Bilstein PSS installation question

mbrady · 06:59 PM

Hey, just got my copy of 101 Projects (thanks Wayne!) and I am attempting to tackle a Bilstein PSS coilover installation. Installation of the rears was pretty easy and uneventful, but I'm stuck on the front assembly. I took the stock strut/spring assembly off, and I'm trying to get the old upper mount bushing/strut hat stuff off so I can put it on the new PSS assembly. I compressed the spring and got enough leverage where I was able to get the 22mm nut to spin, but unfortunately the strut shaft was spinning as well. Is there an easy way to secure the strut shaft so that I can undo the 22mm bolt on top? I don't have an impact wrench, so I'm doing this with a big ol' socket wrench. Thanks in advance!

EDIT: Sorry, forgot to mention that I have a 1994 325i.

Wayne 962 · Wayne 962's Garage

Several pairs of vice-grips are one way - you're taking off and tossing the shocks so you don't care if the shaft gets scratched.

On the other hand, it's a very important tool, the impact wrench, and I recommend this as a vital tool. My $40 swapmeet one just broke on me recenty, so I have ordered this one for myself:

http://www.pelicanparts.com/catalog/shopcart/TOOL/POR_TOOL_CAT291_pg2.htm

I can't stress enough how valuable this tool is - I would really break down and purchase one for your tool collection.

On a related note, I have the PSS9 kit from the book for sale for $1150 right now (brand new)...

-Wayne

mbrady · 09-15-2006, 11:03 AM

My roommate had the idea of drilling into the center of the piston shaft and then inserting a metal rod into the hole to hold it still... but it's a very smooth, hard metal, and it would be really hard to drill into. So, we're thinking about drilling through the top of the shaft -- through the 22mm nut. Going to buy a huge metal drill bit today, so we'll see how that goes.

Wayne 962 · Wayne 962's Garage

Quote:

Originally posted by mbrady
My roommate had the idea of drilling into the center of the piston shaft and then inserting a metal rod into the hole to hold it still... but it's a very smooth, hard metal, and it would be really hard to drill into. So, we're thinking about drilling through the top of the shaft -- through the 22mm nut. Going to buy a huge metal drill bit today, so we'll see how that goes.

Jeepers. Seems like a lot of trouble when an impact wrench will zap this off in less time that it took for me to write this sentence. Plus, it *will* come in handy later on.

AND, you cannot install the PSS9 setup without the use of the impact wrench anyways, so you'll be stuck on the other end...

-Wayne

Jeron · Jeron's Garage

Don't try to drill the shaft. If you are going to destroy it anyway just use vice-grips. If you don't want to buy and impact try to borrow one or take the struts to a shop and have them zap-em off.

My factory rods had a allen top so you can get some tools to make it work but it just isn't worth it since you cant use the same setup on the Bilsteins.

mbrady · 09-15-2006, 12:12 PM

Ahhh... that's true, I hadn't thought of that.. even if I do get the parts off the stock strut, I would still need to put them back on the new strut -- and the piston would spin as I try to torque it down, right? If so, what stops an impact wrench from spinning the shaft too?

Jeron · Jeron's Garage

The nature of the tool with its short quick impacts gets the nut tight without spinning the shaft. A regular twist drill would not suffice. I can't think of a good analogy.

mbrady · 09-15-2006, 02:42 PM

Alright -- I got a impact wrench! But I have run into another problem -- the 22mm impact bit won't fit into the hole where the recessed 22mm nut is! What now? :\ I'm considering trying to shave a tiny bit of material off the walls of the recessed pit in the bushing in order to clear the impact bit.

Keith M · 09-15-2006, 05:10 PM

Its not on that tight so just use a chrome or grind it down to fit.
My H&R's coil overs have a female allen on top. What I did was to use a spark plug socket (the kind with a 6 point nut on the top) and inserted it over the bolt. Then I stuck the allen wrench down the middle to hold the strut and used a wrench on the socket nut. I didn't think I would use an impact to put it on though, but thats just me.

Keith

mbrady · 05:38 PM

I thought spark plug sockets are 16mm?

EDIT: Also, wayne, what's the trick to using an impact wrench? It won't even undo wheel bolts (let alone the 22mm strut bolt), it just clicks rapidly...

Wayne 962 · Wayne 962's Garage

Quote:

Originally posted by mbrady
I thought spark plug sockets are 16mm?

EDIT: Also, wayne, what's the trick to using an impact wrench? It won't even undo wheel bolts (let alone the 22mm strut bolt), it just clicks rapidly...

If your impact socket is too big then use a regular one. The impact sockets are hardened so that they work better.

If you're using it with a regular set, then you might not get good results, as the tool will absorb the impact, and you will eventually destroy your socket set. Try it with an impact set, and it should work. Just hold it on the lug nut for about 10 seconds - it will knock it off...

-Wayne

mbrady · 09-15-2006, 05:58 PM

I am using an impact set... but I did not hold it on the nut for 10 seconds... so you're saying that if I leave it in the clicking state for 10 seconds it will eventually break free and begin to undo the nut..?

Wayne 962 · Wayne 962's Garage

Quote:

Originally posted by mbrady
I am using an impact set... but I did not hold it on the nut for 10 seconds... so you're saying that if I leave it in the clicking state for 10 seconds it will eventually break free and begin to undo the nut..?

Yup, maybe 10-20-30 seconds if it's on there really tight. The tool needs time to work. Don't let it overheat though, and I always use ear and eye protection when using it...

-Wayne

Jeron · Jeron's Garage

A cheap impact wont break a lug nut loose. I have one. What model did you get?

mbrady · 09-17-2006, 09:17 PM

I have the DeWalt one that Wayne posted earlier... not exactly cheap. I found out I had no idea what the concept of the impact wrench is -- the "clicking" was the wrench impacting the bolts and breaking em free. I got it now. I'm actually working on finishing the entire installation right now -- all the four corners are done. I ended up just drilling the old piston shaft with a cobalt bit to get the bushing off.

Wayne 962 · Wayne 962's Garage

Cool, glad to hear it's coming along...

-Wayne

mbrady · 09-18-2006, 02:34 AM

One small (actually kinda huge) problem: the front tires (205/60R15 w/ stock bottlecap rims) RUB against the shock housings (specifically the black adjusters)!! What the hell...? Never heard of this happening. Does this mean I need wheel spacers, or did I royally screw something up in the install? If I need spacers, can I get them quickly at AutoZone? I've got a class in the morning and I didn't see this one coming...

Jeron · Jeron's Garage

Pepboys sells a cheap generic 1/4" spacer that will work in a pinch. You need 5x120mm but I think the spacer may be listed in SAE measurements.

I'm surprised the stock rims could rub. Did you put the rotor on before test fitting the wheels.

Did the impact end up pulling the lug bolts after you let it have a few seconds to work?

mbrady · 09-18-2006, 11:46 AM

Yeah, the rotors were on and everything when I foudn this out... haven't had a chance to test out the impact wrench on the lug bolts, but I'm pretty sure it will work.

Wayne 962 · Wayne 962's Garage

Despite having the same tire sizes, every tire is slightly different, so one brand may rub and another may not. Generic spacers should be a good fix for the problem...

-Wayne