I'm not one to hide my mistakes, stupid as they may be, as it may help someone in the future...

We are replacing the front suspension, including new Bilstein OEM shocks. Pretty much the only thing being reused are the springs. New control arms, new sway bar links, new sway bar bushings, new rotors and pads, new tires, etc, i.e. pretty much everything. This concerns the upper strut mounts and bearings (Sachs in this case, comes as an assembly with both parts) and the shock absorber.

We took apart the old strut assembly, carefully, and using spring compressors. All appears to be original, Jaguar badges on most everything, certainly the shocks and the strut mounts. I'm guessing these were original to the car.

We then started putting it all back together and the big mistake we made was using the new nut that came supplied with the Bilstein shock absorber.

The old factory assembly has the upper strut mount mount and bearing with the shock absorber rod going through the middle of it, then there is a small round spacer which I presume is a thrust washer, then the collared nut.

We did reuse the thrust washer, then used the new nut on the new shock shaft coming through the strut mount/bearing.

We installed that according to the instructions, replaced/reinstalled everything between that and the road and then when needing to torque the brake caliper bolts I asked my son to turn the wheels of the car.

Bang!

And we realized that the new nuts on the top of the shock shaft were not collared, thus not as wide, and somehow pulled themselves AND the center bearing out of the assembly - so now we have the strut with the spring at full extension, the shock shaft jammed into the bottom of the strut mount with the center bearing and nut still attached.to it. And the strut mount/bearing is still attached in the strut tower with the three mounting bolts.

In short, the collared nut sits on top of the main strut mount flange and by dint of the wider collar can't go through the center of it whereas the Bilstein nut can.

At this point, we've removed one side pretty much entirely again, and I suppose I will need to have the now loose center bearing pressed back into the new strut mounts and then reinstall everything reusing the old collared nuts (or buying new ones). Or would a flat washer work between the new non-collared nut and the strut mount flange?

I feel sorta stupid but oh well, it happens. I was hoping to never have to take this suspension apart again but figured if so it would be far down the road, not the same weekend....

 

Take it easy on yourself; we've all been (and most of us continuing be) there. You should see my list of bolixed projects!