Rebuilding Bilstein stuff (pss inside)

[Slimjimmn]

So I didnt have $1500 for a good set of coils. I didnt want to buy cheap entry level coils. So I found a set of used Bilstein PSS coils on vortex and scooped them up cheap, $175 cheap.



1-lock plates were siezed
2-one strut possibly blown
3-missing rear adjuster assemblies
4-pretty dirty, and corroded
5-missing front strut boots


Yea they have some miles on them, but lets see what I can do. My goal was to spend less then $500 total out the door for everything. I first needed to cut off the old lock plates and perches from the front struts.
Got out my tools:





bam done, no more siezed lock plates.


Ordered new ones from Bilstein, along with the spring seat plastic washers. The old ones were kinda beat and they were only $13.00
Lock plates and perches for the front were $45. The guy forgot to ship them with the plastic washers, so he ended up sending me the new ones free of charge.

Now time to disassemble the front struts.

That little guy on the end, he needs to come off. Rusty ole bastard. I let them soak overnight standing up with a pool of PB blaster.
17mm nut and 4mm allen. First break loose the 17mm nut. then continue to loosen it. I realized later the shock end is threaded into the strut body, so just continue to loosen without the allen wrench in. Note, I dont have a vise at home, so I counterheld with my channelock.


After the nut is off, the shock threads in like you are tightening it.


After its out pull the shock tube apart from the shock body.


At this point, all the water will come out thats in there. Any PSS owner knows this is an issue. There is no "drain" hole for this water, thats why the seal needs to be replaced.



All apart:


look inside, all that nasty sewage smelling lube thats 34872435miles old.


Now get that old bump stop out. They are only $7 each and the seals are $15 each.



pretty grody ehh?
I spend a good 20minutes trying to get that little bastard out. it was soo swollen it was hard to get out.

Updates when I get the rest figured out.

[Slimjimmn]

Here is the seal that gets replaced if there is alot of water inside the strut case.


the bump stop on the blown strut tube, probably the reason it blew out, from bottoming out.


the blown strut pushed in fine, then it got stuck and I couldnt even get it out.


On a side note, have to send these in anyway afterwards. The blown one needs a new small shaft, as it broke on the end when removing from the strut body case. $15 each. The other strut thats not blown looks like the small shaft is bent.
So I basically did all this for nothing lol.
Maybe they will charge me less because its all apart and they dont have to spend the 2-3hours on disassembly and cleaning lol.

[Slimjimmn]

bump again for more hot later action

[Slimjimmn]

Coils have been at Bilstein for over a week and half and they have not touched them yet

They have one rebuilder there so I guess he's busy. Good thing I don't have to have these on my car right now. No hurry. Might not even own my car when they are done getting rebuilt.

[Slimjimmn]

sad day.. Bilstein called back.

Strut inserts will be $300 to rebuild, one new tube has to be machined from raw since they are not available anymore.

Housings are non-rebuild-able. They also are not available. Only a new strut assembly at $475 each is available from germany.

long story short, its not worth it to rebuild a coilover.

$200 down the dumper

[onel0wcubn]

damn that sucks bro

[Slimjimmn]

bumpage

[2003 golfer]

1- I'm confused as to why you bumped this thread.
2- Why not buy some Koni inserts or something else and fit them inside? The mkiv forums has a hybrid coilover thread where the OP is getting a bunch of coilovers with blown struts and testing to see which ones the Koni inserts fit into

[Slimjimmn]

Only the h&r coil inserts match the bilsteins as they are both made by bilstein.
I also parted everything out.