Strut/Insert Removal 101!

jphillips-998 · jphillips-998's Garage

Take it slow guys, I have searched the threads and am still a bit lost....My goal is to remove my inserts to have them revalved.

The top of the strut is off (easy), I have also reattached this so that I have some leverage to remove the "roll pin" that I assume is the left pin in the picture below correct?

Wayne says to beat or drill this pin out. I have tried the beating portion without ANY success. Does it go in from the front, back or doesn't it matter. I may just drill it out.

My next question is what is the right bottom hole in the picture? What does the bolt that goes through that hole do? Is this the "wedge bolt" that other posts referred to? Does this have to come out to remove the insert? How about to remove the strut? I will say that I have heated it and beat the threaded end of this into oblivion as well and will likely have to drill it out.

Finally, I have the wrench to remove the castellated nut on the bottom of the ball joint, but again w/a 3 lb sledge could not get it to move. I will try a pipe wrench tomorrow but any other suggestsions?

Very frustrating day in the garage today, hoping tomorrow will be better. Thanks for your assistance.

Early_S_Man · 05-27-2003, 10:30 PM

Jeff,

The ball joint nut will come off easier if you put a floor jack and block of wood under the breaker bar and socket ... and jack up the front end off the ground ... before trying to remove the nut.

Groovy911SC · 10-31-2004, 04:26 PM

Dude,

Did you have any success with removing the roll pin out of the strut? I am having great difficulty removing the roll pin from my drivers side strut assembly. The left side came out with no problem.
I tried beating it out, but it will only move about 10mm. I can beat it on the other side until it is flush with the solid metal housing, but it just seems to bind.
Are there any tools that might come in handy at this point? Is the metal in the pin resistant to drilling?
Sorta at a loss on what to do next. Very frustrated!

jpahemi · 10-31-2004, 05:17 PM

The roll pin holding the strut in the housing is made of spring steel, you WILL have a very hard time drilling it. It's a M7 pin, tap it until flush with the body the use an M6 screw and continue tapping through. Remember it has a slit, so it can't be in there to tight; propably a little bit of rust is making it stubborn. Drilling could damage the housing.
Regards,
J.P.

emcon5 · emcon5's Garage

It should come out either way. It is possible to remove the pin with a standard pin punch, but you can chew things up if you miss. Use a roll pin punch and it is a piece of cake.

For thosae that don't know, (I didn't until I did this job) a roll-pin punch has a little tit on the end which centers the tip of the punch on the pin. You really can't get it misaligned. Whack it a few times with a hammer, it should come right out.

Tom

Groovy911SC · 11-01-2004, 05:09 AM

Thanks for the replies guys! I knew there was a specific tool for this job. I was considering having something made that would help get the rusted pin out. Now that I know a "roll pin punch" exists, I will try to locate one... my DIY abilities were certainly tested with that @#$@!#% pin yesterday!
Now to find one of those "roll pin punches"..... ?

emcon5 · emcon5's Garage

Quote:

Originally posted by Groovy911SC
Now to find one of those "roll pin punches"..... ?

Sears.

Tom

Cdnone1 · 03-17-2005, 04:10 PM

has anyone ever had one end of the strut housing blocked once the roll pin is removed so you can't get it back in? Thats what has happened t me and I can't figure out what is blocking the inside of the roll pin channell(it is metal)
steve

emcon5 · emcon5's Garage

Is there anything blocking the hole if you remove the insert? It could be that the insert shaft is not in all the way so the channel for the roll pin in the insert shaft isn't lined up with the holes in the strut body.

Tom

Cdnone1 · 03-17-2005, 04:38 PM

No there is nothing in the strut housing. The shock or insert is sitting on the foor
I have taken the inserts out of my Bilstien struts and now there is some form of metal blocking the roll pin channel in the strut that will not allow me to get the roll pin back in. If you are looking back from the front of the car to the rear you can see into the roll pin channel, if you are looking forward towards the front of the car there is a solid piece of metal blocking just inside the strut housing so you cannot get the roll pin in. I have seached everywhere I can think of and cannot find anyone who has heard of this or knows a solution. Do you have any idea of what I am talking about and how to fix this. I'm overhauling my suspens and sure was not planning on buying a new strut housing. It is only on the passenger side , the driver side is perfect
Any help I would appreciatte besides the strut. The driver side came apart and when back together fine the pass side only came apart fine

qcwang · 03-17-2005, 04:41 PM

Hi Jeff,

For the roll pin, try a flat 1/4" punch. These were my experiences.
A few whacks and the pin came out!!
Newbie Bilstein Shock Replacement- My Adventures....and Misadventure!

Good luck!!

qcwang · 03-17-2005, 04:52 PM

The Sears link that Tom put in is what I used, sorry, I called it a flat punch.

Jay Auskin · 03-17-2005, 06:51 PM

Jeff---

Where in Chicago are you?? I'm in the West Loop. I need to replace front struts....well whenever the salt washes away. I have Boge housings, so it won't have the roll pin, but I wouldn't mind helping out with your replacement if you're near by. I'm sure I'll learn by the experience. I'm no master mechanic, but I rebuilt my engine, so I know my way around a floor jack. Let me know.

Good luck!