New Bilstein inserts clunk
 

I bought some new HD Bilstein inserts for my 82 SC with Bilstein struts. I thought this should be straight forward enough and fallowed the instructions in the 101 Projects book. I knocked out the roll pin, undid the top nut and pulled out the old insert. I compared the new insert to the old and they look identical. The insert was pushed down into the strut and the new roll pin properly installed. I put on the dust cover and metal spacer on top of that. The threaded part of the insert did not want to come all the way through the rubber mount. I banged on the rubber portion of the mount with a rubber mallet and the top slowly came up far enough to get a few threads of the nut on. I tightened the nut enough to get both the washer and nut on and then torqued to 58 ft lbs. Driving on my bumpy country road the shocks banged loudly. The car felt good and was quite on smooth and highway roads. I jacked up the front end tonight and lifted up on the hanging wheels. At the top of about 1 inch of travel was a clunk.

I spent much time searching the subject and now have an idea of how much I do not know. I did not add any grease to the insert. I don't understand the tightening tool you now need to buy from Bilstein. It is possible that I did not push the insert far enough down into the strut and got the roll pin under the bottom of the insert.

Where do I go from here except to a professional mechanic. I am trying to learn this but the books leave much uncovered and get me into trouble. I make plenty of mistakes, but have learned a lot for the experience and the help here.

It sounds like you did everything correctly.

One item that is often overlooked/not well understood is the two bearings that are inside of the strut housing.

These are plain babbet type bearings. They do wear over time/miles.

In my 200k+ SC it sounded and felt like an incredibly loose wheel bearing. At autocross there was an audible clunk under quick transitions.

You might double check the wheel bearings on your car and then after confirming you're "good", grab the wheel of the car at 12 and 6 and do some pulling. If you still have a clunk it may be time for new struts.

Cooper

Almost certainly you have answered your own question.

It is too easy to miss with the roll pin. Remove from the camber plate and give a good tug on the insert to see if that roll pin is engaging.

If it is not engaged, a major racket will ensue just as you experienced.

What he said

and install the roll-pin with the curve against the shock rod, not the groove.

Thanks Chuck. I did as you said and the inserts were not seated into the roll pin. I would add to anyone new to installing Bilstein inserts; Put insert into strut and get it into place. Block up the wheel hub to take the play out of the insert. Put nut on insert without camber plate and washer and tap down on the nut with a rubber mallet or block of wood to seat the insert into the bottom of strut. Then place roll pin with slit 180 degrees from insert groove. Put the plate, washer and nut back on and torque. Push up and down on hub to see travel, listen for noises and check for smooth action before putting the wheels back on.

If you see anything wrong with what I did, please correct. It may help someone else get this right the first time.

Thanks to all,
Bill