1996 Nissan 240SX SE Suspension Test - G The Factor

My next call was to anti-sway bar manufacturers, Suspension Techniques. We desperately needed some help taming our 240's inclination to attempt to grind the mirrors in the turns, and ST was happy to help. Our SE model 240 came equipped with front and rear anti-sway bars, but in extreme situations the stock bars are not quite big enough for the job in hand. The front Suspension Techniques bar is 1 1/8-in. thick and is 22 percent stiffer than the stock 27.2mm bar. The rear bar is 13/16-in. thick and provides a colossal 182-percent increase over the puny stock 15.9mm bar. Our bars came equipped with all necessary mounting hardware, including urethane bushings.

The Brakes
It was obvious from our track tests the stock 240 brakes would be a limiting factor in the canyons. The last thing we needed was to find ourselves brakeless after a spirited driving session in the hills, so we decided to upgrade in search of better fade resistance and overall performance.

We called the ever-helpful staff at Courtesy Nissan in Richardson, Texas, and talked to parts manager Steve Richardson. Steve proved to be a veritable mine of information, and after listening to our tales of woe he was more than happy to supply the parts that would solve our problem.

As one of the largest Nissan Motorsports dealers in the country, Courtesy had everything we needed on the shelf. Steve disappeared into the vast parts warehouse and reappeared 10 minutes later with our parts.

The 240SX brake upgrade that Steve appeared with is a genuine Nissan upgrade, featuring parts sourced from the Infiniti Q45 luxo-barge. The discs are 280mm in diameter and 28mm thick, as opposed to our stock 252mm and 20mm O.E. rotors. With directional cooling veins and the extra material in the new discs, overheating should not be a problem as it is with the stock setup. The kit also included a set of calipers with dual 42.8mm pistons (stock is a single 54mm piston) and a set of pads that give an increase in effective area of more than 40 percent.

While we were at it, we decided it would be smart to install a set of Goodridge braided steel brake lines, and we also bought a bottle of high-performance AP brake fluid. Once again, these products were all available from the warehouse at Courtesy Nissan.

Other Stuff
We decided to try to liven up the KA24DE powerplant with the help of a lightweight flywheel. With constant gear changing up and down the box, a lightweight flywheel definitely makes life easier. Engine response to throttle input is greatly increased, and overall this is one of the best mods to make to the KA if you're in search of more performance.

We called the crew at Indigo Speed for our aluminum flywheel. Indigo has been manufacturing high-quality aluminum components, including flywheels, pulleys and radiators, since 1997 and has established a reputation for producing top-quality parts. The Indigo Speed flywheel is CNC machined from T6061 aluminum and fitted with a changeable steel friction surface. The steel ring-gear is heat shrunk in place, and the total package weighs in at less than half the weight of the stock cast-steel flywheel.

While we were changing the flywheel it made sense to upgrade the clutch to withstand Harrison's (and possibly my) abuse. Advanced Clutch Technologies (ACT) had a performance upgrade that was perfect for our application. Our stage two clutch came complete with a new thrust bearing, pressure plate and disc rated at 275 lb-ft of torque, more than enough for our mostly stock KA24DE.

So, what's the result of all this planning? Tune in next month as we install our chosen aftermarket parts and put them to the ultimate test.

By Chris Harrington

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