Tip on installing front struts

["Paul C. Waterloo" <74543.407@compuserve.com>]

I have replaced the front struts on my '87 5KQ before, and it was a bear!  You
have to disassemble the whole front end, tie rod ends, strut knuckles, etc.,
etc.  It took me 20 hours the first time!

Three year later, I had to do it again.  However, I got a good tip from a
mechanic.  On the 5K (I imagine also on the 100, 200 etc.), you can remove and
install the struts by never even taking off the front wheel.  Procedure is as
follows:

Jack up one side to the point where the front wheel is almost off the ground.
With a pair of large channel locks or monkey wrench, go into the wheel well and
remove the strut cartridge nut from the strut assembly.

Next go inside the hood of the car.  Mark the strut plate and outside of the 13
mm washers with a pencil in order to line them up to the marks later.  Undo the
three 13 mm nuts that hold the upper strut assembly plate to the strut assembly
(these are located inside the four nuts that bolt the strut assembly to the
body).

Then pull the strut cartridge out of the strut assembly, up through the engine
compartment.  Take parts off of old strut cartridge (probably will need impact
wrench to get 22 mm nut off at end of strut cartridge).

Drop the new cartridge (only) down through the engine compartment and put it in
the strut assembly.  Put the space in at the top, and drop the new lock nut
down.  Screw it hand tight.  You might have to turn the wheel back and forth
with raising and lowering the jack to get it to go in just right.

Put the other rubber components back on the shaft and put the upper strut
support plate back on (I recommend replacing the upper strut support with the
cartridges, it is probably cracked).  Drop the support plate back on the studs,
and use a screw driver in the alignment holes to line it up to where it was
previously.  Tighten the nuts down (use new locking thread nuts).  Tighten the
large 22 mm nut down (probably need an impact wrench).

Go back to the wheel well and tighten strut cartridge nut to final torque (I use
blue torque for this one -- torque it until I'm blue in the face).

Put rubber boot back up and you're done!

It took me two hours to do both sides.  I was quoted over $500 dollars for this
job, parts are about $140.

Hope this is helpful to someone.

Paul Waterloo

'87 5KQ
'95 Subaru Legacy Wagon LS
'75 Triumph TR6