Nissan 240sx 5-lug Conversion: A Comprehensive Overview

The Nissan 240SX, particularly the S13 and S14 chassis, is a beloved platform for drifting, time attack, and general performance modification. One of the most common and impactful upgrades is the 5-lug wheel conversion. This article will provide a comprehensive overview of performing this conversion, outlining the benefits, necessary parts, different approaches, and potential pitfalls.

Why Convert to 5-Lug?

The stock 4-lug configuration on the 240SX has inherent limitations, particularly when chasing higher horsepower or aggressive driving styles. Here's why upgrading to a 5-lug setup is often desirable:

Increased Strength & Durability: 5-lug hubs generally offer superior strength compared to 4-lug designs. The additional lug nut and stud distribute the load more evenly across the hub, reducing the risk of hub failure, especially under the stress of drifting or track use.
Wider Wheel Selection: The aftermarket wheel industry heavily favors 5-lug patterns. Converting to 5-lug vastly expands your wheel options in terms of style, size, and offset. Finding desirable 4-lug wheels, especially with specific offsets, can be incredibly challenging.
Brake Upgrade Compatibility: Many larger, higher-performance brake kits are designed specifically for 5-lug hubs. This conversion opens the door to significant improvements in braking performance. Often, bigger brake kits also come with a 5-lug hub.
Enhanced Aesthetics: While subjective, many enthusiasts prefer the look of 5-lug wheels. It provides a cleaner and more aggressive appearance.

Understanding the Options: Hubs and Spindles

There are several approaches to performing a 5-lug conversion on a 240SX. The most common involve swapping either the entire spindle/knuckle assembly or just the hub itself. Understanding the difference is crucial for making the right choice.

Spindle/Knuckle Swap

This method involves replacing the entire spindle (front) or knuckle (rear) with a 5-lug version from another Nissan vehicle. The most popular donors are:

Z32 300ZX (1990-1996): The Z32 300ZX is a very common donor. Front spindles and rear knuckles provide a relatively easy swap. The front hubs require modification to fit the 240sx ball joint. The rear is nearly a direct bolt-on.
S14 240SX (1995-1998) SE/LE Models: Some higher trim S14 models came factory equipped with 5-lug hubs. These are a direct bolt-on for S14s and can be adapted to S13s with modifications.
R32/R33 Skyline GTS-T: Skyline components can be used, but the swap is more involved and often requires more specialized knowledge and potentially custom parts. They are also usually priced higher than 300ZX counterparts.

Advantages of Spindle/Knuckle Swap:

Potential for improved suspension geometry: Depending on the donor vehicle, the spindle/knuckle may offer slightly different geometry, potentially impacting handling characteristics. This can be positive or negative depending on the specific setup and goals.
Generally considered strong and reliable: Since you're using OEM parts, they tend to be durable, proven designs.

Disadvantages of Spindle/Knuckle Swap:

Potentially more complex installation: Depending on the donor vehicle and your specific 240SX model (S13 vs. S14), modifications may be required to ensure proper fitment. This could involve modifying ball joints, tie rod ends, or other suspension components.
Used parts availability and condition: Sourcing used spindles/knuckles can be challenging, and the condition of the parts may be questionable. Pay close attention to wear on ball joints, wheel bearings, and other critical components.
Wheel offset considerations: The track width can change with a spindle swap, which can impact wheel fitment. You'll need to carefully consider wheel offset to avoid clearance issues.

Hub Swap

This method involves pressing out the existing 4-lug hub from the spindle/knuckle and replacing it with a 5-lug hub. This can be achieved using aftermarket hubs specifically designed for this purpose. Typically these are offered from vendors like Circuit Sports, ISR Performance, or similar aftermarket companies.

Advantages of Hub Swap:

Simpler installation: Generally, this method is considered simpler than a full spindle swap, as it avoids the need to modify suspension components.
Retains stock suspension geometry: Since you're using the original spindle/knuckle, the suspension geometry remains unchanged.
New parts: You're usually purchasing new hubs, ensuring a higher level of reliability and minimizing the risk of dealing with worn components.

Disadvantages of Hub Swap:

Hub pressing required: You'll need access to a hydraulic press and the appropriate adapters to safely press the hubs in and out of the spindle/knuckle. If you don't have access to this equipment, you'll need to take the parts to a machine shop.
Potential for reduced strength: While reputable aftermarket hubs are generally strong, some cheaper options may not be as durable as OEM designs. Research the brand and read reviews before purchasing.
Wheel bearing quality: Check to ensure the supplied wheel bearings are of decent quality. Some cheaper options use substandard bearings, which can lead to premature failure.

Parts List

Regardless of the method you choose, here's a general parts list to consider:

5-Lug Hubs or Spindles/Knuckles: Obviously, the core component. Ensure you get the correct parts for your specific chassis (S13 or S14) and desired configuration (front and rear).
Wheel Bearings: If you're using used spindles/knuckles, consider replacing the wheel bearings as a preventative measure. New hubs should come with bearings, but it doesn't hurt to verify their quality.
Lug Nuts: 5-lug lug nuts, preferably with a conical seat to match your chosen wheels.
Brake Rotors: You'll likely need 5-lug brake rotors to match your new hubs. Depending on the swap you choose, you may need specific rotors. For example, using 300ZX hubs often requires 300ZX rotors.
Brake Calipers (Optional): If you're upgrading your brakes, you'll need appropriate calipers and brackets. Consider the compatibility with your chosen hubs and rotors.
Brake Lines (Optional): Stainless steel brake lines are a common upgrade for improved braking feel and performance.
Ball Joints: If performing a spindle swap, inspect the ball joints on the donor spindles. Replace them if they show signs of wear or play. You may also need to adapt the ball joints to fit your 240SX control arms.
Tie Rod Ends: Similar to ball joints, inspect and replace tie rod ends as needed. You may need different tie rod ends depending on the spindle swap you choose.
Dust Shields (Optional): Some enthusiasts choose to remove or modify the dust shields behind the rotors for improved cooling.
ABS Sensors (If applicable): If your 240SX has ABS, ensure the ABS sensors are compatible with your new hubs or spindles. You may need to swap or adapt them.
E-brake cables: If swapping rear knuckles you may need to adjust or replace the e-brake cables to ensure proper function.

Step-by-Step Installation (General Guide)

The specific steps will vary depending on the chosen method and donor parts, but here's a general outline:

Preparation: Gather all necessary parts, tools, and fluids. Park the car on a level surface, engage the parking brake, and chock the rear wheels. Loosen the lug nuts on the wheels you'll be removing.
Disassembly: Raise the car and secure it on jack stands. Remove the wheels. Disconnect the brake lines, calipers, and rotors. Disconnect the ABS sensors (if applicable). Disconnect the tie rod ends and ball joints.
Hub or Spindle/Knuckle Removal: Remove the existing hubs or spindles/knuckles from the car. If pressing hubs, use a hydraulic press to carefully press out the old 4-lug hubs.
Installation: Install the new 5-lug hubs or spindles/knuckles. If pressing hubs, carefully press the new 5-lug hubs into the spindles/knuckles, ensuring they are properly seated. Connect the tie rod ends and ball joints. Reconnect the ABS sensors (if applicable). Install the new 5-lug rotors and calipers (if applicable). Reconnect the brake lines.
Bleeding the Brakes: Bleed the brake system thoroughly to remove any air bubbles. This is crucial for proper braking performance.
Reassembly: Install the wheels and torque the lug nuts to the manufacturer's specification. Lower the car and remove the jack stands.
Alignment: After completing the conversion, it's essential to get a proper wheel alignment to ensure optimal handling and tire wear.

Potential Pitfalls and Considerations

Incorrect Parts: Double-check the compatibility of all parts with your specific 240SX model (S13 or S14) and desired configuration.
Worn Components: Thoroughly inspect all used parts for wear and tear before installation. Replace any worn components as needed.
Improper Installation: Follow the manufacturer's instructions carefully and use the correct tools. Improper installation can lead to component failure and safety issues.
Brake Bleeding: Bleeding the brakes thoroughly is essential for proper braking performance. If you're not comfortable bleeding brakes, seek professional assistance.
Wheel Offset: Carefully consider wheel offset to ensure proper clearance and avoid rubbing issues. You may need to use wheel spacers to achieve the desired fitment.
ABS Compatibility: If your 240SX has ABS, ensure the ABS sensors are compatible with your new hubs or spindles.
E-Brake Function: After swapping knuckles, verify the e-brake is functioning correctly and adjust or replace cables as needed.

Conclusion

Performing a 5-lug conversion on a Nissan 240SX is a rewarding upgrade that offers numerous benefits, including increased strength, wider wheel selection, and improved brake upgrade compatibility. By carefully planning the conversion, choosing the right parts, and following the proper installation procedures, you can significantly enhance the performance and aesthetics of your 240SX. Remember to research thoroughly, consult with experienced mechanics if needed, and prioritize safety throughout the process. Always double check your work and test the car in a safe environment after completing the conversion.

Disclaimer: This article provides general information and should not be considered a substitute for professional mechanical advice. Consult with a qualified mechanic before performing any modifications to your vehicle.