I ordered new Bilstein strut inserts (part number 34-001127-M512) to replace the old Koni's (part number 82R-1730) that I removed from my '73 914. Both inserts should fit a Boge strut, but the new Bilsteins are too tall (about 3 mm longer than the Koni's) and don't fit the strut housing. Any idea what's wrong? Did I order the wrong part?

If you are talking about the collar not fitting flat against the tube, that is just the way the fit.

When I put the insert into the strut housing, I can't get the threads to engage in order to screw the insert into the housing. The insert is just a little too high.

Wrong insert?

Here's a picture. The insert fits in the housing, but it bottoms out at the bottom of the housing and won't engage the threads. Can anyone point me to the right part number if this is the wrong one? Thanks in advance.

Alex

Does this happen on both sides or just one? You may have a bent housing if it only does it on one.

I checked and it is both sides with both housings and both inserts. When I look in the bottom hole where the ball joint would enter, it looks like the bottom of the strut insert is all the way down and bottomed out.

Can we see a picture of your struts?

This is kind of a long shot, but did you check to make sure the retaining nut fits all the way down on top of the green shock body? Try sliding the nut up and seeing if there's anything trapped under it. I installed a set of those struts a couple of weeks ago, and they dropped right in.

The other possibility is that maybe you have a pair of Koni strut housings. IIRC, they require a slightly different length cartridge than the Boge housings.

I'm thinking you may be right about the koni strut. How would I tell for sure? If they are Koni's, then the Koni inserts sold on Pelicanparts should fit right (http://www.pelicanparts.com/More_Info/KON86411077SPORT.htm?pn=KON-8641-1077SPORT&catalog_description=Koni%20Sport%20Strut%20Insert%2C%20Front&SVSVSI=5882)?

They never made Koni struts for a 914. I checked the application and the part number is correct. Sure thee is nothing in the bottom of the strut housing? Note the locatiing nub on the bottom of the Koni ?

Make sure they are seated right @ the bottom,recently fitted Boge/Sachs and they were out buy a turn or 2 but weren't going anywhere after I did them up,no issues after driving.
Sound a little strange the situation you have .

same with Bilstein's most of the time the nut will sit 1-2mm proud.

Once you have it figured out don't forget to drop about 1 to 1-1/2oz of oil into the strut before installing the insert. This is mainly to stop corrosion, but it also helps to cool the strut.

Bilstein no longer recommends oil in the strut housing but I did spray a little in mine for corrosion resistance.

The other thing is to check the bottom of the strut cavity. Since the Konis you removed are shorter than the new Bilsteins, maybe whoever installed them put spacers in the bottom to make the Konis fit properly.

Your Bilstein part number matches up with what my supplier lists for a 914-4.

When I loaded the full size picture, it looks like there is the end of a part number here, obscured by the undercoating that's all over.

Did I miss the part where you mention if this is a 4- or 5-lug strut?

It looks to have a straight arm so that would be a 4

Double check the part no. on the struts you got (insert bodies & box nos. should match the correct p/n ordered - Bruce confirmed ordered p/n was correct already), since they may have shipped the wrong ones to you (poor pick-n-pak at the DC).

Any of the Boge/Sachs, Koni or Bilstien inserts made for the OE Black/Gray Boge 914-4 Struts should be plug-n-play, as noted by BillC above.


Tom
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Problem solved! It turns out that neither threaded collar was fully seated on the strut insert. Admittedly, it was my fault, and I feel pretty stupid about it. I pushed them down by hand when I first got them, but it turns out it wasn't enough force. Bruce from Pelican emailed me and asked me to pull the collar up and take a measurement of the insert. When I put the collar back down on the insert, I used the Bilstein tool that lets you torque the insert into the strut and I was really able to apply some downward force. Both sides "clicked" and now fit easily into the struts. Thanks for the feedback everyone, and especially to the customer service at Pelican!

Easy to over think a problem. Check the simple things first. Glad we found the problem.