Pain In The A$$ - Special Tools Needed

[Brando_SLT]

So starting to tear into my front suspension rebuild, feeling absolute defeat right now. I get the wheels off and get ready to start taking everything apart. First thing I notice, it looks like the small little 6mm flange on the tops of my shocks are rounded out - thanks to PepBoys. Brand new freakin' shocks too.

Then, trying to figure out how the spring compressors I bought will work, and they won't. Re-reading the service manual I missed that Special Expensive Tool DD-1278 is needed. But can only be used once the shock is removed. So now I'm stuck at an impasse where the cost of tools to get this all disassembled is going to equal what it would cost for the suspension shop down the street to do all the work, and an alignment. FML.

Any insight you guys can share here to keep my sanity? Thanks.

 

[Snake15eyes1998]

If it where me, I would replace your shocks as a whole. New spring and shock. That will eliminate using the spring compact tool. Which will also narrow things down to, " how will I get the top 3 flange nuts off" so now your only focused on 1 thing now. Their basically studs on top. Then the flange nuts go on top. I would cut them off. The new coil-overs will have new studs on top. You would just have to buy new flange nuts at this point. If you have a welder, you could even put a nut on top of those flange nuts and weld a nut to them, and pull them off that way. But now that I'm writing this, I'm trying to remember how far the stud sticks up past the nut. I don't think the flange nuts are up far enough on the studs to weld to them. You would also be welding to the stud. Maybe a bigger nut, and weld just on the flange nut?? Leaving the stud untouched. I realize what I'm saying is easier said then done. Good luck man.

 

[pacofortacos]

You have to remove the shock to compress the spring, there isn't enough room on the truck to compress it far enough.
Why in the world would you cut the three nuts off that hold the top flange nuts off? They usually come off easy enough.

As far as the top of the shock being rounded off - once the shocks are off of the truck and the spring compressors are on and stable - you might be able to just use an impact wrench on the main shock nut and get it to come off.
If it won't without the shaft turning, you might be able to vise grip it tight enough to hold the shaft to get the nut off.

I used free tool loaners from Autozone and used their spring compressors - now I will admit, a loaded spring using compressors can be dangerous.

I removed the lower strut bolts, then the 2 inboard lower control arm bolts (the ones used for alignment), then the top 3 nuts and dropped the assembly out of the bottom, change shocks, reinstall, get alignment (which should be done not matter how you do the change out.
This way is much easier than separating the lower ball joint and getting clearance that way.

 

[MikeG71]

Is it the top of the shock that is rounded.....? (Circled in pic)



If so you could take a grinder/ Dremel to it to flatten out two sides, then you’ll be able to get a wrench on it.

 

[Brando_SLT]

That is correct @MikeG71 - those are what are rounded off, nearly sheared off at this point. If I had spare nuts for the shocks I would double-nut them to break it loose, but I don't. If I had a welder, I would consider grinding the tops down and welding two allen-head screw caps on there. I don't know why Sachs put that tiny little 6mm flange (not even a hex-head) on there. Especially when some dumb$hit at PepBoys zipped it on with a socket that was 1 size too large (nuts are rounded) and used vise grips on the top.

Is it the top of the shock that is rounded.....? (Circled in pic)

If so you could take a grinder/ Dremel to it to flatten out two sides, then you’ll be able to get a wrench on it.

@Snake15eyes1998 I agree with cutting the shaft/nut if the shocks were old, but these have less than 600 miles on them, nearly-new Sachs shocks. They really ride nice and I don't want to drop another $100 to replace a nearly-new part because someone else fudged the part on install. I've checked with PepBoys, O'Reilly, and AutoZone for a spring compressor rental. They offer 2 styles.

This one is most common (what I bought):


And this style:


What I need is this tool, which compresses the spring into the top of the frame/spring perch.

 

[Sandevino]

If I had a nickel for every special tool I had to buy over the years....lol

 

[kevkev]

I still have my $200 worth of special tools for removing Ford spark plugs.

 

[Brando_SLT]

A friend of mine has a 2010 F-150 that still has 3 original spark plugs still LOL. Just for this very reason.

I still have my $200 worth of special tools for removing Ford spark plugs.

 

[Brando_SLT]

I caved, took it to a local suspension shop. They quoted a 2-day turn-around and the truck has to be ready to go by next week. Looking to order additional tools, I wouldn't get them until late next-week anyhow. It just really sucks when the time crunch hits like that.