Strut Removal and Replacement – 2.5L NA

Overview

This procedure outlines the steps to remove and replace the front strut assembly on all Porsche 944 with an 8-valve engine configuration. The strut assembly, which includes the shock absorber and coil spring, is critical for maintaining suspension performance and ride quality. This guide covers both the pre-1985.5 (83-85.5) and 1985.5 onwards (86-88) variants, with specific steps clearly marked where differences apply. Replacing or rebuilding the strut ensures proper handling and safety.

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Tools Required

• Metric socket set (various sizes, e.g., 13mm, 17mm, 19mm)
• Metric wrench set (various sizes, e.g., 13mm (1/2 inch), 17mm (11/16 inch), 19mm (3/4 inch))
• Scribe, paint pen, or brightly colored nail polish
• Air impact wrench
• Strut spring compressor (double or professional rigid type)
• Porsche tool 9186 or equivalent (for rebuilding old strut)
• Jack stands
• Floor jack
• Vise (for rebuilding old strut)

Parts Required

• Strut insert (if replacing), 944 343 031 00 (pre-85.5) or 944 343 031 01 (85.5 onwards)
• Strut bearing (if worn), 944 343 013 01
• Thin oil or ATF (automatic transmission fluid) for shock absorber housing (optional, max. 2/3 full)

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Disconnect the negative battery cable to prevent electrical issues.
2. In the engine compartment, locate the four strut mounting bolts on the strut tower and loosen them several turns using a 13mm (1/2 inch) socket. Do not remove them yet.
3. Place the vehicle on jack stands to safely elevate it.
4. Remove the front wheels using a 19mm (3/4 inch) socket.

Step 2: Disconnect Components from the Strut

5. Remove the brake line from the clip on the front strut to free it from the assembly.
6. At the bottom of the strut, locate the two bolts attaching the strut to the spindle assembly. The top bolt is an eccentric bolt used for camber adjustment.
7. Using a paint pen, scribe, or brightly colored nail polish, mark the orientation of the eccentric bolt relative to the strut to preserve alignment.

Step 3: Remove the Strut

8. Remove the eccentric bolt and the bottom retaining bolt from the strut using a 19mm (3/4 inch) socket and wrench.
9. Pull the strut away from the spindle until it is free from the bottom of the assembly.
10. Support the strut and remove the four mounting bolts at the top of the strut tower using a 13mm (1/2 inch) socket.
11. Remove the strut from the vehicle.
12. If replacing the strut, note the eccentric bolt alignment mark from Step 2 and transfer it to the new strut to maintain camber settings.

Step 4: Replace the Strut Insert (Optional)

13. Caution: Use extreme caution with double spring compressors, as springs can pop out and cause injury. Make small adjustments, alternating sides, to compress safely. Alternatively, use a professional rigid wall or stand-mounted spring compressor, or take the strut to a suspension shop for insert replacement.
14. Using a strut spring compressor, compress the coil spring until there is only slight pressure on the strut assembly top plate.
15. Note: A regular socket and ratchet will cause the strut rod to spin when removing the top plate retaining nut. Use an air impact wrench to remove the nut quickly without spinning the rod.
16. Using an air impact wrench and a 19mm (3/4 inch) socket, remove the spring strut bearing retaining nut.
17. Remove the bearing from the strut.
18. Slide the strut assembly out of the spring.
19. For rebuilding the old strut:– Clamp the strut assembly in a vise.

    – Remove the strut insert cap using Porsche tool 9186 or equivalent.

    – Remove the old insert from the strut.

    – Clean the inside of the housing and remove any oil.

    – Install the new strut insert, ensuring the spacer is placed between the cap and the cartridge.

    – Torque the cartridge cap to 150 ± 30 Nm (111 ± 22 ft-lbs).

20. Note: To improve cooling, the shock absorber housing may be filled with thin oil or ATF, but no more than 2/3 full if the cartridge touches the bottom of the housing. Excess oil may leak when hot, leading to incorrect diagnosis of a defective absorber.

Step 5: Reassemble the Strut

21. Install the spring onto the new or rebuilt strut assembly.
22. Install the bearing onto the spring strut assembly.
23. Using an air impact wrench and a 19mm (3/4 inch) socket, tighten the spring strut bearing retaining nut to 77 Nm (57 ft-lbs).

Step 6: Install the Strut

24. Insert the new or rebuilt strut assembly through the top of the strut tower and loosely install the four retaining nuts using a 13mm (1/2 inch) socket.
25. Slide the bottom of the strut onto the spindle and install the bottom retaining bolt and the top eccentric bolt using a 19mm (3/4 inch) socket.
26. Align the top eccentric bolt to the orientation mark made during removal to preserve camber settings.
27. Tighten the eccentric bolt locking nut and the bottom retaining bolt locking nut to secure the strut.
28. Note: Even with the eccentric bolt aligned, have the vehicle’s camber checked at an alignment shop as soon as possible.
29. Tighten the four retaining bolts on top of the strut tower using a 13mm (1/2 inch) socket.
30. Attach the brake line to the clip on the strut.
31. Install the front wheels using a 19mm (3/4 inch) socket and lower the vehicle from the jack stands.

Post Procedure Checklist

• Verify that all bolts and nuts are tightened to the specified torque values (e.g., cartridge cap to 150 ± 30 Nm (111 ± 22 ft-lbs), bearing retaining nut to 77 Nm (57 ft-lbs)).
• Ensure the brake line is securely attached to the strut clip.
• Check that the eccentric bolt is aligned with the marked orientation to maintain proper camber.
• Inspect the strut assembly for any signs of oil leaks or improper assembly.
• Take the vehicle to an alignment shop to confirm proper camber settings.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• YouTube