Is my strut toast?
 

Boge strut with Bilstein insert.

Jacked up, when I grab the strut at the joint between the insert and strut (dust cover is off) I get knocking and noticeable play between the strut and the insert.

I know the insert is gone, but is the strut gone as well? Cap is tight.

Most just find that the insert is bad. If original it’s not truly an insert so when the bushes go bad the strut rocks as you describe. In either case the only real way to tell is R&R the “guts”. Remember the bottom part of the strut is just a tub with the spindle attached. Everything else is replaced with the new strut “cartridge”.

THere is a teflon coated bearing sleeve that the insert rides in. When the teflon wears away, you get play in the strut. If you are changing the inserts, just change the bearing sleeves, too...your Bilsteins will be as good as new!

OK, got everything apart, the play is coming from the screw cap.

Do you get a new cap with Bilstein inserts?

Yes it is a different cap from the Boge.

Todd, was this difficult to do? I have to put Bilstein inserts in my Boge struts soon. Diffcult job? Any warnings?

I'm sorry, I totally miread your post....I thought you had Bilstein struts......DOH!! I feel stupid.......8^)

OK...the new bilstein inserts came with the cap at the top of the strut.

I've installed them and the play is gone. The insert in the cap had indeed gone bad.