73T - Bilstein Strut Rebuild

[Highfield]

I finally got round to 'starting' on my front bilstein strut / insert refurb - spurred on by James (Hot66) and his Boge / Bilstein write-up - thanks James.

I acquired these as part of a complete front suspension, the A-Arms of which have gone to Bert for his Targa rebuild project, and the alloy crossmember of which will be put on to my 73T.

My plan is to strip, repaint, revalve and assemble ready for installation.

Paul at Tuthills has advised on the 'custom' revalve, in line with my needs for a fast road setup, capable of real world use over 'B' roads as well as taking in the occasional Track Day. We settled on what I will refer to as Tarmac Rally specs.

Here is the start point, complete with years of dirt accumalation etc.



The strip down was somewhat of a challenge, given my poorly equipped garage and the need to securely retain the camber plate whilst attempting to remove the top retaining nut. A rather Heath Robinson affair involving a workbench and green washing line eventually secured the camber plate whilst the nut was removed.



I will keep hold of the camber plate and nut etc. until I can choose the better of the two from it and the original on the car when that is removed.

Next came the removal of the pin that retains the insert in the strut housing. This involved an amount of WD40 / PlusGas and then a large punch and big hammer - job done but the pins will be replaced.

Question 1 - where do I get new pins from ?

The inserts can then be pulled out, leaving behind what appears to be two bands of white grease inside the housing. The insert rubbers had white grease residue on them also - apology for the awful photo.





Question 2 - should this grease be here, and do I need to renew any internal seals or grease ?

I have packed the inserts and rubbers in newspaper and will get them over to Tuthills for revalving.

The strut body was then given a thorough scrub and is ready for painting.



Question 3 - can they be powder coated (along with the dust covers), as the heating / baking may affect the internal rubber seals and grease etc. If not, should they be simply sprayed - I say simply, which means not by me

Question 4 - they are date stamped as August 1981, so from an SC with 3.5" brake caliper mounting hole distance. I assume these are a straight bolt on to my 73T, but will I need a different or anything to match them ?

I will reassemble and post final picture here when done.

[hot66]

the inserts are 'upside down' in a Bilstein, so those rubber donuts will be the internal bumpstops won't they?

[Highfield]

Yes they are upside down, so I guess that is what they are.

'Appear' in good order, just a little covering of what appears to be grease.

When I insert the revalved insert, do I oil or grease it or the strut ?

Pelican suggests John Deere Green enamel paint - might just paint them myself

Ian

[Highfield]

Please see the responses on Pelican here :-

http://forums.pelicanparts.com/showthre ... ost3698216

I really need information on what to do to the inside of the strut body. Do I remove the grease and liners / top seal and replace with new items ? How do I know if they have worn ? If so, where on earth do I get them from, and how do I fit them.

Thanks as always for help to my odd questions.

Ian

[hot66]

the new inserts are a sealed unit so just side in & you fit a new roll pin. Or am I missing something?

[sladey]

I'd written a whole reply agreeing with James but thinking about it you've got bilstein shock with Bilstein struts havent you Ian. James and I both have bilstein inserts for Boge struts - in this case the bilstein just pops into the strut and is held in there by the collar.

So no idea I'm afraid - looks like youve got some help on pelican though

Cheers

Mark

[Highfield]

James, Mark

Yes, I can just pop the revalved insert in to the body and secure with the new pin.

My real query is whether the old grease (if that is what it is) needs to be cleaned out and replaced, and whether the inner sleeves or bushings need to be removed and replaced.

Basically - is there a simple 'how to' on rebuilding the strut and what parts should be cleaned, greased or replaced ?

Thanks,

Ian

[hot66]

I assume because the insert is upside down, the main insert outer slides up & down into the lower strut body & the bushes you refer to.

If thats the case then I would renew the grease. By looking at the bushes you should be able to see if they're scored. Also trial fit the new insert in & see if they are a tight fit in teh top bushing.

If the top seal is damaged thay might need replacing too