Incorrect strut insert?

[Tun]

Currently tidying the front suspension on the 90 stripping down for painting. I remove the strut cap and was shocked to see such big gap between the insert and leg is this normal or have the wrong inserts been fitted in the past.



Insert measures approximately Ø38.5mm
Strut leg measures approximately Ø44mm

[msh]

Gap is normal as long as the shock has been made for this application and is fitted with appropriate spacers to keep it in center. Remove the shock and google it's part code.

[Ben]

The 20v has the larger diameter struts, my 90 had the smaller dampers inside but had spacer caps and a washer underneath to center them:





The dampers off the 20v coupe that I replaced them with were a snug fit.

[Tun]

The insert/damper is a bilstein with a part number of 020 7P30 3006H0. The bottom of the strut appears to have a recess for centering (squint and you can see it), while the cap has built in lip seal which I suppose is taking care of the top. Perhaps I'm worried over nothing. I can't find anything useful on google with the part number.

[Mellis46]

Sorry to bring a thread back from the dead!

For a while I've been nursing a noise from the nearside front suspension on my 1989 'G' 90q 10v sport (KV engine). It apparently has a factory lowered suspension similar to the 20v Sport and this is bourne out by the paint splodges on the springs.

Ive had a good poke around and nothing is apparently loose, its also just gone through an MOT with no issue, top mounts are about 2 years old and still good I'm told, however with the steering straight ahead I get a wobbly rattle from that side, especially noticeable at motorway speed or on bumpy roads. Any amount of steering input left or right makes the noise go away.

The garage thinks the shock on the nearside is weak and apparently this isn't tested for anymore (?) The Bilstein B4s are still a good price at Demon Tweeks and I am tempted. Only thing is the talk of different diameter strut inserts is bothering me.

The car has this set up, with the later 2 part strut and wheel bearing housing but earlier anti-roll bar arrangement:



Item 7 appears to be the contender:

(7) 8G0413503B -

gas-filled shock absorber / for vehicles with sports-type running gear
front / KV,NG,NM,6A, 7A

although it may have had a standard damper in the past:

(7) 8A0413503B -

shock absorber
green / 5 cylinder: KV,NG,NM

Sorry for the length of this post

Demon Tweeks do this B4 damper as a direct replacement it seems, if you go in with a 2.2 90 Quattro or 2.3 20v Quattro you get the same page:

http://www.demon-tweeks.co.uk/perfor...absorber-front

part number BLS21-030444 (obviously the picture is generic and doesn't show the actual part...)

With Roystons original post in mind, what if any, is the significance of the text: "Fits vehicles with a sports suspension. Outer Diameter 50mm."?

Cheers

[simons2]

If I understand you, 50mm is the thickness (OD) of the shock body. So what size is your strut (ID)? There were two sizes I think from memory and two thread sizes on the shock thread M14 & M12.

[Mellis46]

I havent dismantled it as want to get the correct parts first as I need to keep it on the road.

I guess in a nutshell I'd just like to confirm that the strut as fitted to the car will accept the Bilstein insert. From the 2014 posts it looks like (on the 20v sport at least) there are 2 possible diameter inserts one which fits snug in the tube and one which requires spacers. If its the outside diameter of the strut tube thats 50mm, the one on Demon Tweeks should correspond to the snug one? Just want to make sure

[mikes2]

The only problem with the Bilstein is you have to use the top caps from Bilstein - you can't use the original one.

50mm is the smaller diameter, 55mm is the larger. If your car has the early strut with no ARB drop link fitting point, you will have the smaller version.

I've got some spacers if you get stuck. My Coupe 20v had KYB shocks when removed and there were some black metal collars under the cap

[Tun]

I bought a replacement insert for mine from demon tweeks but it was too long, and the cap was different so the gaiter didn't fit so I sent it back. I have had these in my watch list for a long time.
http://www.ebay.co.uk/itm/3813315247...%3AMEBIDX%3AIT

I dread to think of how much time I have spent trying to get rid of noises from my 90's front suspension, more top mounts than I can count, bottom ball joints, drop links wishbone bushes and steering rack steering rack damper....and the noise is still there

[Mellis46]

Originally Posted by mikes2

The only problem with the Bilstein is you have to use the top caps from Bilstein - you can't use the original one.

50mm is the smaller diameter, 55mm is the larger. If your car has the early strut with no ARB drop link fitting point, you will have the smaller version.

I've got some spacers if you get stuck. My Coupe 20v had KYB shocks when removed and there were some black metal collars under the cap

Thanks Mike, this is good info and good of you to offer the spacers if needed, will bear it in mind! Interesting about the top caps, what is it that stops you reusing the originals?

Originally Posted by Tun

I bought a replacement insert for mine from demon tweeks but it was too long, and the cap was different so the gaiter didn't fit so I sent it back. I have had these in my watch list for a long time.
http://www.ebay.co.uk/itm/3813315247...%3AMEBIDX%3AIT

I dread to think of how much time I have spent trying to get rid of noises from my 90's front suspension, more top mounts than I can count, bottom ball joints, drop links wishbone bushes and steering rack steering rack damper....and the noise is still there

Frustrating! Couldnt help notice the part numbers of the shock in your original post and the one currently on Demon Tweeks seem to be very different?!