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Spring/Bump Stop Replacement

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2006 Honda Insight, 2005 Honda Insight, 2004 Honda Insight, 2003 Honda Insight, and 2002 Honda Insight. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • Bolts and nuts with the * mark are special corrosion-resistant Dacro fasteners. Use the same type if replacement is necessary.
  • The illustrations show left side of the vehicle.
  1. Raise the rear of the vehicle, and support it with safety stands in the proper locations (see SAFETY STANDS ). Remove the fender skirts and rear wheels on the right and left sides of the vehicle.
  2. Disconnect the wheel sensor connectors (A), and remove the wheel sensor brackets (B) and the brake hose brackets (C), on the right and left sides.
    Fig 1: Disconnecting Wheel Sensor Connectors And Removing Wheel Sensor Brackets And Brake Hose Brackets On Both Sides With Specified Torques
    G03682416Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Place a jack under each end of the rear axle beam.
  4. Remove the flange bolts (A) at the bottom of the dampers on the right and left sides.
    Fig 2: Removing Flange Bolts At Bottom Of Dampers On Both Sides And Torque Specifications
    G03682417Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Lower the jacks on the right and left evenly, and remove the spring (A) and upper spring cushion (B).
    Fig 3: Removing Spring And Upper Spring Cushion With Specified Torques
    G03682418Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Remove the nut (C) and bump stop (D).
  7. Install the bump stop and spring in the reverse order of removal, and note these items:
    • Align the spring upper end (A) with the stepped part of the upper spring cushion (B), and align the spring lower end (C) with the stepped part of the spring seat on the rear axle beam (D).
    • When installing the flange bolts connecting the bottom of the dampers to the rear axle beam, first lightly tighten the bolts, raise the suspension with the jacks to load the vehicle weight, then fully tighten the bolts to the specified torque value.
    Fig 4: Aligning Spring Upper End
    G03682419Courtesy of AMERICAN HONDA MOTOR CO., INC.
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