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Struts Replacement: Removing the Old Strut Steps for removing a worn-out strut from a vehicle From "Weekend Mechanic" episode WKM-208

Removing the Old Struts

With the car on a jack and jack-stands, and the wheels and tires removed, work can begin removing the old struts from the vehicle. In this segment, removal of only one strut is shown. The procedure is essentially the same on the other struts, but consult your owner's manual or service manual for procedures that may be specific to your vehicle. (Continued below)

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	Weekend Mechanic Bruce Bonebrake begins work removing worn out struts from the vehicle. The struts on this car were in such bad condition that they needed to be replaced before a wheel alignment could be done.
	Figure N
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F
	Figure G
	Figure H

Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand repair kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: Always wear eye protection, and follow proper safety precautions, when working under a vehicle or working with power tools.

Safety Alert: Be sure to use jack stands and a jack that are rated for the weight of your vehicle, and follow proper safety procedures when jacking a vehicle.

Safety Alert: Coil springs are held under tension, and could cause injury if released too quickly or improperly. Use a coil-spring compressor, use caution and follow safety recommendations when removing and releasing coil springs.

• Once the wheels and tires have been removed, begin taking apart the strut assembly at the top. Begin by removing the dust cap (figure A).

• The strut is held in place at the top with bolts. (In our case, there were three bolts per strut.) Before removing bolts it's a good idea to mark one of them, and mark the location of the adjacent hole, so that the new strut can be installed in the same orientation as the old one.

• Use a socket to remove the securing bolts (figure B). Once the bolts are removed, the strut should drop down slightly.

• The next part to be removed is the stabilizer-bar link which is held in place by a bolt, nut and bushing (figure C). This will need to be removed so that the assembly can drop down further. You may need to spray the bolt with penetrating oil to help loosen it before it can be removed.

• Use a socket to remove the nut. Use of power tools or an air-ratchet is not recommended for removing this nut. It could snap under pressure.

• Once the nut and bushing have been removed, inspect the rubber bushing for signs of cracks or wear (figure D). Ours was in good shape, so it was retained for reinstallation with the new strut.

• Tip: It's a good idea to take a digital photograph of the strut assembly at this point to make sure that the new strut is installed the same way.

• Next, remove the nuts that hold the caliper brake-hose in position. Inspect the brake hose (figure E) for signs of cracks or wear. If the brake hose is damaged, it may need to be replaced as well.

• Remove the bolt at the bottom of the assembly. This bolt may be secured tightly. If you find that you need to tap the bolt in order to loosen it, leave the nut in place and tap the nut rather than the bolt. In that way, the bolt is less likely to become damaged. This large bolt will be reinstalled later.

• With the bolt removed the strut can be loosened, but it's still not ready to be removed. The next step is to loosen and remvoe the bolts and nuts at the top of the control arm. A socket with a long extension and swivel may be required to access these bolts (figure F).

• Once the control-arm nuts have been removed from the bolts, carefully pry the assembly loose from below (figure G). Use care not to force the assembly out, as you could cause damage to the bolts and connections.

• With the control-arm loosened, the old strut can be lifted out (figure H). Use caution when removing the strut to avoid damage to the brake lines.

In the segment that follows, the usable parts are transferred from the old assembly onto the new strut in preparation for installation.

RESOURCES :

The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books

Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896

Tires, Suspension and Handling
ISBN: 1560918314
Author: John C. Dixon
(Society of Automotive Engineers