Editing S130/frontstrutreplacement php (section)

=== Rebuild Struts ===

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Using the two holes in the bottom of the strut where it attaches to the steering knuckle, bolt the strut to something solid.
My setup: A 6 ft. section of 6×6 landscape timber with two 5/16" holes drilled 3⅛" apart and counter-bored 2" deep. Quarter-inch × 6" bolts went through to secure the strut.

* Detach the bottom of the old strut boot from the top of the housing by spreading the lower boot clip.
* Compress the coil spring using spring compressors per manufacturer’s instructions.
* Once the spring is loose in its seat, remove the old strut piston nut (should be easy if loosened earlier).
* Remove the upper mounting insulator. The bearing may come with it or stay on the lower half — note orientation for reassembly. Clean the mounts and bearing dust cover.
* Remove the lower half of the mount with the old boot and bump stop. Replace with new boot and bump stop, matching the original orientation (flat side toward mount, rounded toward housing). Transfer the lower boot clip to the new boot.
* [Optional but done here] Remove the coil spring with compressor still attached and store safely away from the work area.
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Remove the gland packing nut with a 14" pipe wrench, being careful not to damage the housing.
My bolts bent slightly from the force, but they were cheap (86¢ total) so I didn’t mind replacing them.

* Remove the rubber seal under the gland nut using a pick tool.
* Slowly remove internal strut components. Avoid spilling the oil inside — then unbolt and pour it into a jug for proper disposal.
* Rebolt the housing to the mount and install new Tokico Illumina inserts. Shake gently to seat fully. Tokico recommends a light oil bath; I reused the old oil, as the insert nearly fills the housing.
* Grease the sealing surface of the new gland packing nut and washer, then carefully install without scratching the piston.
* [If spring was removed] Recompress coil spring.
* Seat the coil spring in the lower perch and install the lower half of the upper mount with boot, bump stop, and clip onto the piston.
* Install upper strut mount bearings (new or reused) and bearing dust covers.
* Install the top part of the upper mount and thread on the new self-locking piston nut (remove protective rubber cover first). Hand-tighten for now; final torque will be done on the car.
* Slowly release the spring compressor, ensuring the spring seats properly at both ends.
* Spread the lower boot clip, slide the boot over the housing top, then secure the clip.
* Unbolt the rebuilt strut from the solid mount — it’s now ready for reinstallation.