Okay, so I have recently learned that the FE5 suspension package changes (almost completely) between the 2007 and 2008 model year. What I want to try and learn is; What's different? I plan on doing a large amount of suspension work in the near future and want to get all of my ducks in a row.

 

Higher spring rates,
Different damping rates
different lower control arms
larger integrated rear sway bar
different front sway bar.

And its all more expensive than the SS/SC FE5

If your doing a "large amount" of suspension work, Id recommend you go with your choice of springs(I noticed very little difference between the 2 spring sets)

Go with your choice of dampers(Koni yellow inserts?) The TC dampers are nice, but they arent adjustable, and arent really "cheap"

Go with the SS/SC LCA's as they are cheaper and dont offer any difference in the alignment

Right now I'd say TC sway bar, but Ill let you know what difference if any I feel once install it.(ive got an SS/SC now)

End Links are the same.

The rear axle is retarded expensive new(either one), so simply out of economics Id say go with a used SS/SC (doubt theres many wrecked TCs yet) and an aftermarket bar of your choice. Theres a 2mm difference between the SC and TC rear bars. Or go custom and just get a nice big bar welded into your axle.

I'd highly recommend going with TC knuckles. They are stronger. And they only run about $130-140 a piece. Ill proly be ordering some next week if I make any money this week

 

Alright, good stuff.

I'm using Eibach Prokit springs, and will be sticking with those.

I have a line on a salvage 2006 FE5 rear axle (complete). So it seems you answered the question there, which is the newer axle has a larger bar (by 2mm). That's not a problem with the selection of various aftermarket add-on bars that are available. Okay, good stuff there.

I was going to do the GM Racing knuckles, but if that price you have up there is correct, that is a lot cheaper and I'm sure addresses the weakness issue I wanted to fix with the stock FE1 part, so that's good stuff there too.

This is a street car, so non-adjustable dampers are fine for me right now. Stock FE5 should be fine. I'll do some shopping to see what the price difference is between the 07 and 08 models.

Now what exactly changed with the control arms? It's a cast aluminum part, what could be different? The mounts? And what changed in the front sway bar? It's still 24mm, did they change the shape?

 

This imformation would be a good sticky imo

 

If I can collect a complete side by side comparison of the data between the two model years, I'll make a new thread and sticky it in the Suspension section. In fact, to be complete, I'll include all the suspensions (FE1, FE3, FE5). That's a good idea actually.

 

The GMR knuckles are sweet, but I doubt Id ever need that much of a knuckle. Ill be sticking with the TC knuckles.(next week hopefully) They are in between the GMR and other knuckles. Price might be off a few dollars, but they are definitely LESS THAN HALF of what the GMR pieces go for, and they are significantly improved over all other Delta spindles.

I dont have any side by side anymore, but iirc the casting is slightly different(particularly the left side arm) I think the bushings are different durometers and I was told, but havent been able to verify yet, that there is a different ball joint geometry, not different alignment, just ball joint orientation. For me, its not worth swapping out the SC/FE5s Ive already got.

As far as the sway bars go, Ill let you know soon. The TC bar is like twice the price of the SC bar, I think it has to do with its shape, as you pointed out, they are both 24mm(.955" I measured today) If its just the shape, Ill be sticking with the SC bar. I dont need turbo downpipe clearance

 

There were two things that caught my attention.

Do you think the new knuckle design has anything to do with the Brembo brakes? If the caliper mounts are different, that would be important to know.

And as for the front sway bar, I didn't think about the turbo clearance, that makes sense. And again, makes it worth finding out about.

 

It has to do with the fact that hte old knuckle(there is only one for all cars) was crap. The new one is stronger to handle the increased handling, power AND braking. It is a direct swap with previous Cobalt knuckles.

Yup, Like I said I'll know for sure late this week. Ive already got on car pics of the two knuckles in the LNF brake thread, you can very clearly see the difference between the two. Ill be sure to post side by side bench pic when I get them in.