Replacing shocks and strut inserts - What tools do I need?
 

I have a 1982 911SC which I will be replacing the rear shocks with the Bilstein Sports and the front inserts for Boge with the Bilstein HD's.

Outside of what comes with the new shocks/inserts, what else do I need? Can I reuse the tab washers and other items that are already on the car?

What special tools will I need?

I heard about some tricks relative to doing this job. What are some i should use or keep in mind.

Jay

Have a look at the front strut housing and look at how the shock is held in. You will have to jack up the wheel and peek under the upper shock cover. There is a gland nut with either an outer or inner thread (2 types) and you will need a shock wrench to loosen this nut to get the insert out. I got one from Bilstein when I ordered my shock inserts.

A big pipe wrench does the job nicely.
Wedge a block of wood against the strut to keep it from turning as you loosen and tighten
the nut.

I'm sure it will work but it hacks up the nut too much for me. Not sure what you mean about the block of wood. The strut isn't going to turn as it is connected to all the steering bits. I think you mean the shock, but that shouldn't turn anyway if you're only on the nut attached to the strut.

Forgot to mention the rears...on top there is an allen wrench you need to insert on top to hold it firm while you undo the top nut.

@ tonythetiger: I have a tool that came form bilstein with the shocks. is that what you mean?

Thanks pete3799. What do I need a pipe wrench for and clarify the need for the block of wood to be wedged against the strut to keep it from turning. Do you mean spinning or the hub assembly from turning as if it was being streered?

Yes. You'll have to undo the top nut in the trunk, pull the shock down and out from under the fender. Make sure you release the brake line anchor on the tab to give you some extra play. Once the shock is out from under the fender, remove the top cover. Place the wrench over the strut and whack it with a hammer to loosen the gland nut. Reverse for installation.

isn't the bottom of the front cartridge held in with a roll pin like my ' 77?
If so, you're going to need a specific roll-pin punch (1/4" will do) and a BFH.
Bill K
(Bilstein also has new roll-pins. They are available from Porsche but you have to buy the whole strut ass'y.)

The roll pin is only on Bilstein struts not on Boge.

Hello,

in any case you will need new washer and nuts. I was not able to open the nut on top so I cut it up with a dremel (you can not reuse them anyway - they are self securing). To fasten the nut I went to my garage and let the air compressor and the right tool do the job to fasten the nut.

best regards

Heiko

Get a big freakin' breaker bar for the lower rear shock bolts, and an impact wrench for the upper nuts.

No "special" tools are needed but like others indicated, some of the nuts are are not very willing to move. You should douse every nut you need to loosen with penetraing oil (Kroil, PB blaster , liquid wrench etc) for a few days prior to the work.

If you will have the car on jack stands, be sure the car is very, very stable as you will be tugging pretty hard on some of the nuts.

To remove the Boge Strut insert and fasten the Bilstein unit, you will need the Bilstein nut wrench and/or a pipe wrench. For the pipe wrench, put some duct tape on the jaws to minmize marring the surfaces.

Be warned that when you go to pull the Boge insert out, a bunch of (nasty) oil will also come out and if you are not careful saturate your front brake pads.

There is a very good description of thee proccess (project 63) in Wayne's 101 Project book

Plan on being a contortionist to remove the nut on the right rear shock tower.