replacing strut insert on a 924S
 

How hard is it to replace the strut inserts on my struts. Is it just a matter of unscrewing the endcap and pulling the old insert out/sliding the new one in? Are there any compatibility problems to know about? I'm thinking of getting the Bilstein inserts sold here on Pelican.

http://www.pelicanparts.com/catalog/shopcart/944M/POR_944M_SUSshk_pg1.htm#item0

1 - Remove the strut / spring as an assembly.
2 - use a spring compressor (CAREFULLY) to compress the spring
3 - Remove the big nut at the top of the assembly
4 - Replace strut insert
5 - Reinstallation is the reverse of removal.

Scribe, paint, scratch the bottom of the shock assembly where it bolts. You want to keep your front wheel alignment as close as possible. The assembly should have a couple ounces of oil in the tube. Plan to replace or salvage, filter and reuse. You do need a spring compressor or a solid DIY. I save the old chrome strut shafts for future projects.

John_AZ
1988 924S
1987 924S

I assume you have a lathe?

Yard art or if someone breaks off my antenna, I can screw in the threaded end to the fender and tape the radio coax to the shaft. I get alot of my ideas from PBS, "The Red Green Show". Those Canadians are a hoot. I also think they gave another inventor the idea of the "Phone Dial Barbeque".

John_AZ

LOL, or if you had a welder, you could make really really stiff shocks!

Red Green is my role model....."If the women don't find you hansome, they'll at least find you handy"
When I did my inserts I couldn't get the caps off without destroying them. Had to buy two struts from the bone yard.
Good luck

Jon

What's this stuff about the oil? I thought it was a separate cartridge that fits into the strut body, at least thats what the Bilsteins look like.

A little bit is supposed to be added, before you drop in the cartridge, to fill the void between the cartridge and strut housing. It's to help with heat dissipation (thermodynamic coupling to the strut housing). I'm not sure if you need it for high pressure gas charged strut inserts. It can't hurt anything if you add it, but don't put too much in because it will ooze out of the top of the strut housing due to thermal expansion. Might fool you into thinking your new struts leak! People have used a variety of exotic fluids for this purpose, but a light oil or hydraulic fluid or even straight antifreeze should be OK. Don't use brake fluid as it absorbs water and could cause corrosion.

Will be a great benefit to use an air gun on the top strut nut! Speed/torque are needed on this nut. As far as the oil goes just dump what is in the old housing and save it so you know how much to put back in. I use ATF.

Dal

Bilstein inserts are a good upgrade choice. I use Boge F/R and match with Yokohama AVID (87) and A378 (88). No vibration, good cornering, quiet and smooth ride. "Corners like it's on rails!" she says while accelerating.

John_AZ
1988 924S
1987 924S

Thanks everyone. ;)

I know about the air wrench part. I've done struts before, just not these.

The other good thing about the Bilsteins is they come with a lifetime waranty.

Keep us posted on your progress. I need to do struts/shocks all around on my 83 and I may go the route you are going.

Speedy:)

I will. It depends on whether or not I get them for my birthday. If I don't, It'll be a while...;)

How much is involved in removing the assembly in the first place? Do you have to disconnect the sway bars etc?

Never got round to replacing the shocks on my old 924, but tempted to get another one and you can almost guarantee they'll be gone after 20 years or so.....

For those who are short on suspension knowledge you will be able to answer many of your questions if you would read the section on this repair at www.clarks-garage.com

Dal

Jeez. That really is simple. Had to remove the wishbones to do it on my MX5!