Changing inserts

[bilko0795]

I'm trying to get the old inserts out of the struts and they won't budge is there a way of getting them out ie special tool.

Thanks

[Error404]

Have you managed to get the caps off mate? If so the just pull out

[andy10v]

VAG2069A is the cap tool. (long tube with a hex end that fits inside the cap hex)

Most people just use stillsons.

You may well need to use stillsons to wind the shock out the housing, twist and pull at the same time.

[andyg plym]

stilsons all the way and if needs be a bit of heat

[bilko0795]

Tried heat and some giant stilsons no joy

[chezz]

Large metal working vice/heat/hammer...generally, the caps will be damaged/scored by this method.

[mcandmar]

Vice and stilsons with a long metal pipe on the end, if there really stubborn add heat but it will cook the seal on the shock so only advisable if the shocks are being replaced. I have split a bench vice clean in two trying to undo a strut before. I have seen mention on the forum of somebody substituting a street drain instead of a vice to hold it

Either way it will come off, no matter how rusty it looks the threads will probably be perfect once you break it loose.

[K Simmonds]

If your still stuck with Stilsons and heat, using a mini grinder and 1mm disc carefully cut four evenly spaced slits up the side of the top cap that only just make the thread. It will come undone easily then, obviously you'll need new top caps..

[driftin jo]

If your still stuck with Stilsons and heat, using a mini grinder and 1mm disc carefully cut four evenly spaced slits up the side of the top cap that only just make the thread. It will come undone easily then, obviously you'll need new top caps..

I agree, although in my experience 1 slit is enough,
you can just use a hack saw if you done have a 1mm
cutting disc.
Slitting it releases the crushing pressure on the thread
due to rust, this is why they are so hard to undo when they
are old.

[chezz]

I probably have not explained my need for the vice clearly...I inverted the strut and placed the offending cap into the jaws of the vice and tightened it up using a little assistance from the hammer to gain a little extra pressure and then tapped the strut arm to undo the cap.I hope this provides a possible alternative method.

[bilko0795]

Have tried chezzs method no joy time for the disc method can you still get the top caps?

[shaun5]

You could try leaving the caps in a bucket of diesel for 24 hours and see if that helps. Also use the vice as a hard base and give it a tap with a hammer.

[Error404]

Have tried chezzs method no joy time for the disc method can you still get the top caps?

Yes you can, they are not cheap though IIRC about £12 each

[spink]

you quite often get new ones with shockers.before you put the new shocks into the struts tip a little oil in,apparently it helps get rid of heat from the shock.should also prevent it seizing in the strut which isnt fun when that happens.btdt

[rj scotty]

did you do what I did and drill a hole in the bottom of the strut/drift big hammer/weld up?

That was after struggling for half a day trying just about everything else