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Stuck Strut Insert

83 944 and changing the front strut inserts out. I'm using the no alignment method. I have the springs compressed, strut top nut off, top mount off and the threaded cap is off. Now it's miller time and pull the strut out, right? It won't budge an inch. I've tried putting the top nut back on and prying it up. Tried PBB. It is stuck tight. Any suggestions?
Old 10-28-2017, 12:54 PM
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Coeur d'Alene, Idaho
 
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Hmm. I'd go postal on the side with a rubber/wood mallet trying to bang/vibrate it loose. The outer tube you're hitting is pretty stout, but remember you're trying to set up vibrations that will kick it loose. Mine came out in pieces if its the original like mine was. I put it in the vice and ruthlessly grabbed the dampener tube with a large vice grip and just pulled it out.

Doug
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84 944, 87 Vanagon, 88 Mitsubishi Van Wagon, 1990 Audi 90 20V Quattro sedan, 1992 Lexus LS400, 1993 LandCruiser, 1997 LandCruiser, 2017 Subaru Outback.
Old 10-29-2017, 12:41 AM
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curtisr
 
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It might be welded in tight thanks to rust. This was the case in one of mine. In fact, the bottom had also rusted out. I guess the total lack of resistance shoulda tipped me off...
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1987 924s Alpine White featuring a recently seized engine...
1987 924s Kopenhagen Blue (a work in progress and on course to become my track car)
1987 924s Garnet Red
1982 928 Silver (sold)
Old 10-29-2017, 07:29 AM
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Coeur d'Alene, Idaho
 
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Worst case is you continue to remove the strut. If you carefully mark the fasteners n strut mount you can reassemble VERY close to the alignment settings. I just did this and it is so close I cannot detect misalignment while driving and Im a former product developer for two of the worlds largest automakers. I just drove it 250 fun miles on backroads yesterday. Needs a tie rod so I will get that done then professional alignment all at once. So mark things n enjoy. Big thing is whether once loosened you find it was installed with all mount slack pushed inboard. If so push inboard while putting fasteners back in to mount n you will be very close.
Old 10-29-2017, 09:42 AM
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So I'm going to answer my own question after hours of trying different things. In the end, I drilled a small hole in the bottom of the housing and it relieved the pressure. It came right out after doing that. I think they are stuck from pressure more than rusted. I didn't see any rust inside after removing it. I did have to remove the strut after marking the eccentric bolt. We'll see about alignment. I filled the hole with JB Weld.
Old 10-30-2017, 03:04 PM
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I'd have done something similar. So was the old insert leaking oil into the housing?
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84 944, 87 Vanagon, 88 Mitsubishi Van Wagon, 1990 Audi 90 20V Quattro sedan, 1992 Lexus LS400, 1993 LandCruiser, 1997 LandCruiser, 2017 Subaru Outback.
Old 10-30-2017, 10:32 PM
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curtisr
 
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All's well that ends well. +1
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1987 924s Alpine White featuring a recently seized engine...
1987 924s Kopenhagen Blue (a work in progress and on course to become my track car)
1987 924s Garnet Red
1982 928 Silver (sold)
Old 10-31-2017, 06:12 AM
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