911S 2.7 1977 Front Strut Insert Issues.

[Jase77]

Hi Pelican people.

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

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.

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.

[john walker's workshop]

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.

[Jase77]

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!

Cheers.

[Trackrash]

More tricks here. Bilstein Insert Removal [new style]- Tips & Tricks

[Jase77]

Gordon,

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

[john walker's workshop]

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.

[faverymi]

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.

[Jase77]

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!