Preparing QA1 TS801 or TD801 shocks for rear mounting on GJKHPA bodies:
The TS801 and TD801 are rear shocks for 73-87 Buick Regals (including 84-87 GNs), as well as other applications. The TS801s are single-adjustable, with one knob adjusting both compression and rebound at the same time. The TD801s have two knobs that allow adjusting compression separately from rebound.
They are the correct length for the rear of the GJKHPA bodies, but they come with a T-bar mounting at the top, and a short bottom bushing, neither of which work for our application.
Out-of-the-box (next to a stock-style rear shock):
Removing the T-Bar: Using snap-ring pliers, remove one of the c-clips holding the T-Bar in place, put the T-Bar in a vise and work it out of the bushing.
T-Bar and snap ring after removal:
Now the shock has two open bushings on each end, Ύ at the top, and 5/8 at the bottom. We need to find sleeves that are 1 5/16 long and have an inner diameter of .3906 (25/64) to mount them in the stock location using the stock M10 bolts.
Top bushing (3/4 opening): Bottom Bushing (5/8 opening):
Finding Bushings for top and bottom eyelets:
Two options:
1. If you have old stock shocks which have 5/8 OD sleeves in them, you can order a new 5/8 ID urethane bushing for the top (QA part # 9032-106 sold by both Summit Racing and Jegs), replace the top bushing with the new one, then press your stock sleeves into the top and bottom.
2. If you dont have these sleeves, you can get new sleeves at McMaster Carr (
www.mcmaster.com) for the 5/8 and Ύ bushings. This is what the rest of this write-up will cover.
Finding suitable Ύ and 5/8 sleeves:
There are a few problems with finding sleeves that will work for our application:
1. There are no 1 5/8 long sleeves available. This can be overcome by either getting a 1 Ύ sleeve and cutting it down, or getting two shorter sleeves that add up to 1 5/8 in length.
2. The stock bolts are M10 which require at least a 3.906 (25/64) hole to slide through.
3. McMaster Carr has no standard spacers with the correct inner diameter. They do have 3/8 ID spacers, which have a Ύ OD that can be made to work for the top eyelet, but the ID will need to be enlarged. They also have no spacers with 5/8 OD that have an ID anywhere close to the 25/64 we need.
The solution I went with for the top eyelet was to order four Ύ OD, 3/8 Screw Size Zinc-Plated Steel Unthreaded Round Spacers, two of them 7/8 long (# 92414A477 $3.79 each) and the other two 3/4 long (# 92415A132 $3.49 each).
I had to get a 25/64 drill bit to open up the ID a bit, but since 3/8 is so close to 25/64, it was very easy to do.
Top eyelet and spacers before installation:
The bottom eyelet was trickier. They do have 5/8 OD spacers available, but the only ones that come in the right lengths (7/8 and Ύ), are Ό ID (7/8 # 92414A467 $3.11 each, Ύ # 92415A111 - $2.91 each). Those would work if you had a drill press and a way to hold the spacers straight so you could drill them out to 25/64.
There is another way (the way I went). McMaster Carr has 25/64 Steel Press-Fit Drill bushings with a .3906 ID and a 5/8 OD available in 5/8 (# 8491A359 - $6.41 each) and 1 (# 8491A731 - $8.26 each) lengths. I ordered 2 of each; they pressed in perfectly, and the stock bolts slid right through.
Bottom eyelet and Drill Bushings before installation:
To install the spacers/bushings, just put one in each side of the bushing and press them together in a vise. It is a good idea to run a 25/64 drill bit through the sleeves after pressing them in just to remove any burrs and make sure the bolts slide through without too much resistance.
Shock with the eyelets installed:
Compared to the ones they are replacing:
Installation is the same as the stock shocks: