112 GLEN STREET

GLEN COVE NY 11542

1‐516‐801‐8201
universalautosports.com
woodworth@universalautosports.com
 FORMULA DYNAMICS
SPORT SPRINGS INSTALLATION
CREATED AND PERFORMED BY KENT WOODWORTH

2002‐2006 MASERATI 4200

COUPE/SPYDER/GRAN SPORT
 PARTS NEEDED
• SET OF FOUR FORMULA DYNAMICS SPORT
LOWERING SPRINGS.

RECOMMENDED PARTS:
2 NEW FRONT COILOVER SHOCK LOWER BUSHINGS
MASERATI PART # 157630
2 NEW REAR COILOVER SHOCK LOWER BUSHINGS.
MASERATI PART # 194971
2 NEW FRONT SPRING UPPER RUBBER SPACERS.
MASERATI PART # 188993
 PARTS NEEDED
RECOMMENDED PARTS:
2 NEW FRONT SPRING LOWER RUBBER SPACERS.
MASERATI PART # 188994
2 NEW REAR SPRING UPPER RUBBER SPACERS.
MASERATI PART # 188995
2 NEW REAR SPRING LOWER SPACERS.
MASERATI PART # 188996
THESE PARTS ARE RECOMMENDED FOR HIGHER
MILEAGE CARS (30K AND OVER).
FRONT SUSPENSION PARTS
DIAGRAM COUPE/SPYDER
FRONT SUSPENSION
PARTS LIST
COUPE/SPYDER
2002‐2006
FRONT SUSPENSION
PARTS LIST
COUPE/SPYDER
2002‐2006
 REAR SUSPENSION PARTS
DIAGRAM COUPE/SPYDER
REAR SUSPENSION
PARTS LIST
COUPE/SPYDER
2002‐2006
REAR SUSPENSION
PARTS LIST
COUPE/SPYDER
2002‐2006
FRONT SUSPENSION PARTS
DIAGRAM GRAN SPORT
FRONT SUSPENSION
PARTS LIST
GRAN SPORT
FRONT SUSPENSION
PARTS LIST
GRAN SPORT
REAR SUSPENSION PARTS
DIAGRAM GRAN SPORT
REAR SUSPENSION
PARTS LIST
GRAN SPORT
REAR SUSPENSION
PARTS LIST
GRAN SPORT
TOOLS NEEDED
TOOLS NEEDED
 TOOLS NEEDED
• 1/4” DRIVE RATCHET.
• 3/8” DRIVE RATCHET.
• 1/2” DRIVE RATCHET.
• 3/8” OR 1/2” DRIVE TORQUE WRENCH WITH 3/8” OR 1/2”
ADAPTERS.
• 1 MEDIUM (8”) 1/4” EXTENSION.
• 1 LONG (18+”) 3/8” EXTENSION.
• 1 MEDIUM (8”) 3/8” EXTENSION.
• 5 mm 1/4” DRIVE ALLEN SOCKET OR WRENCH.
• 10 mm 1/4” DRIVE SOCKET.
• 9 mm 3/8” DRIVE ALLEN SOCKET.
• 13 mm 3/8” DRIVE DEEP SOCKET.
 TOOLS NEEDED
• 19 mm 1/2” DRIVE DEEP SOCKET.
• 22 mm 1/2” DRIVE DEEP SOCKET.
• 3/8” DRIVE UNIVERSAL (SWIVEL) JOINT.
• 13mm WRENCH.
• 19mm WRENCH.
• 22mm WRENCH.
• 10mm WRENCH.
• ADJUSTABLE WRENCH.
• 2 SPANNER WRENCHES.
• #2 PHILLIPS SCREWDRIVER.
• #2 STUBBY (SHORT) PHILLIPS SCREWDRIVER.
• 1 SMALL PICK.
• 1 PAIR OF CUTTING PLIERS.
 TOOLS NEEDED
• 1 HAMMER (SIZE IS YOUR PREFERENCE).
• I USE A 40 oz. DEAD BLOW HAMMER.
• 1 FLAT HEADED PUNCH OR DRIFT.
• 1 PICKLE FORK (AT LEAST 1” WIDE AT THE MOUTH).
• SAFETY GOGGLES OR GLASSES.
• COIL SPRING COMPRESSOR. I USE A “LISLE”
MACPHERSON STRUT TOOL. PART # 62300.
• WHITE LITHIUM GREASE OR EQUIVALENT.
• RUST LOOSENER/ PENETRATING SPRAY (ZEP 45, WURTH
ROST OFF, KANO KROIL, ETC.).
• PAINT MARKER, ANY COLOR BESIDES YELLOW.
• ELBOW GREASE. PART # I81U812.
 STOCK RIDE HEIGHT SPECS
COUPE/SPYDER 2002
FRONT = 177mm +/‐ 4mm REAR = 188mm +/‐ 5mm
 STOCK RIDE HEIGHT SPECS
COUPE/SPYDER 2003‐2006
FRONT = 162mm +/‐ 5mm REAR = 180mm +/‐ 5mm
 STOCK RIDE HEIGHT SPECS
GRAN SPORT
FRONT = 152mm +/‐ 5mm REAR = 170mm +/‐ 5mm
 MEASURE RIDE HEIGHT
FRONT REAR
• WITH VEHICLE ON A LEVEL • SAME PREPERATIONS AS
SURFACE. FUEL TANK FULL. THE FRONT.
• 165lbs. OF BALLAST ON • MEASURE FROM THE REAR
EACH FRONT SEAT. OF THE REAR LOWER
• TIRE PRESSURES SET TO CONTROL ARM MOUNTING
SPEC. ALL TIRES W/ SAME BOLT CENTERLINE TO THE
TREAD AND EVEN WEAR.
FLOOR (BOTTOM OF TIRE).
• MEASURE FROM THE
FRONT OF THE REAR LOWER
CONTROL ARM MOUNTING
BOLT CENTERLINE TO THE
FLOOR (BOTTOM OF TIRE).
 LIFTING OF VEHICLE
LOCATE FRONT JACKING PAD LOCATE REAR JACKING PAD
 LIFT ARM POSITION
FRONT ARM REAR ARM
 REMOVE FRONT WHEELS
DISMOUNT ALL LINES AND UNPLUG THE FRONT BRAKE PAD
HARNESSES MOUNTED ON UPPER SENSOR CONNECTOR ON TOP OF
CONTROL ARM. CONTROL ARM.
DISCONNECT FRONT UPPER CONTROL
ARM BALL JOINT
DISMOUNT THE SUSPENSION
SENSOR. USING 1/4” RATCHET W/ LOCATE THE 22mm NUT FOR THE
EXTENSION AND 5mm ALLEN UPPER BALL JOINT. USING A 22mm
SOCKET. WRENCH, REMOVE THE NUT.
 SEPERATE UPPER CONTROL ARM
USING THE PICKLE FORK AND PUSH UPPER ARM ALL THE WAY UP.
HAMMER (WHILE WEARING SAFETY GENTLY POSITION THE SPINDLE AND
GLASSES), SEPARATE ARM. THE LINES/HARNESS ASIDE.
 REMOVE LOWER SHOCK BOLT
USING A 19mm WRENCH AND 1/2” DRIVE RATCHET WITH
A 19mm SOCKET, REMOVE THE NUT, WASHER, BOLT AND
SPACER, NOTING THE POSITION THEY ARE INSTALLED.
 REMOVE ENGINE BAY PANELS.
LOCATE THE LH SHOCK CONNECTOR
PROTECT BOTH FRONT FENDERS. JUST AFT OF THE ABS UNIT. USING A
USING THE #2 PHILLIPS SMALL PICK, CAREFULLY PRY UP TAB
SCREWDRIVERS, REMOVE THE AND UNPLUG. REMOVE FROM THE
PANELS. CLIP. SNAKE THE SHOCK WIRE OUT
FOR REMOVAL OF SHOCK.
 REMOVAL OF UPPER SHOCK NUTS
LH SIDE
USING A 5mm ALLEN SOCKET AND A THE LH SHOCK LOCKNUTS ARE
1/4” RATCHET REMOVE THE BOLTS DIRECTLY UNDER THE ABS UNIT.
MOUNTING THE TWO REAR COILS USING A 3/8” DRIVE RATCHET, A
13mm SOCKET, AND A LONG 3/8”
ON THE LH CYL. BANK (THIS HELPS EXTENSION, REMOVE THE 4 SHOCK
ACCESS THE SHOCK LOCKNUTS). MOUNTING LOCKNUTS.
 REMOVAL OF UPPER SHOCK NUTS
RH
LOCATE THE RH SHOCK CONNECTOR
SIDE
JUST AFT OF THE COOLANT THE RH SHOCK LOCKNUTS ARE
RESERVOIR. FORWARD OF THE RESERVOIR
UNDER THE A/C LINES.
USING A SMALL PICK CAREFULLY
PRY UP TAB AND UNPLUG .REMOVE USING 3/8” DRIVE RATCHET, 13mm
FROM THE CLIP. SOCKET AND LONG EXTENSION,
REMOVE THE 4 SHOCK LOCKNUTS.
SNAKE THE SHOCK WIRE OUT FOR
REMOVAL OF SHOCK.
 REMOVAL OF FRONT SHOCK
CAREFULLY REMOVE THE SHOCK INSTALL THE SPRING COMPRESSOR,
FROM THE VEHICLE, PAY CLOSE EVENLY SPACING COILS ON EACH SIDE.
ATTENTION TO THE WIRE. COMPRESS THE SPRING SLOWLY
CLEAN SHOCK THREADS AND LUBE WORKING SIDE TO SIDE.
WITH PENETRATING SPRAY, LET BE VERY CAUTIOUS W/ SPRINGS !!
SOAK.
 REMOVAL OF SPRING
COMPRESS THE SPRING UNTIL USING THE 2 SPANNER WRENCHES,
PRESSURE IS RELIEVED FROM THE HOLDING THE TOP COLLAR, TURN
LOWER SPRING RUBBER SPACER. THE LOCKING COLLAR COUNTER
CLOCKWISE AND REMOVE BOTH
COLLARS FROM THE SHOCK.
 REMOVAL OF SPRING
REMOVE THE SPRING FROM THE PRESS THE BUSHING OUT WITH A
SHOCK. HYDRAULIC PRESS, USING AN
REMOVE THE UPPER RUBBER OVERSIZED SOCKET UNDERNEATH
SPACER AND BUMPSTOP, CLEAN ALL AND PUSHING THE BUSHING WITH
RUBBER SPACERS THOROUGHLY. A 22mm SOCKET.
 INSTALL NEW SPRING
• REFIT UPPER SHOCK RUBBER SPACER.
• LUBRICATE UPPER AND LOWER SHOCK
SPACERS WHERE CONTACTING SPRING WITH
WHITE LITHIUM GREASE OR EQUIVALENT.
• LUBRICATE SHOCK THREADS.
• FIT NEW SPRING ON SHOCK, REFIT LOWER
RUBBER SPACER, INSTALL TWO COLLARS.
• BRING COLLARS UP TO SPRING UNTIL THEY
ARE UNDER SLIGHT PRESSURE.DO NOT LOCK.
 INSTALL FRONT SHOCK
REFIT IN REVERSE ORDER OF
REMOVAL.
REFIT THE SHOCK INTO THE
VEHICLE, PAYING CLOSE ATTENTION TORQUE 22mm BALLJOINT NUT TO
TO THE WIRE. 63 Nm OR 46.5 Ft lbs.
FIRST INSTALL THE 4 UPPER TORQUE LOWER SHOCK BOLT TO 78
LOCKNUTS LOOSELY. THEN INSTALL Nm OR 57.5 Ft lbs.
THE LOWER BOLT WITH SPACER. TORQUE UPPER 4 LOCKNUTS TO
24Nm OR 17.7 Ft lbs.
 REMOVAL OF REAR SHOCK
SPYDER
OPEN SOFT TOP UNTIL COVER IS ALL PULL UP SIDES OF TOP BAY FLOOR
THE WAY UP, INSERT A PROP ROD COVER TO ACCESS REAR SHOCKS.
TO HOLD COVER. PUSH TOP OVER SIDE PANELS CAN STAY PUT.
HOOPS, TURN KEY OFF.
 REMOVAL OF REAR SHOCK
SPYDER
REMOVE THE ROUND RUBBER USING THE 3/8” RATCHET A
GROMMET. DISCONNECT THE MEDIUM EXTENSION AND A 13mm
SHOCK WIRE AND PUT DOWN IN SOCKET, REMOVE THE 4 SHOCK
HOLE. LOCKNUTS.
 REMOVAL OF REAR SHOCK
COUPE/GRAN SPORT
DISCONNECT ANTI‐EVAP PUMP WIRE
THE SERVICE MANUAL STATES TO AND HOSE, REMOVE PUMP AND
REMOVE THE FUEL TANK, THIS IS BRACKET.
UNNECCESARY. USING A 1/4” DRIVE RATCHET AND A
OPEN TRUNK AND REMOVE ALL 10mm SOCKET,REMOVE 2 NUTS FOR
TRUNK LINER PANELS,STARTING WITH PUMP. REMOVE PUMP AND BRACKET
REAR LIP BLACK PLASTIC PANEL. FROM VEHICLE.
 REMOVAL OF REAR SHOCK
COUPE/GRAN SPORT
DISCONNECT THE SHOCK WIRE.
DISCONNECT THE LINES ON THE USING THE 3/8” RATCHET AND A
CARBON CANNISTER AND SLIDE MEDIUM EXTENSION WITH A 13mm
CANNISTER AFT ,REMOVE FROM SOCKET, REMOVE THE 4 SHOCK
THE VEHICLE. LOCKNUTS.
 REMOVAL OF REAR SHOCK
USING A 1/2” RATCHET AND THE PULL THE SHOCK OFF OF THE BOLT
19mm SOCKET, REMOVE THE AND REMOVE THE SHOCK FROM
LOWER SHOCK NUT WHILE USING THE VEHICLE, PAYING CLOSE
AN ADJUSTABLE WRENCH ON THE ATTENTION TO THE WIRE.
OTHER END OF SHOCK BOLT.
 REMOVAL OF SPRING
REMOVE THE REAR SPRING IN THE REAR SPRINGS ARE TALLER THAN
SAME MANNER AS THE FRONT THE FRONTS. SO THE COLLAR WILL
SPRING. CLEAN ALL PARTS BE LOADED ALL THE WAY TO THE
THOROUGHLY BOTTOM. EXERCISE CAUTION !!
 INSTALL NEW SPRING
• REFIT UPPER SHOCK RUBBER SPACER.
• LUBRICATE UPPER AND LOWER SHOCK
SPACERS WHERE CONTACTING SPRING WITH
WHITE LITHIUM GREASE OR EQUIVALENT.
• FIT NEW SPRING ON SHOCK, REFIT LOWER
RUBBER SPACER, INSTALL TWO COLLARS.
• BRING COLLARS UP TO SPRING UNTIL THEY
ARE UNDER SLIGHT PRESSURE.DO NOT LOCK.
 INSTALL REAR SHOCK
INSTALL THE SHOCK AND MOUNT SLIDE SHOCK ONTO THE BOLT AND
THE 4 TOP LOCKNUTS. INSTALL THE NUT.
TORQUE THE LOCKNUTS TO 24Nm TORQUE THE NUT TO 78Nm
(17.7 Ft lbs.) (57.5 Ft lbs.)
 TORQUE ALL SUSPENSION
AND SUBFRAME FASTENERS
• I HIGHLY RECOMMEND THAT ALL SUSPENSION
FASTENERS ARE TORQUED TO SPEC., YOU WILL
BE SURPRISED BY HOW MANY THINGS ARE
LOOSE. (EXTRA TOOLS ARE REQUIRED)
• TORQUE THE WHEELS TO SPEC AS WELL.
• DOUBLE CHECK TIGHTNESS OF ADJUSTED
COMPONENTS AFTER THE WHEEL ALIGNMENT
IS PERFORMED.
• 1 NEWTON METER= .737562 FOOT POUNDS
TORQUE SPECS
FOR SUSPENSION
AND CHASSIS

COUPE/SPYDER/
GRAN SPORT
TORQUE SPECS
FOR SUSPENSION
AND CHASSIS

COUPE/SPYDER/
GRAN SPORT
TORQUE SPECS
FOR SUSPENSION
AND CHASSIS

COUPE/SPYDER/
GRAN SPORT
 SETTING RIDE HEIGHT
• LOWER THE VEHICLE TO THE GROUND AND JOUNCE (PUSH DOWN
FORCEFULLY) THE FRONT AND REAR SUSPENSIONS (THIS WILL SETTLE THE
SUSPENSION).
• MEASURE RIDE HEIGHT FRONT AND REAR (ALL 4 CORNERS).
• AT THIS POINT THE VEHICLE WILL BE AS LOW AS POSSIBLE, SO ACCESS TO
MEASURING MAY BE DIFFICULT.
• RAISE THE VEHICLE AND USING THE PAINT MARKER, MAKE AN INDEX DOT
ON THE UPPER (BIG) COLLAR OF THE SHOCK AND THE SHOCK BODY,
INLINE WITH EACH OTHER (THIS WILL BE A REFERENCE POINT FOR
ADJUSTMENT).
• TURN THE UPPER (BIG) COLLAR WITH A SPANNER WRENCH TO ACHIEVE
DESIRED RIDE HEIGHT. 10 TURNS OF THE COLLAR EQUALS 15mm (.6 INCH).
• ADJUST EACH SHOCK EVENLY UNTIL YOU ARE CLOSE TO THE DESIRED RIDE
HEIGHT, THEN ADJUST SHOCKS TO ACHIEVE THE CORRECT HEIGHT ON
BOTH SIDES OF THE FRONT AND REAR SUSPENSIONS (ALL 4 CORNERS).
• ONCE THE DESIRED HEIGHT IS SET, USING THE 2 SPANNER WRENCHES,
LOCK THE COLLARS TOGETHER. USING THE PAINT MARKER, NOW PUT A
STRAIGHT LINE THROUGH BOTH COLLARS AND THE SHOCK.
• I SET THE RIDE HEIGHT AT 155mm IN THE FRONT AND 173mm IN THE
REAR. THIS GIVES ADEQUATE CLEARANCE FOR ROAD IRREGULARITIES.
 PERFORM WHEEL ALIGNMENT
• JEFF AT FORMULA DYNAMICS • STOCK SPECS ARE: 2002
RECOMMENDS THE FOLLOWING • FRONT‐
ALIGNMENT SPECS: CASTER: +4 DEGREES 30’ +/‐ 10’
• FRONT‐ CAMBER: ‐20’ +/‐10’
CASTER: +4 DEGREES 35’ +/‐ 6’ TOE: +2.5mm +/‐ .5mm
CAMBER: ‐1 TO ‐1.5 DEGREES • REAR‐
TOE: 0 DEGREES CAMBER: ‐1 DEGREE 10’ +/‐ 10’
• REAR‐ TOE: +4.5mm +/‐ .5mm
CAMBER: ‐1.5 TO ‐1 7/8 DEGREES • 2003‐2006
TOE: 0 DEGREES • FRONT‐
CASTER: +4 DEGREES 35’ +/‐ 6’
REMEMBER THIS WHEEL ALIGNMENT CAMBER: ‐30’ +/‐ 6’
REQUIRES SHIMS OF DIFFERENT
THICKNESS FOR ADJUSTMENT OF THE TOE: +4.0mm +/‐ .5mm
CASTER AND CAMBER. CONTACT • REAR‐
YOUR ALIGNMENT SHOP TO ENSURE CAMBER: ‐1 DEGREE 20’ +/‐6’
THEY HAVE THE SHIMS NEEDED. TOE: +4mm +/‐ .5mm
FORMULA DYNAMICS
INSTALLATION
PROCEDURE

I DOCUMENTED THE
PROCEDURE MY WAY
BECAUSE THE SERVICE
MANUAL INSTRUCTS
MOSTLY THE SAME AND IT
IS THE CORRECT METHOD,
AS WELL AS EARLY 2002
CARS CAME WITH NON
ADJUSTABLE BILSTEIN
SHOCKS, SO REMOVAL
FROM THE CAR IS
NECCESARY TO REMOVE
THE UPPER SHOCK MOUNT
AND SPRING FROM THE
TOP.
 FINISHED PRODUCT
A QUALITY, SHARP LOOKING NOTE THE BLUE FORMULA
PRODUCT. DYNAMICS BRAKE LINES.
 FINISHED PRODUCT
I ALSO CLEANED AND PAINTED AND DETAILED THE
THE RUSTED ROTOR HATS. WHEELHOUSE AS WELL.
 FINISHED PRODUCT
INSIDE OF WHEEL BEFORE. LOTS OF INSIDE OF WHEEL AFTER. THIS
CORROSION. I CLEANED WITH A HELPS TO ENSURE THE WHEEL
WIRE WHEEL ATTACHMENT (USING RUNOUT IS CORRECT. LUBE ROTOR
SAFETY GLASSES). FACE W/ LITHIUM GREASE.
 WHEEL ALIGNMENT
MEASURING WHEEL RUN‐OUT. ADJUSTING THE FRONT CAMBER.
 BEFORE AND AFTER PHOTOS
BEFORE SPRINGS. AFTER SPRINGS, ½” LOWER.