TSB about it.

CKit

But he's got an AP2. I haven't heard of any of those failing.

If you're on your stock brake lines, maybe consider replacing those.

TurboViper

SOURCE:
Honda Service News September 2004

TITLE:
Popping From Front Wheel Upper Control Arm Mount.

APPLIES TO:
2000-04 S2000

CKit

I don't know when they went to seam welding instead of spot welding. Does anyone know if it was mid-2004 or really with all AP2s. That'd be important to know.

Andrie

My 2005 have reinforcement across the tab on top and bottom.

Dipstick

My 00 AP1 upper mount failed at Buttonwillow Cotton corners. Colatkitty's also failed there (AP1, 02 I think). Another member's failed at SMMR this past weekend (also a 02 AP1 if I recall), he'll probably post some pics soon.

The guys who rewelded the mount said there's three layers of sheet metal there but the mount is only spot welded to the outer layer. They drilled out the spotwelds and "rosette" welded thru to all three layers, beefing up the entire area. They also seam welded the perimeter of the mount.

Also watch out for these other popular catastrophic failures:
Bump steer kit (mine went at SOWs and wiped out my rear SRC damper reservoir)
Diff failure (after ~180k, took a while but it went, fortunately while I was cooling off in the paddock).
Also replace your bearings once you start hearing the squeak/squeak/squeak...

I've been tracking this chassis since '00 and frequently visit the dirt.

jelanier

Thanks,
I think I found it. Is this a recall or out of pocket repair?

My link

Jim

dan_uk

when you say failed you mean you noticed it was pulling away a bit or the mount actually came off or moved enough to cause some kinda suspension failure?

its on my todo list I just haven't noticed any movement there if its in danger of letting go suddenly I guess I better get it done..

Dipstick

Fail = broken spot welds on the A-arm's upper mounting bracket and separation of the bracket from the body.
On mine it "peeled" away, and was still attached somewhat, on others it's a full separation.
It'll feel like your alignment is off + klunking noises when you turn the steering wheel.

The fix is to remove the a-arm and have the mount bracket welded solidly to the body.
I'll snap some pics when I swap pads this week...