My Rio/Aspire Suspension Upgrade

[1990new]

Here us a photobucket link to pictures of my Rio/Aspire Suspension Upgrade.
http://s1222.photobucket.com/user/1990new/slideshow/Rio-Aspire%20Suspension%20Upgrade


Note the before and after photos of the Kia Rio Alloys. I only found two and
they are in really nice condition. I'm hoping to find two more nice one to complete the set.

I had to cut the shocks off the Aspire rear beam as they were the originals and were totally shot.

I put all the Rio parts on before cleaning them up to make sure everything worked.
After driving, I found out that the right front wheel bearing is roaring. I took it off and
I will replace it with the other that one I pulled, as soon as I get the axle out of the hub.
I hammered it so much that I mushroomed the axle end. I cut the end off and then drilled a hole
all the way through to the inside of the CV housing and now I'm letting it sit overnight soaked
in pb blaster with wheel puller pulling tight on the hub. I'm hoping to find it loose in the morning.
If not, I guess I'll have to apply heat..but I don't wont to ruin the bearings if they are good.

I'll post more pictures to the album as I get more work done.

I was utterly amazed at the difference those ball bearing struts improved the steering.
It felt as if I had installed power steering.

[Team Lightning]

Looks good!! Those Rio top mounts make a world of difference in the steering. I was surprised at how much easier mine is to steer.

Good Job!!

[1990new]

Thanks Jerry.. I still have a ways to go. The new rear shocks that I ordered from Rock Auto are supposed to arrive later this week.
By then I'll have the Festiva rear beam pulled and the Aspire beam cleaned up and mounted, brake lines and e brake cable replaced and will be ready to add the shocks and wheels.

I'm going to put it in as is without cutting any springs to seek how it works first. I'll pick up two 14" steel wheels to put on the rear until I find 2 more Kia Rio Alloys.
I hope to have it finished by this weekend.

[kumalaba]

nice job!

[1990new]

nice job!

Thanks Danny, but so far the job is not being very nice to me.

I had determined that the bearing was good in the right knuckle that has the axle stuck in it, but I have failed miserably in my attempt to remove the CV axle shaft.
After soaking in pb blaster, drilling the center, heating the hub and putting ice water in the back of the empty cv bearing housing and then pressing and pounding, the axle still will not budge.

I took the caliper off the extra left knuckle that I pulled and I can tell the bearing is shot in it just from spinning, so I'm taking it and the stuck axle one back tomorrow.
There is another 92 Rio there that just came in last week. I will pull the right side knuckle and hope that the bearing is good in it.
Only trouble is I won't get it half price. If it turns out to have a bad bearing, I will just replace the bearing myself.
My left side is installed (except for correct tie rod end) and has a good bearing. I ordered 2 Rio outer tie rod ends today and they will be here Saturday.
I will get to work on the rear beam swap as soon as I get the front wheels back on the ground. I think it will be much easier.

[Bert]

For years everyone claimed an Aspire swap was merely a fast weekend's operation. There is always nickle and dime stuff involved as you've discovered. However you will be impressed by the handling and braking of your 'new' car along with the new-found opportunity to use real wheels and tires. In my case clearance bin 155/65-14s were just the ticket on Rio alloys and did not make the car appear like it had been modified.
What it will do though is get you thinking about an engine transplant now that cruising comfortably at 75 is becoming a reality.

Boy are the parts off that dead Aspire ever in good shape compared to rustbelt vehicles! If you don't shorten (ie cut) the Aspire coils you will find that the swapped car sits quite high.

[1990new]

Took the parts with bad bearings back today and pulled the right front knuckle off the other 02 Rio at LKQ. Turns out this was a very good thing because the right side
looks like it has recently been rebuilt. The CV axle looked almost new also. Whoever did the job didn't stake the axle nut so I have a new unstaked nut, plus new brake
pads and a new rotor. I got the right side installed this afternoon and drove it around the block....no bearing noise
You are correct Bert... It is going to ride high with the 175/65 14 tires and uncut springs....but that's OK Makes it easier to get in and out and since it's an automatic,
we will not be doing much high speed highway driving it it anyway.
Also today, I found a 1992 Escort LX with a couple of nice alloys and almost new 175/65 14 tires. I may go back and get the other two and sell the 2 Kia Alloys.

Yes Burt... that 1997 Aspire was very clean and rust free. It was still there today. There was also a Mercury Tracer with 3 13" alloys on it. Two in nice shape but the third was not as nice.

Tomorrow I hope to get the Aspire rear swap at least partially completed. My rear shocks are supposed to arrive Friday so I should have it all done by Saturday.
No new pictures added today...I'll add some more tomorrow.

[Bert]

Not sure about offset and hub hole compatibility of Escort rims but the 02 Rio wagon alloys I got hold of were perfect; hub-centric for optimum fit and the offset did not yield tire rubbing on the spring perches. Try the new wheels on for size before you commit. 175-65-14 is a tall wide tire compared to Festy and even OEM Aspire.

[drddan]

Watching this thread! Which car is getting the swap, Jess?

[Team Lightning]

LX Escort wheels work good on a Festiva. I ran my son's 96 LX wheels for a year or so on mine. They had 185-60-14 tires. Same size I'm running now on Miata solid spokes.

[1990new]

LX Escort wheels work good on a Festiva. I ran my son's 96 LX wheels for a year or so on mine. They had 185-60-14 tires. Same size I'm running now on Miata solid spokes.

Thanks Jerry, I was hoping they would work.

Watching this thread! Which car is getting the swap, Jess?

That would be Trixie, my 89 automatic.

Not sure about offset and hub hole compatibility of Escort rims but the 02 Rio wagon alloys I got hold of were perfect; hub-centric for optimum fit and the offset did not yield tire rubbing on the spring perches. Try the new wheels on for size before you commit. 175-65-14 is a tall wide tire compared to Festy and even OEM Aspire.

Just noticed that I misspelled your name Bert.. (I have a nephew with the same name but he spells his Burt.. short for Burton I believe).
I will be mounting the escort wheels with 175-65-14 tires. I will post tomorrow and report on how they do.

Today I got the the rear suspension installed (my shocks came a day early). All that is left to do is bleed the brakes, mount the wheels, connect the ebrake inside, install the interior plastic and rear seat.
The Kia tie rod ends won't be here until Saturday so I'll only be driving around the neighborhood at 25 until they are installed. Then I will get it aligned and see how it does on the highway.
I added a couple more pictures and will add more tomorrow to show the finished product.

Only problem I had today was that the hole in the aspire beam brake line holder on the right side was to small and had 4 little metal bumps on one side.
I cut the little bumps off and filed out the hole to make room for the line to fit. The head of the Festiva brake lines are larger. On the left side I used the Aspire flexible lines
and attached in the larger hole on the body. Anyone else doing this be sure to do the work on the hole before you install the beam.
Looks like all the brake components including the cylinders and drums had recently been replaced on the Aspire and the wheel bearings were in good shape too.

[Team Lightning]

Only problem I had today was that the hole in the aspire beam brake line holder on the right side was to small and had 4 little metal bumps on one side.
I cut the little bumps off and filed out the hole to make room for the line to fit. The head of the Festiva brake lines are larger. On the left side I used the Aspire flexible lines
and attached in the larger hole on the body. Anyone else doing this be sure to do the work on the hole before you install the beam.
Looks like all the brake components including the cylinders and drums had recently been replaced on the Aspire and the wheel bearings were in good shape too.

I have a Dremel that I used to open the hole up on mine.

[1990new]

I have a Dremel that I used to open the hole up on mine.

Utterly amazing ... while I was in the middle of doing the last post.. my wife asked me if I wanted my birthday present now or wait until tomorrow (my birthday). I said OK.. I'll open it now.
It was a Dremel...first one I ever owned and I'm 70 tomorrow. I had used my 4 inch hand held grinder to cut of the nubs.

[1990new]

Today I finished getting the emergency brake connected, interior back in place, bled the brakes and mounted the 92 Escort LX alloys on the rear.

The size of the tires on the Escort rims that I stated as 175/65 R14 was incorrect. They are actually 185/65 R14.
There is only about 1/4 inch clearance between the bottom of the spring base on the strut but it does clear all around.
Check link in first post to photobucket for added photos of the clearance.

Drove it around the block and all is well. Just need to get the correct outer tie rod ends on, get all the wheels (and the car) cleaned up, and then the alignment will finish the job.
Oh... except for getting a spare tire that will fit the car and also fit in the wheel well. I guess I'll have to go back to using a doughnut as a spare.

Any recommendation on the mixed sizes. Should I use the 185's on the front or the rear? Anyone else running mixes sizes?

[1990new]

I need some advice on alignment after the Aspire rear and Rio Front swap.

1. The rear brackets that mount to the body have holes slightly larger than the bolts. Is that how the rear alignment is adjusted?
2. What specks are used Rio, Festiva, Aspire?