Replacing Front Strut Inserts - Part Deux

[KMoore68]

Hi,

On my 1977 911 S Targa I have successfully replaced one of the front struts with the correct Bilstein insert however I am having difficult re-inserting the roll pin.

Any tips or suggestion on how to re-insert it?

Thanks,

Kevin

[bkreigsr]

McMaster sells specific roll pin punches.
I had to convert US to Metric to figure which punch would work.
Buy one and you will have it forever.
FWIW, Porsche recommends one-time use only on the pins.

[john walker's workshop]

The shaft needs to be lifted up just a bit to align the notch with the hole. Stick a punch in there to find the sweet spot. The pin gap faces away from the shock shaft. I use an air hammer to insert the new pin.

[KMoore68]

Originally Posted by john walker's workshop

The shaft needs to be lifted up just a bit to align the notch with the hole. Stick a punch in there to find the sweet spot. The pin gap faces away from the shock shaft. I use an air hammer to insert the new pin.

Unfortunately I don't have an air hammer, but I've got the pin about 1/2 way in, it just seems stuck now.

[john walker's workshop]

Probably need to get it out a bit so the shaft can be pulled up and aligned with the hole. Try sticking a tapered punch in the other side and prying upward.

[KMoore68]

It's about half way in and looking down the hole, it seems that the end of the roll pin is digging into the metal

[john walker's workshop]

Yeah, it's missing the notch.

[KMoore68]

I appreciate the advice but I'm butting my head up against this wall and don't feel like I can do anything to slide the pin in.

[john walker's workshop]

Just needs to come out a bit so the shock shaft can move up a bit. I assume "up" if there is no debris in the hole keeping it from going down enough so the notch lines up with the pin hole. Grab the pin with big visegrips and twist back and forth as you pry against the visegrips with a big screwdriver. Then stick a punch in the strut hole opposite the roll-pin so it engages the notch in the shaft and holds it there, then finish knocking the pin in.

[Solamar]

Heres a shot of the ends of my Bilstein struts when I pulled them out. You can clearly see that the PO missed the notches and pounded the roll pin in anyway. This caused the roll pins to collapse and give me knocking sounds when I went over bumps.

As John Walker said, you want to make sure the pin is properly aligned with the notches before you hammer them in.

[KMoore68]

Thanks for all the tips and help, I was able to get it in and everything buttoned up!

It does make a dramatic difference to get the insert lined up!

[john walker's workshop]

It's hard sometimes when the snubber is chewed up like a frog in a blender and rubber bits keep the shaft from going down enough to line up the notch with the pin hole.