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Location: Columbia, Missouri
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Front strut engagement用roblem 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 ![]() ![]()
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Don _________ 72 911T Sepia 2.4 08 Audi A6 quattro 3.2 03 Toyota Tundra |
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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. ![]()
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Don _________ 72 911T Sepia 2.4 08 Audi A6 quattro 3.2 03 Toyota Tundra |
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Sepia,
I have a Bilstein insert that I can measure if you want...
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Mitch Leland "03" 996 C2S-LS3 V8-480 HP "84" 911 Turbo Look-Sold w/ found memories |
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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.
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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
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Don _________ 72 911T Sepia 2.4 08 Audi A6 quattro 3.2 03 Toyota Tundra |
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put a jack under the a arm and push the strut up though the bushing
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Tim Lynn 84 911 Carrera PCA E Stock #278 |
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Done that. That's why it's driving me crazy.
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Don _________ 72 911T Sepia 2.4 08 Audi A6 quattro 3.2 03 Toyota Tundra |
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sudo apt-get purge 930
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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???
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Mark 1979 930 Euro ***GONE AND DON'T MISS IT AT ALL*** "Worrying about depreciation on your car and keeping mileage down is like not ****ing your girlfriend so her next boyfriend finds her more appealing" --clutch-monkey |
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curious, wonder what the difference is. I'll do some checking
thanks for the info Mark
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Don _________ 72 911T Sepia 2.4 08 Audi A6 quattro 3.2 03 Toyota Tundra |
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it's correct. 86-1638.
thanks for looking up the numbers Don
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Don _________ 72 911T Sepia 2.4 08 Audi A6 quattro 3.2 03 Toyota Tundra |
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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"
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Mitch Leland "03" 996 C2S-LS3 V8-480 HP "84" 911 Turbo Look-Sold w/ found memories |
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sudo apt-get purge 930
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NP, sorry it doesn't solve your problem. Good luck with it.
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Mark 1979 930 Euro ***GONE AND DON'T MISS IT AT ALL*** "Worrying about depreciation on your car and keeping mileage down is like not ****ing your girlfriend so her next boyfriend finds her more appealing" --clutch-monkey |
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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)
![]() "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
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Don _________ 72 911T Sepia 2.4 08 Audi A6 quattro 3.2 03 Toyota Tundra |
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