Help removing strut insert
 

I know this is in the archive somewhere, but I don't have time to look for it right now. Any suggestions for getting a KYB strut insert out of a front Boge housing? I've hit it with some PBlaster and tried the Big F'ing pipe wrench but can't get it to budge!! I'm leary of using heat in there, but would a torch help, or would the strut explode? Car is on a stand right now with new Bilsteins just waiting to go in - any suggestions would be appreciated!!

Thanks!!

put the nut and big washer on the shaft and work it out with a BFH. i use an air hammer and they come out pretty easily. maybe clamp an old pair of visegrips under the nut and beat on them.

After a trip to Harbor Freight, I'm trying the air hammer/chisel, but I need some guidance here. How exactly am I supposed to use it? All I seem to be doing is cutting the edge of the cap/nut.

BTW - I am referring to the spot where the insert threads into the housing, not the top nut. That come off like nothing:)

I'm confused. Are you saying you can't get the large threaded collar off the strut housing. The piece that holds the strut in the housing? (Pat #4 in the diagram). If it is off then JW's method involves reinstalling parts 9-11 on the end of the strut and hammering the strut out of the housing.

http://www.pelicanparts.com/911/911_...974-75/4-2.JPG

Kurt,
The part I can't get loose is indeed part 4 in the diagram, but on my insert it is not a separate nut, it appears to be part of the insert. It is pretty soft metal and has eight sides, just like the KYB ones I saw pistured somewhere else on this board. Any suggestions?

this is what I'm removing - Can't get threaded part in middle to loosen
http://forums.pelicanparts.com/uploa...1155071429.jpg

Maybe these pics will help - these show the damage I've already inflicted on the cap/nut that I think I am supposed to be unscrewing, and a shot of the new insert which seems to be threaded the same as the one I'm removing(but with a better method for screwing/unscrewing). I'm pulling on this pipe wrenches so hard I'm afraid of ruining the housing or messing up the threads! HELP!http://forums.pelicanparts.com/uploa...1155076245.jpg http://forums.pelicanparts.com/uploa...1155076282.jpg http://forums.pelicanparts.com/uploa...1155076364.jpg

Well, I got the car back together with the old inserts still in the front so I could test out the new Rears - WOW, what a difference from just replacing the rears with Bilstein HD! I can't wait to fell what it will drive like with the fronts changed, as they were worse than the rears to begin with!

Anybody have other suggestions to get these struts apart? I really want to finish this off tomorrow.

Thanks,

i assumed you already had the retainer nuts off. i just use a giant pair of channel-locks, get a good grip, brace myself so i can push real hard, and they usually start to move. those sheetmetal caps rarely get frozen on, so eat your wheaties.

Are they reverse threads? Might try it. Good luck.

not.

Do you think I could have screwed up the threads in the housing, judging from the pics?

Put a little heat on the strut tube maybe??

Cheers

OK - The good news is that I got the other side off fairly easily with really big channel locks(thanks for the tip John Walker!)

Now for the bad
http://forums.pelicanparts.com/uploa...1155146102.jpg

The "nut" part of the cap is getting destroyed and it still won't budge. I've tried 3 or 4 hits of PBlaster and even some heat from a torch and still nothing! Would it be possible for me to use the chisel bits on my new air hammer to basically cut the cap apart to remove? I really don't want to remove the strut from the car and I can't drive it like this!

IF you can cut the nut apart without nicking the threads in side the housing you should be ok. The inserts are junk so do what you have to remove them. My caps came off with not much trouble. My trouble was getting the actual insert out of the housing. The Boges have a rubber seal tht you have to pry out with a dentist 's pick . Once that is out the insert came right up and out.

can't you get channel-locks on the remains of that capnut? looks like you can.

Still can't get it out. Cap nut keeps bending and tearing - plus I now have 2 new dings on the fender:(
Does this seem like it will have to come off of the car, or maybe even replace the housing with a used strut?

i have plenty of early struts if you need one. 3" bolt spacing.

Dremel to cut that little 'mutha up? It "deserves it" for the trouble its given you!

Well, looks like I'm giving up. Stopped by my neighborhood tire/brake/mechanic shop and explained the situation and they're willing to remove the whole assembly and get the thing out on a bench, then install my last Bilstein, all while I supervise. It'll cost my $100, but it's better than me doing even more damage to my strut or my fenders! Boy would I like to take a big set of channel locks to the A-hole who put this thing on in the first place!!

Thanks for all the advice and encouragement - I'll report back when all is said and done.

ALL DONE!
Just got back from having old strut removed and new one installed. Turns out the tire place had a mechanic who used to work at a Porsche dealership 25 years ago and he took one look and it was like "Game On!" It took him an hour and a half, a lot of heat from a torch, an air hammer and a helper, but he got it out without removing the assembly from the car. Plus, I had them cut out some old unused AC lines while they had it on the lift. Total cost = $68 :)

Thanks again for all the advice and ancouragement; I'm off now to go "break them in" ;)

wafoofan,
Just curious, why the hell was it so friggin hard to remove? Was it rusted on? King Kong-installed or what did the tech say?

Wrench said the old insert was just in there WAY too tight - he basically had to destroy the cap nut to get it off. Car rides and drives GREAT now - best fix I've done since I replaced the missing bolt in my engine mount!

Only problem is, now my rear ride heights are off by an inch - Left is 24" and right is 25". What gives - they were both 24.75" before? Fronts are even at 25.25"