[V6-12v] Strut Replacement and other issues

[Chris Thorp]

RGuzz wrote:

> I'll start with the fronts which I'm sure are easiest by far...


The trick for the fronts is to have the special tool.  It looks like a 
pipe with a hex head with a hole in it on one end and a square socket 
drive on the other.  Note that there are two different sizes available, 
need "2069A" which has a 33mm hex head.  It looks something like this:

http://www.samstagsales.com/images/vw_matra_2069a.jpg

With this tool, you can replace the strut insert with the wheels on the 
ground.  Repeat: the wheels MUST be on the ground or you will likely 
break or destroy something (yourself included) when the spring lets go.  
Once you have the special tool, you need to unbolt the top of the strut 
from the camber adjustment plates (remove the black dust caps, if they 
aren't missing).  There is a special tool for this, but if you have an 
air impact gun, you should be able to do this without it.  There are 
also several of these available, too.  I believe that you need "3078", 
22mm.  If you want to buy one, the special tools looks like the following:

http://www.samstagsales.com/images/hz259322.jpg

Once you have unbolted top nut of the strut, you can remove the three 
nuts that hold the camber plate on.  When you look down inside the hole, 
you'll be able to see the strut cap.  This is where the 2069A tool comes 
in.  Stick in down the hole, with the strut shaft going up the inside, 
and wrench on it.  Mine took quite a bit of force to get off.

Once the strut cap is off, you can pull the insert out.  Mine was really 
stuck in there.  I had to put the top strut nut back on pry on that nut 
with a claw hammer braced against a board.  They are a close fit and any 
oil that has leaked will cause them to have a piston-like suction fit.  
Keep at it, they will come out.

Next. put the new insert in and reverse the disassembly.  The one 
problem not having the special strut shaft nut tool causes is when it 
comes time to torque the top nut.  I just air gunned mine back on and 
haven't had any problems.  *knock on wood*  An alternative that I read 
about was to wrap the shiny shaft with some rubber and stick a vice grip 
on them to keep the shaft from spinning.

HTH, YMMV

-Chris.