Koni insert only goes halfway in?

[Vincent Brick]

I'm trying to install Koni yellows, I poured in a little bit (couple teaspoons worth) of oil as it said I should, but I try to install the shock into the tube and it only goes in halfway and now it is stuck. Do I need to pound it in with a hammer? Any tips on getting the strut tube to sit upright? The unit as an assembly is horribly awkward.


I'm now 2 weeks into what was supposed to be a one-day suspension job, I should not be allowed to work on vehicles anymore.

Thanks for any advice.

[jt223539]

There is a good chance that your strut tube is bent. I have installed Bilsteins and Konis in multiple vehicles, and they have always just slid in. Except in one vehicle, which we had thought was hit on one side. Got another strut tube, and the shock just slid in.

I don't think it is you, some cars like to test your patience.

[Vincent Brick]

I was just thinking bent strut tube as well. The outgoing KYBs are smaller diameter so a bend wouldn't be an issue.

This car has done NOTHING BUT test my patience. Instead of getting a reliable daily I got forced into a complete mechanical restoration including new engine, drivetrain and suspension. I have so much more money into it than it is worth and it still needs so much more work, I am about to cut my losses and replace it with a fucking S2000.

[mikebloco]

I feel you on the being mad at your car part. I literally just did H&R race springs and billy sports all around 2 days ago. The drivers side was a pain in my ass, but I finished it and felt accomplished afterwards. Double check part numbers and if they are right then maybe take the old shock you took out and see if it only goes back in when it's clocked a certain way. If it does then that confirms that it is bent. I'm sure you can pick up the drivers side strut housing for fairly cheap. Dude e30 over s2000 every day and, in my opinion calypso is the best color on an e30 so I'd say your lucky.

[Vincent Brick]

The inside of the strut housing is very rusty, as I clean it more and more the insert is going in, almost got it I think.

I've been borrowing an S2000 while I've been doing this suspension job (was supposed to be a one-day job, my E30 is my only car) and I much prefer the S2000 by leaps and bounds. I need something newer, more simple, more reliable, and less needing shitloads of mods to keep me entertained.

[ak-]

I'll buy it from you.

Your car was suppose to be my first E30 in 2009 or so before I was beat to it. :p

[SkiFree]

Housing may not be bent.

I have done several installs with Konis and Bilsteins. Koni's have a little larger OD and have always been a tight fit. What your seeing is something common, but just not talked about very much (I get the tech calls too "what is going on here?"). As you've found, just clean the tubes really well and see how it goes.

[Vincent Brick]

My buddy fabricated a hone to clean the inside of the tube with and it seemed to really help. As it is currently, the one insert is between 2-3mm higher than the other in the tube. It was suggested I confirm the depths of the tubes are the same, and if so, gently tap the insert the rest of the way in. If not, I was told I should find a new strut tube.

Thanks for the suggestions.

[jeffnhiscars]

I handed my mechanic my struts and asked him to install the Bilstein Sports. He said the housing welds stuck out a bit inside so he had to grind them flush to complete the install.