1974911GS Posted 16May, 2021 Report Share Posted 16May, 2021 Hi all, Seems everything i touch just opens a can of worms. Front shocks are goosed so got myself a pair of Bilstein inserts for the Boge struts. Drivers side went in no bother but the passenger sleeve gets stuck in the strut tube and won’t fully seat. KYB’s that came out are thinner than the Bilsetein. Any tricks on getting this thing in without removing the strut itself? Quote Link to comment Share on other sites More sharing options...
OZ930 Posted 16May, 2021 Report Share Posted 16May, 2021 Is the “sleeve” straight ? Quote Link to comment Share on other sites More sharing options...
1974911GS Posted 16May, 2021 Author Report Share Posted 16May, 2021 Looks straight to me although I guess it must be bent slightly? Is there trick to fix on the car or am I looking at a new strut and more $$$? Quote Link to comment Share on other sites More sharing options...
Pembo Posted 16May, 2021 Report Share Posted 16May, 2021 How far away from home are you talking? 1 inch, 2 inch or lots of inches? Quote Link to comment Share on other sites More sharing options...
1974911GS Posted 16May, 2021 Author Report Share Posted 16May, 2021 About an inch from being fully seated. Quote Link to comment Share on other sites More sharing options...
Pembo Posted 16May, 2021 Report Share Posted 16May, 2021 Block of lovingly shaped wood and a mallet. But first take it out and carefully inspect with torch for rust or some other obstruction. Surface rust can constrict a tube pretty quickly. Difficult to clean out if it is rusted. Or could be a small ding from a rock but not likely. Good luck. Quote Link to comment Share on other sites More sharing options...
Merv Posted 16May, 2021 Report Share Posted 16May, 2021 Sounds like an obstruction. If one side fits and the strut is straight . What was in there before? What did the base of the removed shock look like? I recently replaced a friends original factory Boge dampers and there was a lot of accumulated grit in the base of the strut from shock oil that had leaked and granulated over many years in the base. I am not sure what year your car is - '74? Quote Link to comment Share on other sites More sharing options...
1974911GS Posted 16May, 2021 Author Report Share Posted 16May, 2021 KYB in before which is a good bit smaller in diameter hence no issues with fitment. I’ll remove again tomorrow and look a bit closer then have a go with a large mallet Quote Link to comment Share on other sites More sharing options...
1974911GS Posted 17May, 2021 Author Report Share Posted 17May, 2021 Had a crack tonight with a big mallet. Just can’t get it home. No signs of warp on outside of sleeve but i guess it must be off on the inside? No rust or obstruction in it either. Guess it’s time for a new strut Quote Link to comment Share on other sites More sharing options...
Merv Posted 18May, 2021 Report Share Posted 18May, 2021 Post an image of the base of the new shock and the one that came out. What are the measurements from the bases of the shocks to the top where the lock nut holds it (I assume the shocks are a similar diameter)? Are both struts the same brand and part number? Quote Link to comment Share on other sites More sharing options...
OZ930 Posted 18May, 2021 Report Share Posted 18May, 2021 You could try switching sides and see if the issue transfers Merv 1 Quote Link to comment Share on other sites More sharing options...
Merv Posted 20May, 2021 Report Share Posted 20May, 2021 Any update? The Bilstein inserts have a different profile on the base as I recall. However this problem has been around for a while http://forums.pelicanparts.com/porsche-911-technical-forum/481750-bilstein-shock-boge-strut-tight-fit.html Bent strut or the weld line referred to above. Quote Link to comment Share on other sites More sharing options...
1974911GS Posted 21May, 2021 Author Report Share Posted 21May, 2021 Had a closer look. Strut appears straight but the weld line is quite prominent on the side I can’t get the shock in. Machine shop can perhaps take away the high point? Quote Link to comment Share on other sites More sharing options...
Merv Posted 21May, 2021 Report Share Posted 21May, 2021 Should be able to take a bit off with a grind stone on long shaft. Quote Link to comment Share on other sites More sharing options...
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