Bilstein Shock & Strut Install - '83 SC W/Boge Notes

[Gordo2]

Installed a new set of Bilstein Sport shocks/strut inserts in my '83 SC this weekend. I'm pretty sure I pulled off the original Boge shocks and strut inserts ( 190,000 miles...).



A few thoughts and tips:

Tips for rear install:
-Use a 3' cheater bar to break the lower shock bolts free.
-A ratcheting box end wrench would have been very handy to remove the top bolts. I needed 2 wrenches to loosen the old Boge shocks. The top theaded end of the old shock had a 2 sided extension above the nut to hold onto to keep the shock from spinning. I used a cresent wrench on it and an open end on the nut. Slow going - the ratcheting box end would have been nice.

Tips for front install:



-I used a pipe wrench to hold the locking washer while I removed the top nut. The washer below the top nut is keyed into the strut insert and keeps it from spinning when you tighten/loosen it. Easier with a second set of hands.
-I was careful to not over extend the brake line when I leaned the strut out of the fender well to pull out the old insert.
Recommend complimentary project: replacing the brake lines while you are removing the front struts.



-The old insert was difficult to pull out. I reinstalled the top nut to give me something to grip to pull it out of the strut body.
-I used the old strut as a pump to evacuate the old oil out of the strut body; insert it in the strut and press the strut to the bottom. It will fill with oil. Remove it without pulling the insert up out of it's sleeve and it will come out filled with oil. I used a rag on the end of a coat hangar to remove the last bit of oil.



Continued...

[Gordo2]

Continued:


-The new struts come with a small rubber washer. I didn't install this item, search turned up that it is not required and is for packing/shipping only.

-I used a pipe wrench to remove the "gland nut" (the big nut that holds the insert in the body of the strut). I also used a pipe wrench to tighten the Bilstein insert into the body. The nut will not be flush with the body of the strut when it is tight. It bottoms out with approx. 5 mm gap between the nut and the body:



I used the green strut cover instead of the old Boge cover. Either will work if you don't like green...



Will write up ride impressions in another thread.

Info for others considering this project. - Good luck, it's a fairly easy job.

Gordo

[stealthn]

Nice write up, I found that I "had" to aquire 3 new pipe wrenches to get the nut off the strut.

You didn't mention what you put in the struts to dissapate heat, I used rad coolant.

[Gordo2]

Based on searches and discussions, I opted to install without any sort of "coolant" in the strut housing. To me it seemed it would cause more harm than good over the long haul.

Gordo

[ulrichd]

I had a ***** of a time compressing the front Bilstein inserts on my 78SC enough to tuck back into the fenderwell. I was told to pump the shock cartridge a few times before installation to make that easier. Good tip on not extending the brake lines. These forums are priceless for a rookie like me.

Ulrich

[rfuerst911sc]

I used a BF pair of Channel locks to remove and replace the strut nut. Nice write up.

[Ken311]

I may be wrong, but didn't a particular package incorporate Bilstein Shocks from the factory on SC's?

I believe its the sport package, are these the same shocks?

Sorry to get off-topic, it just sparked my memory.

Ken311

[greenkaw]

Now ya tell me. Just did this last week.Good write-up,could have used the tip about getting the oil out. Half on the floor & half inside the strut is not the fun way.
Air impact wrench made quick work of the top nut.

[Gordo2]

Instead of a new thread...

I didn't think the car handled bad with the old shocks. I replaced mainly because I figured the shocks were original and the car would handle much better with new shocks.

I don't track the car but normal driving includes winding roads and on/off ramps - the car felt fairly solid. The only thing that indicated how worn they were was when I would purposely weave back and forth at about 45 mph (like driving through cones). It felt like there was a lot of rear end sway or body roll.

With the new shocks I haven't noticed a significant difference in handling or feel. It does feel more firmly planted, a little stiffer; but by no means harsh or too firm.

I tried my weaving test. Minor difference; I still think the rear end feels like it sways more than it should. I'm not sure if this is how it should feel or if something else may be worn or weak. Feels like the sidewalls of my rear tires are flexing.

Any other thoughts on driving impressions post install of new shocks?

Oh yea, the car also sat slightly higher after the install.

Thanks, Gordo

[greg bradbury]

Gordo,

Hi, I have just put in front and rear HD Bilsteins on my '83 SC and am happy with the ride now. It was good to read about the surpluss rubber o'ring that comes with the front struts. It took a while to figure that no matter where I put it would mean that the whole weight of the car was going to be resting on that rubber, so I tossed them in the rubber parts bin at home. Some instructions would have been nice.

I intend to do the front and rear bushes with Polybronze units fron Elephant racing. I am getting the same feel from the rear end as you. I think it wil be cured once I replace bushes and the front and rear sway bar rubbers (I can see daylight through the front A arm rubbers) I intend to replace parts one at a time and then evaluate as I go. I should be able to report back to you with any good changes that come along, waiting on parts at the moment so it won't be until new year.

Regards,
Greg

[Eric-325I]

Thank you Gordo, this will come in handy in the future.

Eric