911S 2.7 1977 Front Strut Insert Issues.
 

Hi Pelican people.

This is my first post on here and I have a feeling it won't' be my last. :confused:

So, I started to change the front strut inserts on the Porker this afternoon after work. To say I was well prepared was an understatement. I had the brilliant 101 Projects book, The Haynes manual (only for torque settings), all the tools required in place, two trolley jacks and two axle stands. I have read, re read, and read some more about what is required and I think I could recite the 101 book word for word. :D

So, guess what brought everything to a grinding halt.......the bloody insert just would not pull out! Yes I removed the roll pin and up to this point all was peachy. I could press and rotate the insert inside the strut but it would not come free. It would move up to a point and then stop and no amount of pulling or colorful language would free it.

Have any of you guys experienced anything similar and if so I would be very grateful to hear about your chosen method of removal. I would rather not remove the strut completely as I have just had my alignment set up nicely.

Any feedback would be great.
Cheers,
Jason.

put the top washer and nut back on and use a hammer under the washer. an air hammer makes short work of it. that's with the strut hanging out of the fender or off the car of course. this is a bilstein unit i assume from the roll-pin comment.

Hi John,

Thanks for your reply and yes it is a Bilstein insert. This will be there first thing I will try when I get back to the car tomorrow. Fingers crossed it will work as I was pulling on this bugger for all I was worth and it still didn't budge.
Now I am off to find the biggest mallet I have!:D

Cheers.

More tricks here. http://forums.pelicanparts.com/porsche-911-technical-forum/793327-bilstein-insert-removal-new-style-tips-tricks.html

Gordon,

Great stuff thanks. Glad I'm not the only one to have these issues!

the snubber will probably look like it went through a blender with oil, so that stuff needs to be thoroughly cleaned out. you can hook the main chunk with a coat hanger and vacuum out the rest. tape a smaller hose onto your vacuum hose so it gets all the way down.

Be sure you protect the fender when you swing the strut out and bang that washer really good. I put tape around the lip. Be careful or you will dent it.

http://forums.pelicanparts.com/uploa...1403693883.jpg

Hi guys,

Thanks to everyone who took the time to reply to my post. All of your comments and suggestions were very useful. I have just got home from my shared workshop with a new set of dampers on the front. Managed to free the old inserts using the pipe, nut and washer method........worked a treat! :)
Next on the list are the rears and I hope to be fitting those on Friday evening. I hope I will not be re-posting for help/advice but if it gets to that point at least I know there will be a positive outcome!;)