Bilstein Strut Insert Issues on SWB

[gper]

I had a failed Koni front insert and decide to replace all 4 shocks with Bilstein. came up with a handful of issues.

The insert being slightly short seems to have been identified by Bilstein as there was a machined "spacer" about 6mm thick taped to the bottom of the cartridge. The overall length with the spacer seemed to match the Koni so in it went. I can only get the gland nut tightened to about 1-2mm proud of the strut housing (about 2 threads showing).

Is this a big deal? I could disassemble,but I think the chances of removing that spacer from the bottom of the housing are slim.

Is there a special tool that will hold the shaft from turning while tightening the top nut? One side went right down snug no issue, the other side just wont get the bushings compressed before the shaft starts to turn. I hate to use vice grips or similar. The shaft has a keyway, no inside hex like some others.

I have to take the top end back off regardless, as the pretty green dust cover rubs the inside of the tire. They were longer than the original, but I did not foresee the interference. Will have to cut down the length or re use the stock one.

Assuming installation of the rears will have slightly less drama attached.

Thanks for any suggestions

[gper]

I contacted Bilstein tech support & got the following information.

They want some tension on the insert so better too tight than loose. A couple of threads showing under the gland nut is not a problem.

No tool to hold the center shaft. Other than making something it looks like a job for BF Channel locks on the top washer. It has a nipple that indexes to the keyway.

They had not heard of the dust cover interference with the tire. Maybe explains why the original Boge cover was so short. Maybe is unique to the non-adjustable struts on the real early models.

Maybe this will help somebody down the road.