Strut Removal and Replacement

Tools

• Metric socket set
• Metric wrench set
• Scribe, paint pen, or brightly colored nail polish
• Air impact wrench
• Strut spring compressor
• Porsche tool 9186 or equivalent (if rebuilding the old strut)
• Jack stands
• Floor jack

Other Procedures Needed

None

Removal

1. Disconnect the battery negative cable.
2. Loosen the four strut mounting bolts in the engine compartment several turns. Do not remove yet.
3. Place the vehicle on jack stands.
4. Remove the front wheels.
5. Remove the brake line from the clip on the front strut.
6. At the bottom of the strut there are two bolts attaching the strut to the spindle assembly. The top bolt is an eccentric bolt providing camber adjustment. Using a paint pen, scribe, or brightly colored nail polish, mark the orientation of the eccentric bolt to the strut.
7. Remove the eccentric bolt and bottom retaining bolt from the bottom of the strut.
8. Pull the strut away from the spindle until it is free from the bottom of the assembly.
9. Hold the strut while removing the four mounting bolts at the top of the strut tower. Remove the strut from the vehicle.
10. If the strut is to be replaced, note the eccentric bolt alignment mark from Step 6 and transfer that mark to the new strut.

Strut Insert Replacement

Caution: Extreme caution must be used when using double spring compressors where the springs are not held rigidly. This type of compressor is commonly sold or loaned at auto parts stores. The key to using them safely is to make small adjustments and alternate sides after each adjustment. The safest option is a rigid-wall or stand-mounted professional spring compressor. Alternatively, take the strut assembly and new insert to a suspension shop and have them swap the insert.

1. Using a spring compressor, compress the coil-over spring until there is only slight pressure on the strut assembly top plate.

Note: A regular socket and ratchet cannot be used to remove the strut bearing retaining nut — the strut rod will spin. An air impact wrench is required to spin the nut fast enough to break it free.

2. Using an air impact wrench and socket, remove the spring strut bearing retaining nut.

3. Remove the bearing from the strut.

4. Slide the strut assembly out of the spring.

5. If rebuilding the old strut: a. Clamp the assembly in a vise and remove the strut insert cap using Porsche tool 9186 or equivalent. b. Remove the old insert from the strut. c. Remove any oil from the housing and clean the inside. d. Install the new cartridge, ensuring the spacer is installed between the cap and the cartridge. e. Torque the cartridge cap to 150 ± 30 Nm (111 ± 22 ft-lbs).

   Note (from factory shop manual): The shock absorber housing may be filled with thin oil or ATF to improve cooling. The housing should not be more than 2/3 full if the cartridge touches the bottom of the housing. Overfilling will cause fluid to run out when hot, leading to incorrect diagnosis.

6. Install the spring onto the new or rebuilt strut assembly.

7. Install the bearing onto the spring strut assembly.

8. Using an air impact wrench and socket, tighten the spring strut bearing retaining nut. Torque to 77 Nm (57 ft-lbs).

9. The strut assembly is now ready to be installed in the car.

Installation

1. Insert the new or rebuilt strut assembly up through the opening at the top of the strut tower and loosely install the four retaining nuts on top of the strut tower.

2. Slide the bottom of the strut onto the spindle and install the bottom retaining nut and top eccentric nut.

3. Set the top eccentric nut to the orientation mark made during strut removal.

4. Tighten the eccentric bolt locking nut and the bottom retaining bolt lock nut.

   Note: Even though the strut was aligned using the eccentric bolt mark, have the camber checked at an alignment shop at the first opportunity.

5. Tighten the four retaining bolts on top of the strut tower.

6. Attach the brake line to the clip on the strut.

7. Install the front wheels and lower the vehicle.