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I'll try to keep this short. I am struggling with a problem with one of my rear upper shock bolts on my 89 745 wagon. At 63 ft.lb. on the bolt, the shock still moves around a tiny bit, which causes a lot noise while driving as the shock compresses and rebounds. I have always had problems getting the upper shock tube into the shock cavity. I kept tightening the bolt beyond 63 ft.lb. in stages, but still had the noise. Eventually I ended up stripping the threads on the weld nut the bolt goes into. After much difficulty, I was able to install a Timesert insert into the weldnut (a story in itself), thus avoiding cutting a big hole on the inside of the frame to put a nut on the backside. So I am back to the original problem, trying to get shock tight enough to not move. I am hesitant to make tighten the bolt any more. At the proper torque, I can wiggle the shock a bit, causing a small tap tap. I have isolated this noise to be the flat outer surface of the shock spacer tube knocking the inner wall it kisses against. So the 2 walls on either side of the shock spacer tube are not perfectly flat, allowing the shock tube to rock. I also think the ID of the shock tube spacer is too much. But how the shock can move at all at 63 ft.lb. of torque is beyond me. It almost defies logic. I am at my wits end trying to solve this, it by far the most frustating thing I have encountered on my car. I may resort to machining a new shock spacer that incorporates washers on either end or ?. If anyone else has any insight or suggestions I welcome them.
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