Leaking Bilsteins? Something Else?
 

Had my car in the shop for something unrelated and they noted dirty grease around the bottom of the struts. They're Bilstein sports, and I think about ten years old. No obvious handling defect and when I had the front end completely apart a year and a half ago the struts were solid.

Any thoughts on what this might be? I think I'll have to scrub them clean and see if it comes back. I had both struts rebushed five or six years ago.... Possibly grease from bushing work?

http://forums.pelicanparts.com/uploa...1691517564.jpg
http://forums.pelicanparts.com/uploa...1691517564.jpg

When my front Bilstiens started leaking, it was mostly evident at the area where the top cover comes over the bottom strut area. The oil came out the top of the strut by the large flat nut that hold the insert to the strut, and the oil leaked down.

That almost looks like the ball joint is leaking. I would clean it all up, and drive it more and see where the oil is.

Does it make any clunking noise when going over a undulation in the road?

No noise with up and down, but it will make a clanking noise when braking or turning hard, basically any time there is a large longitudinal (front/back) load on the suspension. This will include putting the wheel to full lock and then moving forward or backwards at low speed. That issue has been present through two changes of ball joints, though, as well as the struts being re-bushed.

Also these are Bilstein inserts in Bilstein struts, not Boges, so no top nut. Just the bottom roll pin.

This video from three years ago shows the issue, and the whole suspension has been removed and reinstalled in the interim. Bushings are... eight or nine years old now? The steering rack has also been disassembled and re-greased with new bearings (original bushings were okay).

https://www.youtube.com/watch?v=PAlq-9bp04g

I made a thread on that a while back. Several shops have looked at it as well and none come up with a solution, let alone a proposal even. I've had it on track a dozen times with that clunk to no issue, though, so who knows. Maybe it's just haunted.

There’s suppose to be oil inside the housing that keeps the strut cool.

Even with the inverted Bilsteins? I don't see any way for it to be sealed for that.

mine do not have oil inside to keep the strut cool.

No oil needed on Bilsteins typically just some lithium grease near the top bushing.
Clean it up and see where the oil/grease is coming from

Okay I'll give it a check soon, thanks for the input.