Removing Bilstein front inserts

na2ub · 09-03-2010, 06:26 AM

I removed the roll pin on my front bilsteins inserts, now what? They don't appear to want to come out.

Thanks,
Doug

tonythetarga · 09-03-2010, 07:20 AM

have you unscrewed the retainer at the top of the strut? To get that you need to pull the top of the shock out from the tower, out the wheel well and let the shock uncompress. You may need to remove the brake caliper so the line does not become a factor. Once out in the open, pull the top outer cover of the shock off and you should see the gland nut holding the insert in place.

Bob Kontak · Bob Kontak's Garage

You may have to grab the top cover tube of the shock/strut assembly with a big Channel Lock plier to get the top nut loose.

Also the new retaining pin has to go back in a certain way or it may fail. I will try to locate info and post.

gtc · gtc's Garage

There's no gland nut on bilstein struts. The inserts should just slide out once the roll pin is removed.

The roll pin should be inserted with the seam facing away from the strut insert.

Bob Kontak · Bob Kontak's Garage

Thanks Graham.

jimrs2000 · jimrs2000's Garage

Even when you have got the top mount loose and the roll pin removed you will find that they won't slip out easily due to the corrosion where the insert fits into the hole where the roll pin goes.

My solution was penetrating oil and a pin punch. By tapping the part of the insert you can see through the roll pin hole I managed to get it rotating freely, I could then use a large set of channel lock pliers to pull the insert out.

gtc · gtc's Garage

That brings up another good point. Since the bottom of the strut housings are not well sealed, be sure to thoroughly clean out the strut (it will probably be absolutely filthy) and apply plenty of fresh grease.

na2ub · 09-03-2010, 08:56 AM

Thanks. No, the bilsteins do not appear to have a top nut retaining the insert. Sounds like corrosion at the bottom is what's holding these in. I will try some penetrating oil, and see if I can budge them loose. I don't want to mess up any of the surfaces, as these are getting re-valved. Will post back with results.

Doug

na2ub · 09-08-2010, 05:41 AM

Alright. More tugging, pounding, and no luck. I even tried putting a 2" pvc tube between the top of the strut housing and the insert washer / nut and cranking down on it with my ****ty impact gun - nothing. Any more ideas? I cannot beat up these inserts because I am going to get them re-valved.

I read somewhere that you can punch them out from below if you remove the ball joint. Is that true? I cannot really see any of the insert through the roll pin hole. I have sprayed it with PB Blaster about 10 times. Both sides are the same.

na2ub · 09-17-2010, 08:58 AM

Results: I gave up and brought them into my local shop. Cost me 1 hour of labor at $88/hr.

And yes, I know it probably only took him 5 minutes, but in his defense, he does have to make a living too.

I asked him what his trick was to get them out, and he just said "you just can't be afraid of them." Which, I believe was just the polite way to say "dude, don't be such a giant labia next time."

In retrospect, the harbor freight $50 5lb slide hammer, would probably have been a good investment.

Just thought I would share for others.

Doug