What's the trick to tighten those Bilstein strut caps?

[Ameer Antar]

Thanks for the email. Ya, this is on the front. I guess I'll just leave it as it is, cuz the strut cap is all chewed up from slipping so much. I hope this doesn't make any clunking...It'll be interesting, to say the least, when it comes time to remove the struts... I haven't got to the rears yet, but I'll have to. Sounds like all this suspension work is a real PITA. I was planning on using a box-end wrench and a hex drive socket on a torque wrench, but I don't know how hard this will be. When I get there, I'll definitely ask for some advice. Thanks again.

-Ameer

----Original Message----
From: "Dave C." <conner at cfm.Ohio-State.edu>
Date: 3/14/04 1:31:15 PM
Subject: What's the trick to tighten those Bilstein strut caps?

You wrote...
"Anyone have any advice on tightening those strut caps on the Bilstein
struts for a type-44? It seems like a terrible design... The tool just
keeps popping out of place and damaging the strut caps. The booklet that
came w/ the struts says to tighten to 95 ft-lbs., but there's no way I can
tighten 'em up that good. 80 ft-lbs is all I can do. Holding the strut
housing is enough of a problem, and the strut cap design just makes it
impossible. What a PITFA! I much appreciate any sage advice."

Ameer,
You are talking about the front struts?

I recently installed Bilsteins at all four corners on an 87 5ktq.
If I remember correctly I had a similar problem.  I think I used a large
pliers or pipe wrench to finish tightening.  Of course I had to guess at
the amount of torque.

My bigger problem was tightening the top nut on the rear struts. Have you
dealt with these yet?  
Bilstein specs something like 40 ft lbs and expects me to hold the thing
with a 7 mm hex,  No way!  The hex key recess in the strut rod stripped,  I
ended up with the top mounts too loose and it caused a rattle when driving
over bumpy roads ... very disturbing.  Let me know if you have a problem
with the rear struts, and whether you find a solution ... I may be able to
help.
Dave C.