KYB Front Strut Installation Woes

[ReallyDirtyThirty]

Hey R3V. I was wondering if anyone here has had any experience with the KYB front struts for a '91 M42 E30. I'm running stock springs on the car.

Last Saturday I went to go change my front strut inserts out, and try as I might, I can not get the front shocks to fit back on the car. I even cut a coil out of the stand spring to see if that would help (really didn't). When I fully extend the KYB shock out and look at the shock I pulled off my car, its readily apparent that the KYB is 2-3 inches longer than the OEM strut from my car.

I've been spring compressing the hell out of this thing to no avail. I even had a more experienced E30 wrencher than myself try to help out and we still couldn't get the strut assembly back on to the control arm.

Does anyone know if these KYB struts are longer than OEM struts? Would buying a different set of shorter struts or buying some lowering springs work for my car? I'm currently car-less right now R3V, so any help would be greatly appreciated. Thanks.

-Rob

[jlevie]

The shocks are the wrong length, but you should be able to get the struts back on the car. Bolt the upper strut bearing to the shock tower and compress the strut with a floor jack until the control arm can be connected.

[ReallyDirtyThirty]

Been trying that approach, but the spring wants to push the entire strut assembly out as opposed to up. I really don't mind spending another $180 IF it will get the car back on the road without such a damn struggle.

Has anyone remounted stock springs and struts without drama? If so, what struts did you use?

[02stu]

The shocks are the wrong length, but you should be able to get the struts back on the car. Bolt the upper strut bearing to the shock tower and compress the strut with a floor jack until the control arm can be connected.

I'm the asshat that he convinced to help him and that was my first approach too. I've changed out a dozen e30 suspensions and this one just has me beat! I've tried all the tricks in my book, I even broke out the welder and grinder to modify the spring compressor so I could grab more of the spring. I'm admitting defeat a bit and suggesting that he just buy some lowering springs so we can bolt it right it. Anyone running lowering springs on KYBs?

[jlevie]

Lowering springs may not help. The solution is to use the correct strut inserts. Ditch the KYB parts and get Bilstein HD's, Koni SA's, or Sachs/Boge parts. I.E., something meant to be used on the car.

[ReallyDirtyThirty]

Is there a way to see the dimensions on the two different strut inserts. I've seen lots of people actually using the KYB's on here, so I'm feeling kind of surprised that this is the first reported fitment issue.

[DRTSRFR]

If I'm reading this correctly, the inserts fit in to the housings, but the strut shaft is longer than stock?

Either way, it shouldn't have any impact on the ability to put the spring and tophat back on.

Can you post some pics?

[ReallyDirtyThirty]

I'll try to snap some pictures if I can. I can get the spring and top hat back on just fine. I have to compress the spring a fair amount, but I can reassemble the strut assembly without issue.

The problem is the increased lengh of the strut shaft is making the re-installation of the strut assembly into the car damn near impossible due to the spring being less compressed than it was in the original housing. I've had spring compressors on it but it still won't clear the control arm to bolt back in.

[jlevie]

Been trying that approach, but the spring wants to push the entire strut assembly out as opposed to up. I really don't mind spending another $180 IF it will get the car back on the road without such a damn struggle.

Use a strap & turnbuckle or come-a-long to keep the bottom of the strut from moving outwards.

[rares]

I am running Kyb shocks with lowering springs on my car... i installed them without a single issue... i am not quite sure what happened with your shocks... i am not sure how i can help...when i bought mine, the parts guy gave me some other ones, but i noticed they were different and made him double check...He then found out he had gien me the wrong ones and made it right... that is all i have... i am sorry, i know that doesn't help... they are Kyb gas-a-adjust shocks...eiback pro kit lowering springs...

the install went smooth, no issues at all.

please be safe guys, springs and shocks are very dangerous, work safe... i hope you get the car on the road..

good luck

[LJ851]

Do you have the sway bar disconnected on one side at least? if you are doing one side at a time the sway bar will keep the control arm up and not allow enough room to get the strut assembly in. I just recently installed KYB's with H&R Sports on my car with no issues, but i did need to disconnect the sway. Also, don't bolt the upper strut mount in until after the the bottom ball joint is connected, the rubber strut mount is under a fair bit of side load (tension) at full droop.

[ReallyDirtyThirty]

Do you have the sway bar disconnected on one side at least?

Yes I do.

the parts guy gave me some other ones, but i noticed they were different and made him double check...He then found out he had gien me the wrong ones and made it right

I bought mine off of partsgeek.com. I found on KYB the part number they reccommend for the E30. I'm going to check them up against the parts I have right now.

Also, don't bolt the upper strut mount in until after the the bottom ball joint is connected, the rubber strut mount is under a fair bit of side load (tension) at full droop.

In order to get even close to the bottom ball joint I have to have the upper strut mount fully flush with the shock tower mount.

am running Kyb shocks with lowering springs on my car

I had stock springs orginally, now I have stock spring minus one coil. They are super compressed in the housing right now and I'm still unable to get to the lower ball joint. Thoughts on if lowering springs would help? How much "smaller" are they compared to stock springs with a coil cut. Thanks.

[LJ851]

Thoughts on if lowering springs would help? How much "smaller" are they compared to stock springs with a coil cut. Thanks.

It won't make much difference, they still fully extend the shock.

[rares]

lowering springs are shorter in length by about the equivalent of 2 coils or so... which is why they lower the car, but yes they do still extend the shock... i am just hoping the shocks are right ones...if they are, then something might be wrong with them, like maybe the valving is off... this is so strange that they won't go in...

so sorry to hear

[DRTSRFR]

My catalog shows 86-3/92 318is...part#364021