Strut Assembly: Assembly

For the disassembly and assembly of the strut assembly, use of Strut Spring Compressor, Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, is recommended to compress the coil spring. Follow the manufacturer's instructions closely.

1. Place the coil spring in the compressor lower hooks following the manufacturers instructions. Proper orientation of the spring to the strut (once installed) is necessary. Consider the following when placing the coil spring in the compressor: From above, the compressor back is at the 12 o'clock position, and you, standing in the front of the compressor, are at the 6 o'clock position. Place the lower coil spring end at the 12 o'clock position for left springs and at the 6 o'clock position for right springs. See Fig 1.
   Fig 1: Spring Positioned In Compressor (Right Spring Shown)

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - COMPRESSOR LOWER HOOKS

   2 - COIL SPRING END

2. Install the upper seat and upper isolator on top of the coil spring. Position the notch in the perimeter of the upper seat toward the front of the compressor (same 6 o'clock position as in step 1).
3. Position the upper hooks on top of the coil spring upper seat so the upper hooks span approximately 1 inch past outside diameter of upper seat. See Fig 2. This will allow proper clearance for upper mount installation without pinching the hooks in-between the two pieces. Do not allow hooks to be placed closer to edge. 
   Fig 2: Hook Placement On Upper Seat

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - HOOKS POSITIONED 1 INCH FROM EDGE

   2 - PIVOT BEARING AND UPPER SEAT

4. Compress the coil spring far enough to allow strut installation.
5. If the pivot bearing has been removed from the upper seat, install the pivot bearing on the top of the upper spring seat. See Fig 3. The bearing must be installed on upper seat with the smaller diameter side of the pivot bearing toward the spring seat. Be sure the pivot bearing is sitting flat on the spring seat once mounted.
   Fig 3: Pivot Bearing Installation

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - PIVOT BEARING

   2 - UPPER SEAT

6. Install the spring isolator on the lower spring seat of the strut. See Figure.
7. Install the jounce bumper on the strut shaft. See Figure. The jounce bumper is to be installed with the small end pointing downward.
8. Install the dust shield on the strut. Collapse and stretch the dust shield down over the top of the jounce bumper until the dust shield snaps into the slot on the jounce bumper. The jounce bumper will be at the top of the inner dust boot. Return the dust shield to its fully extended length.
9. Install the strut through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil spring. The clevis bracket on the strut should point straight outward away from the compressor (to the 6 o'clock position). If necessary, reposition the strut or coil spring in the compressor so the strut clevis bracket lines up with the lower coil spring end as indicated in the figure. See Fig 4. Install the clamp to hold the strut and coil spring together.
   Fig 4: Coil Spring Positioning

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - END OF LEFT COIL SPRING AT STRUT LOWER SEAT

   2 - END OF RIGHT COIL SPRING AT STRUT LOWER SEAT

   3 - LOWER SEATS OF STRUTS

   4 - RIGHT STRUT CLEVIS BRACKET

   5 - LEFT STRUT CLEVIS BRACKET

10. Install the strut mount over the strut shaft and onto the top of the pivot bearing and upper seat as shown in illustration. See Figure. Loosely install the retaining nut on the strut shaft.
11. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft retaining nut. See Figure. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 100 N.m (75 ft. lbs.).
    NOTE: Before releasing the tension the compressor has on the spring, using the following figure as reference, make sure the upper spring seat, coil spring and strut clevis bracket are all lined up properly (within 5° of one another). See Fig 5.
    Fig 5: Components Lined Up

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - IMAGINARY VERTICAL LINE

    2 - CLEVIS BRACKET

    3 - END OF COIL SPRING (RIGHT SIDE ONLY)

    4 - NOTCH IN UPPER SPRING SEAT

12. Slowly release the tension from the coil spring by backing off the compressor drive fully. As the tension is relieved, make sure the upper mount, pivot bearing and upper seat are align properly. Remove the clamp from the lower end of the coil spring and strut. Push back the spring compressor upper and lower hooks, then remove the strut assembly from the spring compressor.
13. Install strut assembly on the vehicle. (Refer to SUSPENSION/FRONT/STRUT - INSTALLATION)