Upgrading old suspension from original Bilstiens

[Elldawg]

Hi all,

 

I recently acquired a yr 2000 live axle xflow Caterham S3. It's on its original 25+ year old Bilstien suspension and I'm thinking these things are probably a bit long in the tooth. I'm not planning to track the car much if at all, it's primarily a road car. Whats a good replacement that also gives some adjustability too? Would be nice to dial in the ride height and rake at least. I've seen Meteor Motorsport in the UK thrown out there as a goto solution. Any good options this side of the pond too? 
 

the sump also seems really low :/ 

Edited June 16, 2025 by Elldawg
Adding a photo of how low the sump is

[MV8]

If only they'd made the car a couple inches taller to have the engine a couple inches higher in the chassis. A ride height adjustment can be made with a shim on the spring seat or swapping for the threaded sleeves and seats from Cat (or possibly something Bilstein can sell directly). It SHOULD be as simple as sliding off the standard lower seat, leaving the wire ring or an integral step on the damper body that located the original seat. CAT specs for length extended and compressed and attachments are not universal to where those used for racing here are a direct fit as-is plus the damping would be another variable to figure out. You might also look at GAZ.

Edited June 17, 2025 by MV8

[wdb]

Subbed for answers. I'm in the market for a set for my live axle S3 as well.

[Elldawg]

Thanks MV8, I’ll look into possible shimming too, although I’m thinking the suspension is a bit tired being how old it is, maybe not? I don’t really have any other comparable car to reference.
 

I had not heard GAZ as an option before, will investigate. I’ll probably also end up contacting Meteor for some advice and my local Caterham shop. Will let yall know what I find. 
 

For now gonna enjoy low and cautious. They made the handling so good so you could dodge sump mines right?!

Edited June 17, 2025 by Elldawg

[MV8]

All Lotus S2 and S3 live axle, as well as Caterham live axle should use interchangeable dampers front and rear. For front only, include S1 and '89 and newer Seven when in a chassis equipped with a Dedion that is using stem upper mounts on the rear.

 

 

[IamScotticus]

Was wide track an option for the late 90s-2k Xflow live axle S3?

[MV8]

I doubt it. The wide track was an option  for DeDion equipped from '96-on.

'96-on standard track DeDion and 91-96 DeDion are also different from each other as well as different from wide track.

Not sure about what was used on the rear of '85-88 DeDion.

 

It looks like GAZ has the most reasonably priced adjustable seat damper for live axle.

Spring rates for touring / ride quality appear to stay around 95# front, 55# rear.

[Elldawg]

Thanks for the additional info. I'm still actively researching and reaching out to various manufacturers and shops.  As far as direct replacements this is what I've found so far as of June 2025, just dampers not springs, but easier to get the springs. 

 

Merlin motorsports:

• SPAX fronts a rear adjustable height and non adjustable height - product codes, G775, G776 ~$202 ea
• AVO front and rears adjustable height - product codes,  PC565, PB148 ~$161 ea

Direct from GAZ

• GAZ front and rears adjustable + springs - product codes, GP4-2032, GP5-2037 ~GBP 116 ea

Caterham

• Bilstein replacements, non adjustable- reference # 75526, 75524  ~GBP 200 ea
• Bilstein height adjustable kit for the non adjustable shocks - reference # DSSU01K  Caterham says these will retrofit my old yr 2000 Bilsteins and also fit on their non height adjustable Bilsteins, my local Caterham mechanic Rich Kamp has some experience with them and says they may need an additional ring machined to locate properly but its a way to get the Bilsteins height adjustable. ~GBP 245 set

Meteor - started a dialog with Ben, there. Have not gotten confirmation that they would be able to build a set for my live axle car with the threaded top rear mount.

 

Leda - I have an inquiry with them, they seem active in the UK and could build a set for the car.

 

I'm looking into possibly updating the entire front end to wide track but to do that the uprights would also need to be replaced with the more modern spherical bearing ones, the later model live axle cars have the brass trunnion steering swivel thats not compatible. This would at least get the front to be the same as the more modern cars and open up lots of possible front coilovers and basically make the front like a new car. Juice might not be worth the squeeze as this option still leaves the rear live axle issue of finding LA mountable rear coilovers to pair with whatever fronts I use. I'll inspect the trunnions and front uprights for damage per Rich's advice, if the uprights need replacing, may just go for it.

 

Will update as I sort it out. I've also found out that my oil sump is actually from an Elan so its not the slightly flatter bottom one Caterham made. Could hack and weld... would prefer to just raise the car slightly.

[The Stig]

I can recommend the Gaz setup. Had a few from them over 20 or so years for various cars and never had any issues. They can also supply appropriate springs too. I believe I’m using 140 rear with a helper spring and 250 front.  Live axle Crossflow. 

[cobra8214]

I have the same car configuration as you except 4 years older and am looking to do the same, so thanks for the update! For what it’s worth, I have heard that Spaxs can be very inconsistent.

[Elldawg]

Update after speaking with Ben at Meteor and doing a bit more internet sleuthing, he is looking into whether or not they can produce their in house Core brand (tractive technology) with digressive damper system for a LA narrow track car. This + new better bushes would be probably one of the best slap in systems an old car like this would ever need. Its certainly not the inexpensive option at over ~$2500, £1850 per set.

 

Meteor and others, some in the states can supply Nitron brand live axle coilover kits. I've found many sources that carry the LA kits for narrow track cars a few linked below. Meteor however states they offer 3 valving solutions based on the driving needs and much nicer looking springs in a soothing dark blue color vs the stock racer boy teal the Nitrons come with. There are various included spring options too from many sources.

 

Nitron Caterham Live Axle Kit 1973-2002 - Part No: NTCCA-015R1 ~$2000 per set

 

Evassive Motorsports

Driftworks

BBGem

 

This is ~2x the price of new non adjustable OEM Bilsteins + adjustable collars and 3x GAZ... and I'm sure lots of folks would consider such expenses on an old LA car unjustifiable, but idk seeing what ppl spend on lifted trucks

 

There is also the Quantum Kit for LA narrow track cars, that Meteor can probably source (they carry Quantum) but it's advertised available at Jack Webb Suspension. Starting to really break the bank now

 

Caterham Quantum One.Zero by JWM - Road/Track Live Axle Calibration   £2249.17 per set + options

 

Anything can be made for the $ i suppose.

 

Other than the Jack Webb system none of the sites ask about what type of axle the car is running, I assume the Nitrons are all for the Marina / Ital and not Ford.

 

 

 

[wdb]

Great update! Nitron is the name I recall from my last foray into suspension foo. As for Ital/Ford I'm not certain the shocks care what axle they connect to so long as the anchor point is in the same place. Happy to be proven wrong, bring on the wizards...

[Elldawg]

9 minutes ago, wdb said:

As for Ital/Ford I'm not certain the shocks care what axle they connect to so long as the anchor point is in the same place. Happy to be proven wrong, bring on the wizards...

 Yeah you're probably be right. Meteor asked for pics of the mounting points at the rear. I'm sure some gurus know what different years / configurations did what with those mounts. maybe indicative of the "1973-2002" years for the Nitron LA option.

Edited June 25, 2025 by Elldawg

[MV8]

See my June 18th post.

[Elldawg]

Figure I’d post an update. So the more I dig into this the only options for live axel caterhams are looking to be the budget friendly stuff spax, gaz, standard Oem Bilsteins or Jack Webb Quantum’s. 
 

Meteor thinks they might be able to make a set but have never done it before and I get the impression they don’t really want to, fair enough as these are old aging cars that are a niche within a niche that will never be made this way again.  
 

The Nitrons while advertised as a product for LA cars are more of an R&D project from what I’ve gathered with my conversations with Jack Webb. He develops products with Nitron and raced a Live Axle car in hill climbs for years, so has experience with them, and he continues to support the LA cars today. After inquiring on my behalf with Nitron, in his words,

 

“It turns out that whilst they list a Live Axle set on their website they haven't actually got any drawings for them - they originally made a damper for a Ford axle car that had a nasty metal bracket to make it fit” 

 

So since they don’t have any CAD or drawings of this setup it would take some development time to design the proper mounting solution. I inquired if there are pics of this Nitron setup. I’d be very curious to hear from anyone who has actually installed them in an LA car. 

 

So for high end, looks like quantum’s or maybe Nitrons but you would need to order a set to know what you end up getting if anything at all, sounds like it’s more of a line item in the catalog vs an actual product idk. 
 

I’ll update with what I eventually go with.

[IamScotticus]

@Elldawg thanks for the sleuthing.  Yea, old tech. Some golden shocks filled with blessed holy water can do wonders for the LA. Then so can replacing SPAX or GAZ when they wear, which may be frequently if you do the miles.  I think the best thing to do for the LA is to lighen it up.

So I suggest, if you're not exceeded 150hp on grippy tyres,  cut off the torque plate to shave pounds. 5 lbs?

Edited July 13, 2025 by IamScotticus