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Struts Replacement: Transfer of Parts How to transfer reusable suspension components from an old strut to a new one From "Weekend Mechanic" episode WKM-208

Figure A

Struts Replacement: Transfer of Parts

With the old strut assembly removed, it can be inspected to identify related parts that can be reused in conjunction with the replacement strut (figure A).

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	Figure B
	Figure C
	Figure D
	Figure E
	Figure F
	Figure G
	Figure H
	Figure I
	Figure J
	Figure K
	Figure L
	Figure M
	Figure N
	Figure O
	Figure P

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 of repair kit or replacement parts 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: 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.

Steps:

• Removing the coil-spring from the old strut assembly requires a special tool, since the spring is held under high tension in the assembly. Improperly releasing the coil spring could cause damage or injury. To safely release the spring, a spring-compressor is attached to the spring. The first half of the compressor is attached to the spring using U-bolts (figure B). The second half attaches in the same way.

• Important: When you install your spring compressor, be sure that the threaded rods are aligned straight and parallel to the strut. This will decrease the possibility of the U-bolts coming loose.

• Once the compressor has been installed and is securely in place (figure C), the top spring-mount can be safely removed.

• The top spring-mount is held in place by a single center-nut. Use an Allen wrench to hold the shaft stationary as the nut is turned using a box-end wrench (figure D).

• Once the nut and washer have been removed, the top spring-mount and rubber insulator can be removed (figure E). Inspect the mount and insulator for wear. If they are in good condition, they can be reused. If the old insulator is damaged or worn out, you'll likely need to buy a new one since most strut kits don't include a replacement insulator. Failure to replace a worn-out insulator could negatively impact the ride of your vehicle.

• Next, remove the clinch-bolt to finish taking the old strut-assembly apart (figure F).

• With the clinch-bolt removed, you may need to pry the sections of the bracket apart (figure G).

• The shaft can then be placed on the new strut cartridge. An alignment tab and notch indicate how the bracket fits onto the cartridge (figure H).

• Position the bracket on the new cartridge, and reinstall the clinch bolt (figure I).

• The new strut assembly incorporates a bump-stop (figure J) that prevents the vehicle from bottoming out when it hits a large bump.

• Install the dust-shield, washer and rubber bushing over the bump-stop (figure K).

• The old coil-spring slides over the new strut. At the bottom of the strut cartridge there is a collar with an indentation. The indentation serves to ensure that the pigtail end of the spring is aligned properly (figure L).

• With the spring in place and properly aligned, the top plate (figure M) and rubber washer can be reinstalled.

• A new nut secures the top plate on the strut assembly. Use one wrench to hold the shaft stationary and a box-wrench to turn and tighten the nut to secure the plate (figure N).

• Double-check to ensure that the spring is positioned properly, resting against the indentation in the collar (figure O).

• With the top plate secured, and the spring positioned properly, the spring-compressor can now be safely loosened and removed (figure P).

• Though not shown in our demonstration, these steps were repeated on the other side of the vehicle to replace the other front strut.

In the segment that follows, the new strut assembly is installed on the vehicle.

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