Bilstein HD Front Strut Replacement Problem

[cab713]

I've just replaced the struts in my 1982SC Targa. I have a knock in the right side. I can lift the hub about 1/2 inch with my hands which lead me to believe something is missing from between the top of the strut insert and the protective cover.

The replacement doesn't come with anything. The diagrams don't show a bilstein insert properly. The pelican techs aren't aware of a replacement piece that goes there.

I took a photo of the used parts to send to a buddy. Unfortunately I threw them away when I was done. It looks there's a piece ontop of a strut insert on one but not the other. Anyone aware of a bushing/gasket type item inside the strut cover?

[Bob Kontak]

It's been a while since I replaced the Bilstien inserts on my 81.

I do remember the protective cover was squished up against the bottom of the inner fender bushing tightly. I did have the huge US ride height spacer between the two surfaces but the cover would not spin.

At first blush, is the nut on the strut fully tight? Are the two sides comparable as to how far the shaft sticks up past the retaining bolt?

Are you sure the slop is at the top of the strut?

[Driven97]

Don't know what #6 is, as I have an 84. Perhaps that's the US ride height spacer referenced by the previous post? Can you post a picture of how it's sitting now compared to the other side?

Sanity check, are you sure the strut shaft was fully seated into the housing at the bottom before you put the roll pin in? A blown inverted strut can leak oil down there and make it hard to seat the shaft correctly.

[john walker's workshop]

I stick a punch through the roll-pin hole and pull up on the insert before running the roll-pin in. The snubber sometimes gets pureed and rubber bits keep the shaft from seating properly.

[cab713]

The pin is in correctly. I've done the insert twice to confirm. Also, this knock can be reproduced by pulling up on the hub with the wheel removed. It's like there's a secret rubber bumper/gasket type thing inside the top protective cover that is missing. I can't find a drawing for bilstein. That is the same drawing that the pelican rep emailed me. I have a 6, but it's wider and flatter than that. Big solid metal washer. #3 comes on the thin shaft at the bottom of a bilstein hd insert, so it isn't that.

[cab713]

Here's the close-up photo again with the thing I think is missing. It's not the snubber, but looks to be rubber with a thin metal wrap. Any ideas?