Help...I can't get my koni in!

[artfuldriver]

It's been a long day. First the mechanic who tried to install my koni yellows said they didn't fit. After a call to tech I knew I had the right ones and decided to do it myself. When I tried to take the lug nuts off, they were so tight that after B blaster and standing on the wrench didn't work, I drove back to the mechanic and he used the impact wrench to loosen. Back at home, with the wheel off, i see that the same wrench monkie used the same impact wrench on the endlink nut and ruined the head. After buying a round bolt remover kit and getting this off, things seemed to be going smooth. Got the front strut out, replaced the stock bump stop, cleaned and lubed the bearings, got the upper strut bolted in and lined up the bottom with the control arm. After moving it around for 45 mins, I finally got it in 1/2 way. I was using a floor jack to push the arm up into the strut. After another 45 minutes, it finally snapped 90% in. There is another 3/16 to go to allow the 2" bolt in the back to pass through. I have tried everything to get the last 3/16 in. I have taken the strut out, and put it back in again only to get to the same point. I sanded the bottom of the new strut, greased it, pried the liitle opening in the back with a screwdriver, everything and nothing is working.

Should I take the car down off the jack stands (with wheels on) and let the weight of the car try and push in in? I am out of ideas to get this all the way in. I still have the right front to do tomorrow.

Thanks for any advice you can give,

Artfuldriver
2008 MS3
MS Catback, MS CAI, SU MM, JBR Shift plate/bushings, HPFP,

 

[ohioan]

I feel your frustration. I remember having to beat mine out with a hammer for about ten minutes... I think I did end up having to put the cars weight on it to get to go in. I know it was a pain in the ass! Good luck

 

[WillD]

I've had my apart twice now and both times I just used the car's weight to get the strut all the way in.

 

[fasteract]

I installed Koni FSD's on my 08 MS3 GT..I had to sand off all the paint on the lower end of the front struts and file down an area where the base weld was a bit "proud". I found PB Blaster worked better than grease as a lube since the thicker grease seemed to "hydrolock" a bit..not the right term but tight clearance with non compressible grease is the idea. I also took 400 grit wet sandpaper and steel wool to the interior of the strut housing, particularly that last 3/16" where you are having problems since it is exposed to salt/chemicals and had built up a nice layer of rust scale. Lastly, I found a piece of 1/8" steel plate and ground a wedge, chisel like edge on it and pounded it into that slit where you tried a screwdriver, to open it up. I live in a fairly winterfree area so the chemical rot isn't too bad...CT is another story !!

If you haven't already done it, take 3/4" off your upper bump stop..there are posts on this mod if you Search.

Cheers