Front strut engagement—problem getting nut on
 

I recently decided to replace the bushings on the front Koni struts with GPR bushings. With the dust covers on (travel is limited by a boss on the shaft) the available engagement is approximately 2" (see photo). Trying just about everything I can't get enough of the strut sticking out of the chassis to install the top bushing and washers, if only it was 1/2" longer. It appears that the existing top bushing was cut down previously because of the same issue (see photo). I'm stuck, what am I doing wrong?

Don

http://forums.pelicanparts.com/uploa...1211145040.jpg
http://forums.pelicanparts.com/uploa...1211145064.jpg

does anyone have a Koni insert laying around to provide a measurement. I'm curious if I have the correct insert since the previous installation shows an altered bushing.

Thanks for any help. You guys are great.http://forums.pelicanparts.com/uploa...1211333307.jpg

Sepia,

I have a Bilstein insert that I can measure if you want...

On one of my front Bilstein inserts, the shaft barely protruded enough to initially get the nut on. I dropped the car and drove her "gingerly" around the block a few times and that forced the shaft up the rest of the way. I realize that if you can't get the nut on at all, that's not a solution in your case, but maybe simply dropping the car and "bouncing it" will get enough of the shaft through...just a thought.

Thanks for the replies Keith and Mitch.
Mitch, I'd appreciate a measurement, just to be sure, but as Keith reported, it's doesn't appear to be unusual.
Instructions say to unhook the sway bar, perhaps that's worth a shot. It's one of those things that should be pretty straight forward.
I'm also fighting the shaft wanting to keep retracting into the shock. Amazing how something you would think would be a one to two hour fun job turn into something frustrating.

Thanks again,

Don

put a jack under the a arm and push the strut up though the bushing

Done that. That's why it's driving me crazy.

Are you sure you have the correct insert? There is:

"86-1308
Front Koni Strut Insert, Only For Cars With Factory Equipped Koni Struts, Sold Per Each, 911/912 (1965-68)"

and

"86-1638
Front Koni Strut Insert, Only For Cars With Factory Equipped Koni Struts, Sold Per Each, 911/912 (1969-73)"

Maybe the PO put the wrong insert in and that's why he had to cut the bushing???

curious, wonder what the difference is. I'll do some checking

thanks for the info Mark

it's correct. 86-1638.
thanks for looking up the numbers

Don

Sepia,

Sorry I missed your request for measurements. Here are dimensions for my Bilstein front strut inserts.

Threaded shaft = 1 1/16"

Shaft directly between the threaded shaft and the piston cylinder = 1 1/2"

Your "X" Measurement = 17 1/16"

NP, sorry it doesn't solve your problem. Good luck with it.

To all who responded to my various requests, I solved it. Definitely remove the links on the adjustable sway bar and slightly rough up the top GPR bushing so it stays in the receiver. I had to use a smaller plain washer to engage the bushing and then quickly remove the nut and washer and install the large slotted washer and lock washer. It was a PITA but I feel good now. Definitely helps to bounce issues off of other 911 owners. Now to modify my Weltmeister strut brace (where it all started) SmileWavy

"Zen and the art of classic 911 maintenance"

When you get stuck take your time and think about it.

Thanks again, you guys are great.

Don