Strut Assembly Order - A Definitive Answer

[kyepan 291]

Paul, ant, tom and myself have been trying to resolve my crashy sounding suspension issue....

 

And we can't decide on the proper order of the suspension, can someone that knows for sure please detail what order the bits go in, inlcuding any washers...

 

Suspension sounded rattly, found knackered top mounts and bearings, replaced them.. and it's not any better... infact it's getting worse and has spread from the left to both sides Almighty bang on bump, and on rebound. Shakes the whole car, makes you wince.

 

New ish (2 years) bilstein challenge spec struts....

 

Cheers

J

 

picture for reference.

​

[Anthony 1,002]

What do you mean we can't decide?

 

It's as per that photo, minus the bumpstop (as that's internal on Bilstein's) and with a large washer on first (not pictured)

[Slo 283 1 Cars]

knackered struts? nothing else it can be surely

[kyepan 291]

anyone know what the spec of said washer is?

[Anthony 1,002]

I've got a set of 205 top mounts in pieces in the garage that I can measure the washer on later if needed.

 

It's much larger than the washer at the top underneath the nut though, probably a good 40mm diameter and 3-4mm thick.

[welshpug 1,655]

Spec is on servicebox, being inverted, have you checked the bottom nut and emptied water from the lower leg?

[kyepan 291]

what are you getting at mei, do they fill up with water?

[welshpug 1,655]

one of mine did indeed and made a bloody big bang on sharp edged bumps, top dust seal was worn.

 

I had other struts to hand so I haven't tried them since.

 

 

I had the old PTS steel solid top mounts btw, big bearing and no play in them.

Edited September 30, 2014 by welshpug

[BusEngineer 7]

Interested to see the definitive answer to this as I have the exact same symptoms, two different sets of front shock absorbers tried so far so I've ruled those out.

Edited September 30, 2014 by BusEngineer

[stu8v 68 1 Cars]

Checked the antiroll bar drop links?

[GLPoomobile 958]

Have you checked the subframe is bolted up tight?

[dobboy 231 2 Cars]

A guy put mines together with an impact gun, same order as servicebox, then I got knocking every now and again. Turned out the top nuts on the shock weren't as tight as they should have been cos he never held the stud with an Allen key when tightening the nut....everything was spinning. I only noticed when I could move the earth tags by hand.

[Paul_13 212 1 Cars]

We've told you many times Justin where that sodding washer needs to go. It's not we can't make our minds up. I've had struts apart many many times and I know what goes where

[stufarri 98 3 Cars]

Sorry if I am being really dense but where does the thick washer actually go please, is it on top of the shock rod, the very first item?

 

I think having reassembled mine with the washer between the small cup with rubber on the outside and the the larger silver cup which I now think is wrong.

 

Can you please clarify, sorry!

[welshpug 1,655]

yes! also should be a smaller washer under the nut plus the brake pad earth tab

[stufarri 98 3 Cars]

Yes, as in it goes on first? Sorry!

 

I have the other washer with the earth tab too.

[pug_ham 244 3 Cars]

Yes, as in it goes on first? Sorry!

 

I have the other washer with the earth tab too.

The large washer goes directly on top of the bump stop (it fits into the top of the bumpstop) on the piston at the bottom of the threaded section before any parts of the top mount.

 

The washer isn't shown in the picture below but it should be on the top of the piston/ bumpstop under the gaitor;

 

g

[Daviewonder 533 3 Cars]

I replaced both rubbers and bearings on mine but now one creaks as I turn it.

 

 

Any ideas?

[welshpug 1,655]

I found that the bearings rarely have enoigh grease so I always add more if the bearing can be opened, most can.

[stufarri 98 3 Cars]

Thanks lads, I need to take them apart again now!