Front Struts, Shocks, Confusion -- Need Help!

[piscator]

I've either got the wrong struts or the wrong shock inserts and could really use some help!

As part of the refresh of my 1979 SC Targa, I proceeded to put new Bilstein inserts into my Bilstein struts. I ordered the inserts months ago, specifying the model and year to a reputable Porsche parts supplier.

So here Is the strut that came off the car. I'm pretty certain it’s the original.





First I banged out this roll pin.



I used this Porsche approved wrench to remove, what I thought to be the gland nut and discovered it had no threads on it.



Next, I pulled, pushed, yanked on and swore at the old insert, but it wouldn’t come out of the strut. I did a Pelican search and found a post by the inestimable John Walker; who advised putting the nut and a washer back on the top of the shock and giving that assembly a gentle whack. I got out my gentle whacking tool.



We whacked and whacked but the insert wouldn’t come out.



So we brought in a hot persuader to help.



After much whacking and heating, the silver thing at the top of the photo popped out.
Now this is a lovely piece of machinery, but being a perceptive fellow, I noticed that it doesn’t resemble the replacement shock insert that arrived from the reputable Porsche supplier -- which is the green one on the bottom.



And therefore, probably doesn’t belong to this strut.



So what does? Do I have the wrong replacement insert? Or do I have the wrong strut? Can someone explain what I’ve got here? And what I should do about it?

I never expected this and I’m very confused.

Thanks, Robert

[Superman]

We don't see a picture of the replacement strut insert (shock). The one that came out looks like the correct one. You have Bilstein struts.

[brp914]

Looks like you received a bilstein insert for a non-bilstein (ie boge) strut.

[Superman]

Okay, now I see the pic of the replacement. That green thing, right? That's not a Bilstein strut insert. The silver thing next to it is....the proper insert for your Bilstein strut.

[piscator]

Superman and BRP,

Thank-you very, very, much! That's the answer. I ordered those shocks six months ago. I probably didn't know what struts I had at the time. I simply ordered them by model year and that's what the supplier sent. This has been a big project to keep track of. I'll have a word with the purchasing department!

Were Boge struts offered in 1979 as well? I wonder if they were more common. Is there any reason to prefer one strut over another? I could look for some Boge bottoms to match the Bilstein tops that I have. Or sell the tops and order the correct inserts.

I really appreciate your help.

Robert

[john walker's workshop]

No mention of removing the roll-pin at the bottom of the strut. Did you actually manage to get the insert out wimthout removing the pin..

[piscator]

Hi John,

Thanks for all the great advice you offer here! I did bang out the roll-pin. I said so above the fourth picture. Maybe I should have asked this question without so many photos. I was so befuddled when I compared the strut inserts, that I thought this was more complicated than it turned out to be. Now, I'm relieved!

Robert

[brp914]

Originally Posted by piscator

Superman and BRP,

Thank-you very, very, much! That's the answer. I ordered those shocks six months ago. I probably didn't know what struts I had at the time. I simply ordered them by model year and that's what the supplier sent. This has been a big project to keep track of. I'll have a word with the purchasing department!

Were Boge struts offered in 1979 as well? I wonder if they were more common. Is there any reason to prefer one strut over another? I could look for some Boge bottoms to match the Bilstein tops that I have. Or sell the tops and order the correct inserts.

I really appreciate your help.

Robert

As I recall, by the time the 3.2 came out Boge was standard, with bilstein optional. If your car has a zillion miles like my '77 does, the spindle vs tube angle can change, making alignment difficult. Also, the spindle itself and the bushings in the tube can wear. I can't comment on boge vs bilstein. For my '84 project I gave Chuck at [some place] a call and started over with new Bils with spindle support, raised 19mm.

[mepstein]

Boge was standard, Bils were an option. You need an insert just like you removed. Next time, to get out the insert, just use a thin punch in the hole at the bottom of the strut. A couple firm taps will drive the insert out without heat or fuss.

[Superman]

Raised spindles are for lowered cars. In my view, factory USA ride heights are way too high. Lowering causes 'sump steer' because the tie rods are not level. Various methods are available to deal with this. I actually sent my struts to Clint at Rebel Racing for the fancy-schmantsy tie rod brace thingie in addition to raising the spindles. VERY happy. This car has never steered so accurately or effortlessly.

I also had the strut inserts custom-valved and I replaced the ball joints. (turbo) tie rods were fine.

[BlueWing]

My 79 came with Boge as stock.

If you have issues exchanging the strut inserts you have and can verify fitment I'm sure they can find a new home from here on Pelican

Must be someone here looking at a front suspension rebuild with Boge struts in the near future.

Terry

[piscator]

Originally Posted by mepstein

Boge was standard, Bils were an option. You need an insert just like you removed. Next time, to get out the insert, just use a thin punch in the hole at the bottom of the strut. A couple firm taps will drive the insert out without heat or fuss.

Mepstein, very interesting. I saw that hole and thought about using a punch there. But to my eye, peering into the hole, it also looked like hex socket. I didn't want to bang it up without further information. I appreciate your confirming this!

BRP914, Do you have any idea why the Bilsteins were optional? To my limited understanding, a strut is a strut. Why would you prefer one over another?

Superman, I considered lowering the car but decided to keep it stock. Maybe that will be a project for another day.

Thanks for comments, guys! I'm going to get in touch with Chuck at Elephant Racing. He has the correct inserts listed on his website. They're half the cost of the Boge inserts I purchased. I sure wish I'd been more careful, but, live and learn!

Robert

[calidude]

May want to try ******** for lower prices on the inserts as the research I did was they were the cheapest.

[911obgyn]

If you cannot return your inserts I have bogey that I want to change to bilstien.

[mepstein]

Originally Posted by piscator

Mepstein, very interesting. I saw that hole and thought about using a punch there. But to my eye, peering into the hole, it also looked like hex socket. I didn't want to bang it up without further information. I appreciate your confirming this!

BRP914, Do you have any idea why the Bilsteins were optional? To my limited understanding, a strut is a strut. Why would you prefer one over another?

Superman, I considered lowering the car but decided to keep it stock. Maybe that will be a project for another day.

Thanks for comments, guys! I'm going to get in touch with Chuck at Elephant Racing. He has the correct inserts listed on his website. They're half the cost of the Boge inserts I purchased. I sure wish I'd been more careful, but, live and learn!

Robert

I didn't realize it was this easy until I had one where the insert was stuck. Took it to Will Pyle - longtime Porsche Tech and shop owner and he knew exactly what to do. I got a quick education from a pro.

[piscator]

The inserts for my Bilstein struts are on the way. I had a hard time believing how skinny they are. Thanks for all the help, gentlemen!

Robert

[lateapex911]

I always put a coating of oil on the struts, to A: aid install, and B, prevent rust, and C- help transfer heat. Not sure what others do....but I don't think it can hurt.