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Randy,
Well I installed those Boge Turbo Gas inserts. The tubes had the bottom spacers, whcih I couldn't use, because they made the Boge's stand too tall in the tube for the mounting nut to catch a thread on the top of the tube.
Some green Volvo (made in Japan) strut inserts came out. I wonder if KYB had supplied Volvo for a while during the mid to late '80's.....?
I reused the Volvo bump stops with their dust boots. If yuo eliminate the bump stops, as Bently says to do, I don't see any way to provide a covering over the piston, which is what the boots do. The Volvo boots fit around the wide bottom groove of the bump stop, just under the spring plate.
And now I have clunking on both sides. Just like I did when I installed KYB GR-2's in my '84.
I went back and installed my 3/4" ID washers on under the top nuts (above the strut beardings). But this didn't cure the clunk.
Let me see if I have things assembled in proper order...
Install the inserts and tighten the tube nut.
Slide the bump stop and collar down the piston until it rests on the piston journal.
Fit the still compressed spring with its top plate, making sure the spring ends engage into the notched in the seat and top plate.
Fit the strut bearing and piston top nut.
Shove the assembly back into the strut tower and fit the three nuts inside the engine compartment.
Torgue the piston top nut to final spec (15 ft lbs)
Retighten the tube nut
Am I missing anything?
I noticed that the hole in the top plate of the spring looked large engouh for the journal (shoulder) on the piston to pass through. Now, because I have the bump stop mounted under that plate, I can imagine the journal would not raise up and through thre top plate.
Could that be my problem?
There was a 1/4" gap under the piston top nut before I installed the extra washer under that nut.
Probably the piston journal isn't high enough to become flush with the top of the strut bearing where the piston top nut can clamp it tightly.
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