DIY Network

Racing-Suspension Upgrade: Jacks, Jack-Stands and Safety From "Tricked Out" episode DTRK-204

	The project car: a 2003 Ford Focus SVT.
	The upgrade: Factory springs and dampers are replaced with adjustable performance struts.

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In this episode of Tricked Out, host Andrew Totolos installs a suspension system into a Ford Focus SVT for a quicker steering, better handling and the ultimate driving experience. This system improves the vehicle’s traction capabilities, allowing the driver to experience the road as they always imagined. It is an aggressive suspension which lets you put all you have into driving, and allows you look forward to attacking the next unknown turn. In this first segment Andrew introduces the project car and, since this project requires getting under the car, discusses the proper and safe use of jacks and jack stands.

Materials used in this episode:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, etc.), tools and materials used in this episode include:

Suspension kit
Floor jack
Jack stands
Wheel chocks
Rubber mallet
Torque wrench
18mm open socket
Measuring tape
Vise
Spring compressors
Safety glasses

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Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of upgrade-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

DIY Difficulty Rating for This Project: We gave this a difficulty rating of 4 on a 5-point intermediate-level scale. The work will need to be done with the car on jack stands, and some effort will be required swapping the dampers. Experienced gear-heads should have no problem.

The Project Car: Ford Focus SVT

In all matters of performance the Ford Focus SVT focus outperforms its popular ZX3 sibling. But even though the SVT suspension is lower and firmer than the ZX3 model, there’s room for improvement. We replace the factory SVT suspension with a fully-adjustable damper kit that will hold tight to the curves and will provide the adjustability to go from street to track to show with minor adjustments.

This 2003 SVT sports a hot euro package in bright yellow and a spiced-up exterior with custom airbrushed vinyl graphics. Behind the 17" lightweight alloys wheels, factory 4-wheel disc brakes clamp down on cross drilled rotors with street performance pads.

Under the hood, the cold-air intake feeds the Focus's dual-stage intake manifold, and an upgraded coil pack and plugs provide a hot spark. The inside features factory leather bucket seats and an upgraded short throw shifter.

	Figure A
	Figure B
	Andrew Totolos demonstrates the proper use of a floor jack.

Jacks and Jack Stands

Unless your avid about vehicle tuning and mods, chances are good that the only car-jack you have is the one that came with your car. This is suitable for changing a flat tire, but it's not designed for the kind of work in this project. It's not very stable, and it can only be used at specified jack-points around the car -- namely for lifting the car up to change a tire. Because this suspension project requires that you work under the car, you'll need a more substantial jack and, without question, a good set of jack stands.

A floor-jack (figure A) is a good investment if you do a lot of work on your car. They come in a range of sizes, capacities and prices. For most compacts like the ones featured on Tricked Out, a 1.5-ton floor-jack is sufficient. (1.5 tons equals about 3,000 pounds.) You can pick up a 3-ton jack for around $100. This is an important piece of equipment, so buy the best one you can afford. For lowered vehicles, low-profile racing jacks (figure A, right) are available as well, though they're a little more expensive.

For this project, you'll also need jack stands (figure B). These come in adjustable ratchet and pin-types. Most professional jack stands still use the pin method to lock the stands in place. When selecting jack stands, go with a name brand and make certain that they are rated at the same weight as your floor jack.

Wheel chocks are placed in front of and behind the wheels on the ground to ensure that the car can't roll while you're underneath it.

Safety Alert: When you need to work underneath a vehicle, never get under a vehicle supported only by a jack. A jack is designed for lifting, not for supporting. And vehicles can fall off a jack! Make certain that yours is properly supported by jack stands before you get beneath it.

Proper Jacking and Use of Jack Stands

• First, park you car on level, solid ground. Put the transmission in park or low gear and set the parking brake.

• Place wheel chocks behind and in front of a tire that’s staying on the ground (figure C), and locate a solid jack-point.

• The car’s owner’s manual will identify manufacturer’s recommended jack points (figure D), but if you’re working under the car, you’ll need at least one point on each side to fit the jack and another nearby location for the jack stand.

  Figure C

  Figure D

  
  

  Figure E

• Under the front of our Ford Focus, the reinforced uni-body channel provides a good jack point (figure E), and the cross-member works well for supporting the weight of the front end on the jack stands.

• Move the jack to the other side and set the second jack stand so that the load is evenly distributed and the car sits level.
  

• After everything is set, make sure the saddles make full contact with the car (figure F), and all four corners of each stand’s base remain on the ground (figure G).

  Figure F

  Figure G

  
  

  
  

  
  

  RESOURCES :
  

  Tires, Suspension and Handling
  ISBN: 1560918314
  Author: John C. Dixon
  (Society of Automotive Engineers

  
  Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
  Author: Joe Pettitt
  Order this book from Amazon.com.
  Voyageur Press (October 2000)
  ISBN: 1884089526
  

  TEIN USA, Inc.
  Website: www.tein.com
  

  ALSO IN THIS EPISODE:
  	Racing-Suspension Upgrade: Jacks, Jack-Stands and Safety
  	Racing-Suspension Upgrade: Adjustable Front-Struts