Front strut insert replacement help ASAP

bill3667 · 01-18-2003, 12:39 PM

I received the new Bilstein strut inserts (for Boge Struts) and the instructions said to refer to the enclosed diag. as to which parts to replace w/ the new Bilstein parts...only they didn't enclose a diag!!

What I need to know is if (refering to the Bentley manual pg 401-6) part nos. 4 (plastic shield) & 5 (rubber bumper) go back into the strut under the new dust cover and on top of the new Bilstein insert and it's new cap screw? I suspect that the parts (4&5) go back in but I don't know for sure and don't want to have to take it apart again.

Thanks,
Bill W.

bill3667 · 01-18-2003, 01:33 PM

I've done a search of old topics but didn't find the answer to my question however I did find a post refering to Smart-Racing.com's instructions on Front Factory Bump Stop Modification.

The rubber Bump Stop they show looks just like the rubber bumper that I'm talking about except they show it as being at the bottom of the strut and not under the dust cap as mine is. Now maybe their drawing is of a Bilstein Strut since it also shows a roll pin below the bump stop which I think is only on the Bilstein Strut. Still, I suspect the idea is the same and since I plan to lower the car to 25" front and 25.5" rear should I cut 1 or 2 sections off the bumper?

TIA
Bill W.
88 Cab 911

john walker's workshop · 01-18-2003, 02:47 PM

no. there's no place for them with bilsteins.

masraum · 01-18-2003, 03:30 PM

Bill, don't know how far you've gotten, but I just put Bilsteins in my Boge struts today. There is no bumpstop to put in the Bilstein insert for Boge struts. It's a completely different setup than the stock boge or stock bilstein. There is a bumpstop on the rear bilsteins.

bill3667 · 01-18-2003, 03:34 PM

John, I understand there is no room for the bump stops UNDER the strut but there is room (I believe) for the plastic shield and the rubber bumper on top of the insert and under the dust shield, even on the Bilsteins.
Are you saying the rubber bumper is not used at all?

Thanks,
Bill W.

Adman · 01-18-2003, 04:19 PM

Bill...I sure hope that none of those parts go under the dust shield!
It must have been shock day. I just finished installing front and rear HD Bilsteins on my Boge equiped 87.
Real pleased with the improvement in ride and handling. My shocks had 89,000 on them.
My car is now sitting exactly 1/2" higher after driving about 50 miles. Guess I will do some lowering tomorrow.
Sure hope I didnt leave any neccessary parts off.
Matthew

john walker's workshop · 01-18-2003, 04:40 PM

i guess i should have just said throw them away.

old seventy six · 01-18-2003, 04:42 PM

Bill - No those parts don't go back in. They had a function on the old Boge oil insert that doesn't apply to your new Bilstein gas insert.

MBAtarga · 01-18-2003, 04:44 PM

I'm putting Bilstein HD on the front and Sports on the rear Right NOW. With the HD fronts, Bilstein included a new lock nut (understand where this goes!) with a small black ring - hard rubber/plastic. It will only slide down over the threaded rod portion of the strut rod. I don't understand where this is installed, as it would be crushed/deformed once on the vehicle. Is this just used for packaging from the factory?

It's off to the rears now...I'll check for an answer later.

bill3667 · 01-18-2003, 06:13 PM

OK John, thanks, the rubber bumper and dust shield will be tossed.

Along the lines of MM83Targa's question since the Bilsteins don't have the key slot in the threaded shaft the large concave keyed washer can't be used but the nut and small rubber ring alone just don't look like they'd hold it. Is that all that get's fastened to the top of the strut (inside the trunk area)?

It would have been much easier if Bilstein had just included the diagram like the instruction said!!

Thanks again,
Bill

MBAtarga · 06:57 PM

Okay, 10:22 PM, just finished the rears. I essentially did the driver's side shock twice. Thought I had finished it and then went to the right side rear. Rubber bushings looked quite a bit different. Then I realized the bilstein shock rubber bushings slide apart, one with the metal sleeve inserts underneath, the other goes on top with the new washer and lock nut.

Bill, I just double checked. My Bilstein HD's DO have the key slot in the threaded portion - just like the stock Boges I removed. The large cupped washer and locking washer can be used.

But I'm still waiting for an answer to the question that Bill has asked about the small hard rubber ring.

Off to do spring plate bushings til then...

Adman · 01-18-2003, 07:05 PM

Bill...are you sure you have he correct front shock cartridges?
My Bilsteins had the slot in the shaft so I could use the large washer. You have to use the large washer...
Right or Wrong...I slid the black plastic ring down the shaft till it was flush with the top of the dust shield. I then inserted it into the tower. I guess it helps you seat and center the shaft in the tower. Couldnt find anywhere else to put it

Matthew

bill3667 · 01-19-2003, 05:13 AM

OK, OK, egg on my face...it was dark, no.. alcohol involved, no, maybe that was the problem..it was cold..yes.
The strut insert shaft does have the key slot, just not as pronounced as the Boge is. Will go at it again after the garage warms up a few deg (15 this AM..high today 28..)

Good thing the car isn't my daily driver and since the salt/dirt crap is all over the roads I'll have time to request the tool from Bilstein to torque down the cap nut.

Thanks again for the assistance, sounds like several of us did this upgrade this w/e.

Bill W.

old seventy six · 01-19-2003, 05:34 PM

MM83targa -
Throw away the little black ring. It is just packaging on the insert when it was shipped. Instead of the the Bilstein tool you can use a spanner wrench or very large channel locks. The Bilstein tool is flimsy and often deforms before you get the torque you want.

bill3667 · 01-20-2003, 09:14 AM

Note to self: RTFI, dummy.
Although the Bilstein mounting instructions did not include the diagram they said would show which parts to re-use if I had read the $#@& instructions a little more thoroughly I would have seen
"Do not reuse original bump stop, since Bilstein cart. has built in bump stop". They don't mention the rubber ring but I would suspect Old 76 is correct in tossing the ring.

I did call Bilstein at 800-745-4636 and requested the tool for the nut. Since it's free (per Bilstein should have been w/ the strut) and it's the proper tool I'll have one on hand. Also, it may make removing the cap nut easier should it become necessary down the road.

Thanks for the help,
Bill W.