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Bilstein Struts erupt through top strut mount- it's a 940 but I need all the help I can get. 200

posted by  emaycom on  Wed Apr 27 22:38 CST 2011
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last visit: Thu Aug 16 02:05 CST 2012
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I've got a 93 940 that I replaced the struts on last summer. I bought Bilsteins and a set of new top mount plates from FCP. The car rode fine for quite a few months- nice and smooth. A month or 2 ago I posted that I heard a thunking sound coming from the front pass. side, several folks told me to check various front end components for looseness, wear etc..
I did this, but only checked the bushings. ball joints etc...- all things in the vicinity of the wheel. I found nothing out of order. 3 weeks ago I noticed the same thunking sound coming from the drivers front. Again, checked everything outside and underneath on that side- nothing again seemed bad.
The other day after doing a oil change I was pouring oil into the crankcase, I looked up and noticed that the strut pistons had literally cored out the interior of the strut mount and were protruding up about 4-5 inches from the tops of the strut mount plates. What did I do wrong when I installed these struts?
The installation instructions specifically stated that the old rubber bump stops were not to be used as the Bilstein piston was tapered and the stop wouldn't fit anyways.
I'd appreciate any help with this as I need to know how to proceed from here.
I know I'll need new strut mounts but there's got to be something that prevents these strut pistons from trying to erupt through your hood. I feel like I'm driving Fred Flinstone's car with the square rocks for wheels. Help!






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