So after lunch, spent about 30 minutes going around looking for that socket. Found it eventually, and tightened down the driveshaft bolt to get it into the hub on the left side.
So time to get the strut into the other hub. The other side seemed to go in much quicker:
The rubber mallet was able to get a lot further compared to the other side:
You can see the metal tab bit on the strut as it goes through the strut bolt hole. Presumably, the bolt prevents the strut flying away due to this tab, in addition to it being bloody tight I guess.
Then a lump hammer and a few more taps to get it home:
Or at least nearly so. This took an hour in comparison to two for the other side. No idea.
I'm guessing the yellow paint job on the Bilsteins add a thickness, the hubs having years of corrosion, and possibly the spreader tool I used not spreading enough, were contributing to this crazy struggle I've had.
If I get to a position where the struts need to be separated again for whatever reason, I'll probably need to research and see if there's a more significant spreader tool, just a fraction of a millimetre more was probably going to be enough.
Anyways, fitted the strut to the turret:
Then got one of the strut bolts and checked it goes in:
So that appears to be fine. So then it's the same as the other side, tapping with a mallet to get the driveshaft into the hub, then lowering the arm to get the ball joint bolts in:
Once a few more taps got the driveshaft in enough for the bolt, then began tightening it down:
So it looked like this before:
Then once the driveshaft bolt couldn't tighten by hand anymore:
So once the ball joint nuts are tightened up, and the track rod end nut, then only torquing them up to spec is left.
Well, bar the strut bolt, so for that just went mad with the Alumslip:
Then put it into the strut, rotating it as I went in to try and get the grease spread out and filled the strut void as much as possible. The end wasn't greased, for the nut to be winded in:
It's an 18mm nut, and an M14 spline bit for the bolt, just hand tightened for now.
Then slapped some corrosion block grease where the bracket mates to the hub and copper grease on the bolt:
Need to tighten this down later (or maybe source a stainless replacement).
Then dry fitted the wiring to the Damptronic:
The Bilstein dampers are supplied with an adapter to connect the Damptronic to the OEM connectors, fairly self explanatory, but the routing:
Isn't super clear, so I've left the clip on the strut captive bolt and I'll plan it later. This is mainly to not have any connectors exposed.
With the front struts only needing torquing, time to do something else:
So given the right strut was just done, made sense to sort out the washer bottle, so attached the hoses and connectors to the washer bottle. Looked like it was fairly idiot proof. Used some of the dielectric grease on the connectors whilst I was there.
Then the wiring and hoses were clipped to the top of the washer bottle, and essentially just wedged the washer bottle in:
Takes a bit of wiggling and faff, but it eventually goes in, including that separate side bit, which also needs the hole in the end going through the opening in the windscreen cowl area. Started the nuts and bolt for the washer bottle, to be tightened later.
So with that, went on to something else:
Got the rear level sensor, dabbed some dielectric grease around the connector, and then fitted the top level sensor bracket to the subframe. This is tightened to 5Nm. The top bolt is a little bit of a faff to get to, best to tighten it down first with the bracket swung away, then put into position once ready for torquing. It may be easier to use extensions for the top, but was able to get the small torque wrench in there.
I started dry fitting the bottom:
But decided to undo it for now until the suspension bits on the rear are fitted proper. Not gone round to this as jacking the arms will be involved.
So just the Haldex controller left, so put dielectric grease all over the connectors to try and stop dirt getting in and making it a faff to remove in the future.
Then connected it all up, bolted the top bolt to 9.5Nm, and cable tied the bottom:
Had to use a pair of smaller ones to do so, but tidied up:
Who knows, I'm sure this'll be fine.
So that was pretty much the day gone unfortunately. Got the flap wheel and started to clean up the wheel bearing faces and the brake disc, and have just used the wheel bolts to dry fit the brakes:
They'll be taken off again in order to sort out the torque tightening of everything, but that's me for the week I think.
Was expecting a lot more progress, but the faff of the struts into the hub really kaiboshed the day, and the ripped coolant hose just felt like icing on the cake really.
Technically, I could still get the car's ignition on, which would be enough to get the washers activated, which could be something I could do during the week, to basically flush out the system.
I'll need to disconnect the hoses from the jets front and rear and the headlight washers, fill it with some water and just use the stalk to squirt whatever out. This is mainly because of the bits that were in the washer bottle, which implies said bits are probably in the washer hoses. Could be the cause for the blocked washer jet, so want to make sure that doesn't happen again.
Looking at the spreader tool I have, it looks like it may have suffered some wear from use, maybe that's why it was such a struggle? I need something to spread the hubs further?
Well, doesn't matter know. For all intents and purposes, the suspension is fitted on the car, sort of!
Maintenance: £2190.67
Upgrades: £1322.97
Miscellaneous: £671.37