Front bilstein inserts won't come out
 

Ive done this a million times before, I have the roll pin tapped out, I have the o-ring removed.. this crap refuses to come out. anybody have any tricks?

Hey Todd, It sounds like you have a bent strut. You can get the old insert out with a big slide hammer but chances are that you won't be able to get the new insert back in.

One more thing I just thought of, if they are Bilstein struts, make sure that you vacuum all the rubber bits out of the strut housing before you try to reinstall the new inserts.

Okay, I figured it out, i screwed it back into the top mount and jumped up and down on the caliper - POP

Thanks guys

Anybody have the part number for the insert sealing ring?

Are you talking about the top dust seal? 46mm OD one? Are you replacing the bushings too?

its a hard ruber o-ring thatgoes around the insert and holds it inside the strut tube

http://forums.pelicanparts.com/porsche-911-technical-forum/396098-remove-strut-insert-try-if-insert-stuck.html

FWIW ... I had same problem. Posted the above thread. May help someone down the road.

Ok what gives, countless timem before Ive replaced strut insert with ZERO problems

Now I got one side donea and the strut nut on the other side is so attached Im just spinning the strut as i turn the nut.

Wish I had a torch :( !!!!!

Dont you have to counter hold the large nut with a pipe wrench while loosening the insert nut?

Otherwise the strut will spin ... or am I missing something here?

You should be able to hold the strut rod a number of ways including using a large pipe wrench or a vice grip on the rod or threaded portion of the junk insert.

I dont want to damage the tube... I was planning on getting the insert revalved but this one is not comming of so maybe i'll attack it from the top threads.

almost more trouble than its worth

Todd -

If you can't get the insert out, take a look at my post above where I included a link to a thread.

It is really easy to go to Lowes and buy those pipe fittings - and they are cheap cheap cheap.

Place fittings over insert and they will rest on the strut housing. Then place the large washer and nut on top of the insert and start tightening it down. It will EASILY pull the insert out of the housing.

Trust me, I fought mine for 4 hours and finally decided to go to Lowes (I hate going there on weekends - was beeing stubborn).

Yeah i got the insert out by simply threading it back on tot he top plate, then standing/bouncing on the brake caliper until it popped.

now the other instert, the top nut is stuck

i think ive never spend anythin more an an hour and ahalf doing this.. this one ive spent 3 hours on and right now i put it all back together.. i dont need the car jacked up or the wheel off to keep attempting to break that top nut

of course i did the obligatory smash yer thumb with the hammer when inserting the roll pin

Hey DH; I didn't realize that was you ;)
The tp 3.4 gave it away