Fulcrum Suspensions specialises in the aftermarket manufacturing and supply of steering & suspension components, offering suspension solutions for a wide range of vehicles. Fulcrum combines leading brands with expert advice to provide tailored suspension packages.

Check out some of Fulcrum’s specialist product areas:

• Shock absorbers
• Springs
• Power Steering
• 4WD solutions
• Performance Suspension
• SuperPro Polyurethane Bushings
• Workshop Equipment
  

For more product information:

• Warranties
• Technical Info & Updates
• Product advertisements

Shock Absorbers

On a vehicle’s suspension, shock absorbers provide the friction needed to control and quickly stop oscillation. In Europe, shock absorbers are known as "dampers," which is actually a more accurate name, since the springs actually absorb road shocks, while shock absorbers dampen the spring action. Some Japanese manufacturers refer to shock absorbers as "dampeners".

Due to the large range of uses and applications of vehicles, dampening control in the aftermarket is a science. Aftermarket manufacturers offer a range of shock absorbers and struts designed to give greater control, altered ride conditions and longer life. Fulcrum Suspensions uses these products as part of a complete suspension system solution, whether it be for enhancement or safety. Fulcrum are distributors for leading brand shock absorbers including, TEIN High Performance Suspension, Monroe, KYB, Boge, Bilstein, RAW, and Koni.

BOGE

BOGE has been chosen by the world's leading vehicle manufacturers as original equipment for consistent superior ride-control with the highest quality. Whether it's a Shock, Strut or Insert, BOGE products are built to exacting standards leaving no room for shortcuts or compromise. BOGE have a range of shock absorbers from standard to lowered vehicles incorporating shortened body shock design for maximum comfort and handling with a large range of Aussie tuned big-bore 4x4 shock absorbers also available.

With BOGE you will benefit from...
◊ The one ideal application for your vehicle, taking the guesswork out of your shock-absorber choice
◊ Superior quality from state of the art technology
◊ Shock absorbers especially designed for vehicles unique to Australia, such as Ford Falcon and Holden Commodore
◊ Aussie tuned bi-bore 4x4 shock absorbers
◊ Twin-tube, gas pressurised shock technology through-out the entire range, leading to:

• Improved braking (up to 20%)
• Ride Comfort
• Superior Ride Control
• Safety
• Reliability
• Reduced Tyre wear
• Constant Performance

Monroe

Monroe manufacture a large range and series of shock absorbers to suit the Australian vehicle market. Monroe supplies leading car manufacturers with struts, shock absorbers and high level modular assemblies as well as the aftermarket products from their manufacturing facilities in Adelaide, South Australia. Please see the various series of shocks listed below:

Monroe GT Gas

Monroe GT Gas with exclusive Reflex Technology delivers excellent vehicle stability and handling without compromising driver and passenger comfort.

Product features

Monroe Gas-Magnum

Monroe Gas-Magnum TDT is a super duty gas charged shock absorber that gives you superior performance from your 4x4 both on-road and off. Australian made for Australian conditions, Monroe’s exclusive Twin Disc Technology (TDT) has delivered a tough, durable shock absorber that can keep you comfortable and safe on virtually any type of surface.

KYB

KYB make a large range of shock absorbers that are well suited to the Japanese and Australian car market with a slight edge leading to a more performance based shock, that are a great replacement for the customer that wants more from their suspension system.

RAW 4x4

Fulcrum Suspensions have found that RAW 4x4 shocks have certainly filled a spot in the market place for a quality shock absorber from highway/ city driving to the weekend off-roader. The RAW 4x4 shock range consists of the RAW Nitro and RAW Nitro Max with the range and features shown below.

Raw Nitro

Raw Nitro is a expanded body heavy duty gas shock absorber designed to improve body roll and increase vehicle stability.

Features include:

• Large 35mm bore size
• Low pressure nitrogen gas to eliminate shock absorber fade
• Expanded body for extra oil capacity
• Hi-Temperature multi lip HNBR seal & oil
• Re coil cut off to avoid internal shock absorber damage from over extension
• Hardened polished chrome rod

Raw Nitro Max (Twin Tube)

RAW Nitro Max is the big bore heavy duty shock absorber in the RAW 4x4 shock absorber range. These have been designed for heavy coil sprung and torsion bar vehicles by using proven truck shock absorber design with highly tuned valving for 4x4 applications. With a massive 70mm body and a nitrogen gas cell in the outer tube, RAW Nitro Max will significantly reduce shock absorber fade in the harshest conditions.

Features Include:

• Large 41mm bore size
• Nitrogen gas cell to eliminate aeration inside the shock absorber
• High temperature oil to maintain viscosity under hard working conditions
• Multi lip Viton seal to retain oil at temperatures up to 240 degrees celsius
• Polyurethane bushing
• One piece eye rings & 360 degree welds on all fittings
• Silicone dust boot

RAW Nitro Max (Mono Tube)

The Nitro Max mono tube strut has been designed for the modern 4wd vehicle with a coil over shock absorber front suspension. A mono tube is best suited for this application for heat dissipation as these shock absorbers are usually short and operate on a small stroke. Using a large 46mm bore places less stress on the internal components of the shock absorber providing a controlled and comfortable ride.

Features Include:

• HNBR high temperature seal to retain oil
• Large 46mm bore size
• Nitrogen gas
• High temperature oil to maintain viscosity under hard working conditions
• Mono tube design for efficient heat dissipation

BILSTEIN

Driving a vehicle equipped with Bilstein Gas Pressure Shock Absorbers is an exhilarating experience. Bilstein Shock Absorbers deliver unbelievable control, stability, precise handling, ultimate performance with incredible comfort. Bilstein was the first to apply the patented gas pressure principle to controlling ride characteristics on automobiles and introduced the world's first shock absorber. Today, Bilstein continues to be one of the leaders in mono tube gas pressure shock absorber technology. The Bilstein name graces not only monotube gas pressure shock absorbers, but also single and twin tube Macpherson strut style suspensions. Bilstein offer a precise matched shock absorber to suit your vehicle from high performance on road to the most severe conditions off road.

KONI

KONI shock absorbers are recognized for their premium performance, quality and adjustability. KONI's unique design features and legendary reputation in racing have led to success in a variety of high-end specialized markets, from sport cars and racing vehicles to heavy duty bus, truck, motor home and rail applications. Most Koni shock absorbers have adjustment on the rebound damping to allow for the tuning of the shock to the vehicle, driver and road conditions. Koni's range of shocks include passenger vehicles, four wheel drives and motor sport to suit your required application.

Springs

The springing system is the load carrying device on a vehicle. Although suspension springs all serve the same purpose and have certain characteristics in common, actual spring designs vary widely.

Original Equipment Manufacturers design vehicle springing systems for very specific use or a mass market use. Fulcrum Suspensions is in the automotive aftermarket supply and modification of springing systems for vehicle enhancement or special applications. This involves the supply of a range of coil, leaf, torsion bar, and air spring products that are carefully tailored and matched to provide specific solutions to individual customers.

There are four types of springs currently used in automotive suspensions:

Coil Spring

Leaf Spring

Torsion Bars

Air Spring

Fulcrum distribute a range of leading brand springs, including TEIN S-Techs, King Springs, EFS and Eibach:

• TEIN S-Tech Springs
• King Springs
• EFS
• Eibach
• Polyair
• Firestone

King Springs

King Springs is Australia’s leading specialist manufacturer of aftermarket coil springs for world-wide, automotive applications. As Australia’s largest manufacturer of aftermarket automotive springs, Kings offer perfected research and technology to provide a range of options to suit any 4x4 need. Kings are market leaders in advanced progressive rate type springs in both variable pitch and tapered wire design.

EFS

EFS has designed and developed high quality suspension components, from shackles to leaf springs, to combat Australia’s harsh off road conditions. These products give the benefits of comfort, durability and long life. The EFS range is under constant development utilizing sponsored competition vehicles in testing.

Torsion Bars

EFS Torsion Bars are Heavy Duty replacement bars for use when the owner has fitted load-bearing accessories to the vehicle or the original torsion bars have sagged through years of use. Most bars are a larger diameter than the original although some are the same diameter but made from higher quality material.

Leaf Springs

EFS Leaf Springs are made from high quality Japanese grade SUP9 & SUP9a Alloyed Carbon spring steel. Designed as a comfort Leaf Spring that incorporates special features to give the driver a comfortable ride on road, and increased control off road with increased articulation and clearance. The springs have increased spring rates over the original equipment.

Polyair Springs - Airbag

The Polyair Springs suspension system is designed to aid vehicles with differing variance and load requirements with simple addition or removal of air pressure by the driver. Whether carrying heavy loads, towing a caravan, or driving on rough roads, Polyairs can be adjusted to meet the exact load requirements and road conditions.

Both the Red and Black Bellow series airbags have left and right valve stems to allow for levelling of the ride not only for carrying weight, but also to balance the vehicle from left to right to make up for an uneven loaded vehicle. Polyair Springs Red Bag Series Engineered as an add-on helper spring for both coil and leaf spring suspensions. Typical load support is 450kgs maximum.

Polyair Springs Bellows Series Available for a limited range of leaf spring applications, the system is designed to support big loads. Typical load support is 2200kg maximum.

Polyair Bag Benefits:

• Improve ride, handling, safety, stability and performance
• Help prevent bottoming, bounce and sway
• Renew life in tired springs, extend life of shocks, springs and tyres
• Fit coil and leaf springs on cars, vans, trucks and 4x4s
• Are made of high tensile strength polyurethane for long lasting durability and have a 12 month/20,000km warranty protection.
• Limited lifetime warranty on seam

Power Steering

Fulcrum offer a range of re-manufactured power steering units which are great
value for money. Selecting an exchange power steering unit is crucial to the safety of your car, so here’s why you should choose Fulcrum:

Every unit is completely re-manufactured – rack shafts, sector shafts, housings, tie-rods and ball joints are restored to as new condition. Rotary valves are dismantled, ultrasonically cleaned and re-trimmed. Damaged torsion bars are replaced and pump cams are re-machined to their original contour or replaced. Some suppliers only clean and re-seal the old steering unit whilst replacing the soft parts like seals, so don’t get caught with an inferior alternative that only treats the symptoms of wear and that could result in premature unit failure.

• There's a large range of units available for most models for almost 30 manufacturers. From 4WDs to luxury BMW’s and Jaguar’s, we have a unit to suit most cars.
• Every stage of the rebuilding process is carried out to the Automotive Quality Standard QS9000 & ISO9002. Every unit is tested to OEM specifications before leaving the factory to ensure it meets the performance requirements of the Original Manufacturer. The latest diagnostic testing equipment is used to check flow, leakage, balance and performance.
• Fulcrum offers a 3 years or 60,000kms warranty on exchange steering units for your peace of mind.
  

When did you last have your Power Steering Serviced? more...

Workshop Equipment

CODA Shock Absorber Tester

As part of their development of specialist suspension equipment, Fulcrum Suspensions has seen a need for a quick, reliable and easy way to report to the customer the condition of their vehicle shock absorbers. This Coda Shock Absorber Tester will give you results in minutes and has the ability to print out a report for your customer. Any vehicle that comes in to your business can be tested and diagnosed to give customers peace of mind and to help you grow your shock absorber replacement sales.

The software that comes with the Coda Shock Absorber Tester is very user friendly so that with a small tutorial anyone in the business is capable of down loading results and viewing pass results and statistics with ease.

Download flyer

Suspension Tester

The Suspension Tester machine is a device that can be mounted on a vehicle hoist or alignment ramps, enabling a quicker and more accurate pre-alignment inspection. With suspension being engineered more precisely on the vehicles of today, it is generally becoming harder to inspect worn components. In current practices of suspension diagnosing, it would take two Technicians to inspect the suspension on most vehicles. One of the Technicians would apply force to the road or steering wheel, while the other looks for worn suspension components from underneath the vehicle. The force that can be put on the road wheel by a Technician generally cannot equate to the same force put on the average vehicle under cornering, braking and general driving.

With the brake pedal and steering wheel locked into place, the Suspension Tester is capable of applying force to the road wheels while the vehicle remains at static road height, thus simulating road forces that would normally be put on a vehicles suspension. The mechanical platforms will not only pull the wheels forward and rearwards, but also force the front of the wheels inwards and outwards. This puts the Technician in a prime position to be able to see any worn components and also be able to track any noises that may be in the vehicles suspension. This machine allows demonstration to the customer of the relevant problems with the suspension and diagnoses any movement in suspension components that could normally be overlooked and not included in the repairing quote.

Download flyer

Spring Compressor

Fulcrum Suspensions’ Spring Compressor makes light work of normally difficult and complex tasks. The floor mounted hydraulic Spring Compressor allows technicians to dismantle and assemble struts in a safe and timely fashion, to help gain efficiencies in their job and provide for a safer workplace by using an apparatus specifically designed to perform these tasks.

The Spring Compressor is particularly suited for use on vehicles such as the BA to BF Falcons, which have a front strut and coil assembly in the form of a large free length coil fitted to a strut containing an internal rebound spring coil. The compression required to mount the top cap and nut assembly into place is more than 200mm, making the need for a quality spring compressor apparent. Fulcrum has invested considerable research and testing into finding a Spring Compressor that fulfils all the criteria required to perform the job in an efficient and safe manner, to help increase business efficiency and ultimately profitability.

Download flyer for details

Download Disassembling Demo of BA Falcon Strut (1.8MB)

Download Demo of Assembling BA Falcon Strut (2.7MB)

Technical Information

Bump or Toe Steer

SuperPro Technical Info

Identifying and Measuring Shock Absorbers

The chart below shows the different types of shock absorbers and the extended and compressed lengths are measured.

General Suspension Fitting Instructions

Never assume the vehicle is at standard ride height. If the vehicle has been fitted with after market or modified springs, beware the new springs may not give the ride height change expected.

Before fitting new springs:

Always measure the existing ride heights, before removing the old springs. To get accurate measurements the vehicle must be on level ground and all the tyre pressures must be set. The measurement to be recorded is the dimension between the centre of the road wheels to the guards, the Centre of Wheel to Guard (CWG), which must be recorded on all 4 wheels before any suspension parts are fitted. The diagram below shows how to measure the CWG.

After fitting new springs:

Always road test the vehicle before re-measuring the new ride heights. Record the newly finished ride height and add to chart below.

Use the charts below and record the before and after Centre of Wheel to Guard measurements.

Special Notes

Ride Height changes affect the vehicle’s suspension settings. The toe settings, camber settings and castor settings may be effected by changing the vehicles ride height. Always perform a front and rear wheel alignment after fitting new springs.

Fulcrum offers a range of after market parts to correct most alignment issues, please contact your nearest Fulcrum Service Centre or Authorised Dealer for more information.

Power Steering Fluid and Correct Service Intervals

Today, many manufactures specify special Power Steering Fluids for their systems but do not list service intervals. This has created uncertainly amongst technicians when servicing the Power Steering System.

Evidence suggests that fluid in a power steering system in city and urban operations is degraded at odometer readings as low as 12,000 km. Degradation of fluid will ultimately reduce the effective service life of power steering components.

Additive packages in lubricating oils are formulated to precise specifications. In operation the lubricating oils do not wear out but the additive package becomes saturated and can no longer perform its desired function. Accelerated wear may occur in components because of foaming oil, oxidation, corrosion and the inability of the dispersant additive to hold contaminants in suspension in the fluid. The fluid itself will appear darker in colour and will have burnt smell. The only remedy for this condition is to completely flush the system with the correct power steering fluid.

Fulcrum sampled power steering fluids ranging at odometer readings between 10,000 to 60,000km in increments of 10,000km. After tests results our recommendation is to flush the system at 20,000km intervals to provide maximum protection to the system and all the steering components.

Flushing of the system is performed in the following easy steps:

1. Remove the fuel pump fuse or relay.
2. Disconnect the fluid return line at the power steering pump or reservoir.
3. Wind the motor over on the starter motor, directing the return fluid into a container, whilst at the same time, adding the correct power steering fluid into the fluid reservoir, (Take care not allow the reservoir to run dry) and turning the steering wheel from lock to lock. This will ensure that all the possible contaminates are flushed out.
4. When the fluid returning to the reservoir is the same colour as the new fluid being added, the flushing of the system is then complete.
5. Reconnect the fluid return line to the power pump or reservoir, replace the fuse or relay, start the engine and turn the steering wheel from lock to lock to expel any air that may have entered the system.

Note do not over rev the engine when flushing or bleeding, as this will cause aeration in the system. Also do not hold the steering on full lock for more than 5-10 seconds as this can cause excessive pump wear and or complete pump failure.

CLEAN FLUIDS ARE IMPORTANT

Fitting a Filter

When repairing, replacing or servicing a power steering system it is a good practice to fit a return line filter and this protects your customers steering system. Fulcrum recommends fitting a return line power steering filter to remove contaminants and extend the life of components.
Fulcrum Part No ‘s BF001 (For 8 mm ID return hose)
BF002 (For 10 mm ID return hose)
These two filters fit the most common vehicle applications available. When these filters are installed there are additional benefits to be obtained. Magnets inside the filter remove ferrous particles and the ribbed outer shell of the filter provides an extra element of cooling to the fluid in the system.

Fluids

To determine the correct power steering fluid for various vehicles, Technicians should consult the lubricants guide available from most major oil companies or seek
the vehicle‘s manufacturer's specification on power steering fluid requirements.

Power Steering Hoses Checking and Replacement

Power steering hoses are a vital component in the operation of a power steering system, quite often they are not given the consideration that should be afforded to them. Their function is to convey the power steering fluid, under pump pressure of up to 1,500 pounds per square inch (10,300kPa), from the pump to the steering rack or box as well as returning the fluid at little or no pressure back to the reservoir. As well as performing this fluid function the high pressure hose also acts as an accumulator to ensure a constant correct supply and flow rate of fluid is available for all steering operations and to act as a surge chamber to even out the pulsation’s in the fluid leaving the power steering pump.

Operating Temperature

Because the power steer pump is driven in the majority of cases off the front pulley of the engine, these hoses are located in a harsh environment. They are subjected to engine under hood temperatures and usually in close proximity to the engine manifold and exhaust system. These temperatures cause the outside covering of the hoses to harden and eventually crack and perish leading to leakage and pump noise due to their inflexibility.

Effect of Heat Generation

Due to the heat generated the power steering fluid also degrades and at this point in time none of the vehicle manufactures specify a power steer fluid service interval. Fulcrum through their continuing research program had performed specific performance and durability tests on power steering fluids. The result of this test program is to specify the changing of power steering fluid at 20,000 Km as well as recommending the fitting of filters. Power steer systems only contain on average about 0.65 of a litre of fluid and this continual heating of the fluid causes a build up of contaminants on the wall of the hoses restricting the flow of fluid and thereby creating problems such as:

1. Heavy steering
2. Shuddering of the steering wheel whilst turning at low speeds
3. Cavitation of the P/s fluid
4. Aeration of the P/s fluid
5. Noisy pump operation
6. Additional generation of heat in the P/s fluid

Inspection

Hoses that appear harmless may have hidden problems. They deteriorate from the inside out, passing small particles of contamination from the lines throughout the entire system. This can result in premature failure of the steering system. A careful inspection of the pressure output and a flow test will indicate to the technician the condition of the system and the need to replace the power steer hoses or system components to remedy the problem. It is essential that condition of both the supply and return hoses are checked as in most cases the return lines are often over looked.

After Market Power Steering Hoses

Fulcrum after market hoses are manufactured to original equipment standards to ensure that they mirror the vehicle manufactures design factors including any internal restrictions to control the flow rate of power steer fluid within each system.

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