Replacing front shock inserts
 

I'm in the middle of replacing my front shock inserts. I have boge struts.

I'm having two problems.

1. I can't get the drivers side stut off of the ball joint pin. I rubber deadblow hammer worked well on the passenger side. But the drivers side won't budge.

2. What is the best way to get the strut cap off? It looks like it needs a special wrench, which i don't have.

1. As an alternative you can remove the ball joint from the a-arm instead.

2. Pipe wrench or a big channel lock wrench.

I don't have the special tool to remove the ball joint from the A-arm.

I tried a big pair of channel locks. Maybe I'll give the pipe wrench a try. I was also thinking of just bringing them to a shop and having them remove and replace the shock inserts.

But I still have to get that drivers side strut off!!!!!!

Sure you do, it's called a pipe wrench ;)

And before you say anything, yes, it's my favorite tool :) You can also use it to hold the washer when you remove the struts top nut.

New Problem
 

Ok...so I got the shock out of the strut (the one on the drivers side that I couldn't get off the ball joint). Guess I really didn't need to take it off.

Now I have a new problem!

The old shock is a Koni Red. The new shock I'm installing is the Bilstein Sport (revalved to Smart Racings specs). :)

The shaft sizes are different diameters. And the gland nut that fit over the Koni's does not fit over the Bilsteins. I bought these Bilsteins used and they did not come with a gland nut.

Is it just a mater of getting the correct gland nut from Bilstein? Or do I have the wrong shocks for my struts. It doesn't seam like there is alot of space left in there for the gland nut once I slide the shocks into the strut.

http://forums.pelicanparts.com/uploa...1186256313.jpghttp://forums.pelicanparts.com/uploa...1186256325.jpghttp://forums.pelicanparts.com/uploa...1186256336.jpg

I would say you have the wrong shocks. What Bilstein part number have they?

I hope not.

The part number is F4-p36-0113-h003.

That should be the right part, you probably only need a new gland nut.

I hope so. Guess I'll have to call Bilstein on Monday.

The Bilstein-for-Boge inserts use a special top nut that has a seal as well. You'll need these, obviously.

Matt, why don't you just call the people who did the revalving for you. I replaced my old Boges with Bilstein Sports and the flanges came in the box with the new inserts. The people that did the revalving for you may have them sitting on the bench in the shop. If no luck there, call our host, they may have exactly what you need.

mike

Mike, I bought the shocks used so I never had the hardware to begin with. I thought the existing stuff I had on my current set up would work.

So after doing some more research, it looks like I do have the right shocks. I just need to get the proper hardware.

One more question....Do the Bilsteins use bump stops? The ones I have on my Konis will not fit due to the shaft size difference. But it doesn't look like the bilsteins for boge inserts even come with them.

It looks like the Bilstein is shorter, is that true?

Matt; Not sure why you removed entire strut to change insert?
In addition to the new gland nuts you'll need, you do not use the triple stack rubber bump stops with Bilsteins, they are built in. If you try use them you won't have enough piston shaft to go up through the mount.

Because I followed the Bentley manual. I ended up leaving the drivers side in place.

I'm doing a caliper rebuild and replacing the rotors too. So most of that stuff had to come off anyway.

Matt; Bentley manual does not apply to my car, 71', but I have read there are some incorrect and unnecssary procedures in it. Most of our normal repair tasks are posted throughout this forum with many practical step savers.
I recently did "all" of the repair (upgrades) you are doing with my struts on the car. Just a thought!
David

David - you're right. Bentley has some faults.

I actually am going to have to put the passenger side strut back on the car to open the gland nut. It was easier to do it that way than in a vice.

When I did mine, the strut assembly stayed mounted to the car. The Boge insert came out, & the Bilstein Sport insert went in. I used some large Channel locks to get the Boge flange nut off and I used the Bilstein tool to lock down the replacement flange nut that came with the inserts. It turned out to be alot easier than I had anticipated. It looks like the part # for the strut flange tool is MS08/4.

Yes it is. The yellow and the red part meet at the same point. However from that point to the top of the threaded shaft, the Bilstein is shorter.

Good to know its the same in the front.

When I changed from Bilstein HD to Sport (clubsport really) in the rear, the sport was 20 mm shorter.

strut removal
 

I just replaced my front Boge with Bilstein struts. I used a pipe wrench.
I tried a channel lock first but found that because the pipe wrench grabs more as you turn it, it worked much better. Still a tough job.

I have used this tech article before with good results--->

Paragon Products - Tech Session - Porsche Tech and Information

Bilstein 36mm Ring (or Gland) Nut Tool
 

Hope this is appropriate thread for this...

Determined the tool is essentially NLA from Bilstein or their distributors... our host doesn't list them that I could find...

Bilstein trool for Boge strut inserts, part nos:
- Old 420017
- New E4-MS08/6
- "MS08/6" - stamped on part. Also stamped on it is torque to use with this tool - 140Nm (≈103 lb-ft).
It's also described as "Bilstein 36mm Ring (or Gland) Nut Tool".

However I found them on eBay (US): Search for "VW Rabbit Scirocco Shock Insert Cartridg Gland Nut Tool" (Item Description also has "Cartridg" - missing the "e") - $13 + $5 S&H. I bought two, plenty more there. Part numbers not listed in description, found part/seller via Google image search. If you look at eBay worldwide, they seem to be in ready supply in Canada or Australia, given at a premium.

Of course only useful with strut top free, or removed completely and in a vice... if one can use this tool to torque the nut correctly when installing new inserts, certainly no teeth marks, and maybe less chance of needing Channel Locks/pipe wrench to tighten a loose nut in situ later... and reserve those puppies for removal of worn out units...

Cheers!

I just purchased the special gland nut tool directly from Bilstein; called them in North Carolina. They shipped it to me in a few days.

Well I'll be darned! Guess shouldn't have mentioned I was in California, or something! After calling Bilstein at several locations - including NC - was told either not available or to order it through distributor... called distributors, was told either not available or to call Bilstein... LOL.

Oh well!