KIA Rio brakes

[Safety Guy]

Here's what I think is pretty solid:

-All measures I took comparing the struts were the same or extremely close.

-Part numbers between Aspire and early Rio Monroe SensaTracs at Rockauto were different, but could reflect the bracket changes or stiffer valving.

-The Rio springs look thicker than the Aspire ones, so I just went out and tried a 7/16" wrench on each. It snugly fit the Rio spring but was looser on the Aspire, so yes, they are thicker. If you want to use cut Rio springs you'll probably have more stiffness.

-We know from Hot Wheels' experience that Rio hubs will fit Aspire knuckles. Both Rio and Aspire use National A18 bearing sets (as do Festiva front hubs).

-Calipers appear to be the same, and take the same size brake pads as Aspire AT calipers. Rotors are the same. I believe many Escorts use the same calipers, pads and rotors as well.

-Aspires, '01 and '02 Rios, and '03 Rios with both engines use the same TRW tie rod end part number (from Rockauto) #ES3388. Also, since the last two of those were apparently sold, I checked Raybestos Prof Grade. Their tie rod end part #4011641 fits both '01 and '05 Rios. (Kia/Hyundai model change occured at '06.)

So, 1.5L Rios can provide us with AT Aspire equivalent calipers, rotors and pads. Struts and strut mounts should work, and *may* be heavier duty.

Using Rio knuckle assemblies is not yet a given, since Jim seems to have found a different measure of the Rio tie rod end placement. Would the tie rods make up for any difference, or could we substitute Aspire tie rods (inner or outer) to solve the problem? Don't know.

If you are scavenging from a 1.6L Rio, watch out that you aren't messing with entirely different parts! I think Kia upgraded stuff for cars with the bigger engine. My hope is that this area will show us more upgrade capability for both Festivas and Aspires!

By 2006, all bets are off. Looks to be a totally different animal, and the Rios are closer to Hyundais than before.

We'll keep collecting thoughts and info in this thread. If you get the chance to go a junkyarding and can do some work comparing various front suspension parts from '01 to '05 Rios, post it here. Be mindful of the engine sizes and years. Compare part numbers at Rockauto and other car parts sites to get info and ideas.

Karl

[hot4dl8ly]

Wow! Thats alot of info, it looks like all that we really need for the swap.

[Safety Guy]

Hot wrote:

"Wow! Thats alot of info, it looks like all that we really need for the swap."

Careful! I just sound like I know what I'm talking about!


Another tidbit:

Drop Zone makes lowering springs for the Rios and apparently they work on all of them from '01 to '05. Two inch drop. Might be nice on a Festiva or Aspire, but you have to buy all four, and the rears don't work. They only cost about $100 per set, though. Hmmm.

Also look for coilover and adjustable sets for Rios. See what there is out there, what kind of quality there is, and if you could make a deal with some factory to buy only the front applications...

Karl

[hot4dl8ly]

I dont know how to persuade the jam nuts without a torch, but the ends just require "tapping"(OK, really, hit it hard) the arm of the knuckle with a BM_H. It aint pretty, and it marks the arm- but it works.

[qroger]

It's a Mario!

Strut comparison pics; Rio on left and Aspire

I couldn't grab the knuckles since I always have problems with getting the tie rod ends to come loose. Also the tie rod end and jam nuts. Hmmph. I could use some ideas on how to do this if anyone knows the trick (besides a torch, which I don't have and they don't allow anyway).

Karl

Are you familiar with pickle forks for separating ball joints and tie rods? http://www.northerntool.com/shop/too...ci_sku=1115090
If my link didn't work, just search for pickle fork. As for the Jam nut, you can try a pair of 12 or 14" pipe wrenches. (also works on the tie rod - steering rack end.)

[junk yard dog]

to get the tierod end out of the knuckle use a two jaw puller works great

[zoom zoom]

to get the tierod end out of the knuckle use a two jaw puller works great

Haha, 2years later...

This thread needed revived anyway, Karl has done some great stuff researching Rio parts, and in the next month I will update this thread with my findings on the early 02 Rio knuckles. I have almost the entire front end suspension of the rio laying around and a aspire tore apart waiting on upgrades.

[Rectilinear]

I just installed a set of jy '01 Rio struts on the '92 Festy last week. They bolt right up and the only difference was the length of the steering arm making you turn the tie rod end further onto the rack after installing. Even the brake line swapped in perfectly and was the correct length and routing. I cut off 2 coils (appears to be 2.5 because of the way the spring is flattened on the ends) and flipped them over to retain them in the assembly. This is as much as you would want to cut off the Rio spring as a compressor was not required for installation after cutting them.
Looks fantastic now! Now I just have to put the rear end together...

[FestYboy]

^ pix or it didn't happen

[91mcnasty]

I wanna see those pics too.

Hey arty would rio springs make my car as stiff as bobby's? I need springs bad!!!

[Safety Guy]

So Rectilinear seems to have done the whole strut/spring/knuckle swap if I understand him correctly. Also, any difference in knuckle steering arm length is taken up by the tie rod ends being turned in more back to Aspire spec. (We already knew about the struts and springs, rotors, calipers and hose fitting.)

So far, proper fit of the Rio knuckle has been merely speculation.

Rectilinear, please confirm, and yes pics greatly appreciated!

This should establish you as the first one to document installing Rio knuckles in a Festiva or Aspire.

Karl

[FestYboy]

I wanna see those pics too.

Hey arty would rio springs make my car as stiff as bobby's? I need springs bad!!!

should make it stiff, but more manageable than the prelude springs.

[Rectilinear]

Whoa, guys, wait a minute! I am the first? I guess I missed something here as I was under the impression that this had been done many times before! lol!

Okay, I will take some pics in the next day or so as I still have to install new control arms, tie rods and sway bar bushings to complete the job.

Yes, I used the entire Kia Rio assembly from the jy. It all bolted in as if I were installing a new Festiva unit, quite simply in fact. The tie rod ends, balljoint/control arms and sway bar bushings are all new Festy units.

[FestYboy]

don't be too surrprised, i was the first to successfully doccument the XR2 front brake swap... there's always rumors and attempts first before someone figures it all out, you were that person, just like me.

[Rectilinear]

That's cool. It just sounded like "everyone was doing it" already! Seriously, the only surprise I had when doing the install was that everything went into place like it belonged there.

I will do my best to document this when the new parts go on, I am just waiting on the control arms to get here from Rockauto. And apparently I need steering rack bellows, too.