Koni Struts and Shocks-What are the "must-have" tools

With 315,000 miles on the originals, I am about to tackle this job on my '03 Jetta wagon. What tools do I need? Which are "must-have" and which ones are nice to have but not necessary?

I am trying to avoid spending money on a bunch of special tools that I will only use once. I am hoping that I can borrow/rent the must-haves from Advance Auto down the street.

Any advice would be appreciated.

https://www.fcpeuro.com/products/vw...sing-scw3435?gclid=CJX_vNPA28cCFQenaQodZbkDmQ

http://www.amazon.com/ABN-MacPherso...&sr=8-1&keywords=strut+coil+spring+compressor


All i really needed!

Soak everything in penetrating oil specially the part where the shock goes into the steering knuckle. But the parts werewolf recommended is all you really need (spring compressor & Knuckle Spreader) You may need the counterholder tool

Just read up http://www.myturbodiesel.com/wiki/strut-and-shock-absorber-replacement-for-mk4-vw/

I recently had the struts out of my '02 gas wagon and you'll almost surely need a counter hold tool for the top nut. I have a tool set for shocks and struts that had what I needed but I also found a spark plug socket that would do the job. I'm not positive right now but I think it was 13/16th or 7/8in.

Ha! Since this is a TDI you might not be familiar with spark plug sockets but they typically have hex flats at the top. I was able to use the socket with a wrench on the flats and an allen key in the hole where the socket wrench would go to loosen mine.

+10 on getting that strut removal tool though! I spent half the time on the job trying to "get something to work". I'm both broke and a tightwad and that type of tool is going in my toolbox ASAP.

macmatic said:

I recently had the struts out of my '02 gas wagon and you'll almost surely need a counter hold tool for the top nut. I have a tool set for shocks and struts that had what I needed but I also found a spark plug socket that would do the job. I'm not positive right now but I think it was 13/16th or 7/8in.

Ha! Since this is a TDI you might not be familiar with spark plug sockets but they typically have hex flats at the top. I was able to use the socket with a wrench on the flats and an allen key in the hole where the socket wrench would go to loosen mine.

+10 on getting that strut removal tool though! I spent half the time on the job trying to "get something to work". I'm both broken and a tightwad and that type of tool is going in my toolbox ASAP.

Click to expand...

Well, it's decision time for me then. The spring compressor is sitting on the rental/loaner shelf at Advance Auto. The others (spreader tool and counterhold tool) are mail order only. If I order them, I will not be able to take advantage of the long weekend to get this project done.

I may give it a try and if it turns out to be too much of a PITA, I can always button it back up, order the tools and wait until next weekend. (Rather not, though.)

richmondvatdi said:

Well, it's decision time for me then. The spring compressor is sitting on the rental/loaner shelf at Advance Auto. The others (spreader tool and counterhold tool) are mail order only. If I order them, I will not be able to take advantage of the long weekend to get this project done.

Click to expand...

I just checked my "new" 2003 that I brought home this week and a 13/16 plug socket worked fine to loosen the strut nuts. No need for a special tool if you can get a plug socket for $5.

If you've got a variety of mechanical stuff around the house I'm sure you can do this without the special spreader tool but it would be much easier with. I tried to make a copy of the tool out of a stubby 1/2" drive extension but it broke on me and I think what finally worked was driving a fat screwdriver or a chisel into the gap. I'm not sure now... I may be repressing what I had to resort to...

If you go that route be sure you're not going to drive anything into the strut tube. Oh, and also +1 on the penetrating oil all around the strut to spindle area. I use Kroil mostly but I also like PB Blaster.

But you're right, you can always bolt it back up and try again. I nearly did that myself.

Well, the 13/16 spark plug socket took about 2 seconds to find at Lowes, but a 7/8 socket with hex flats on the top (needed for the new Koni nut) is a bit tougher to find.
Would this work? (I know I can't get a torque wrench on it, but that can't be a critical torque value, right?)
http://www.harborfreight.com/78-in-oxygen-sensor-socket-69022.html

You can use a 1/4" extension and ratchet as a spindle spreader. The 1/4 drive bare fits in the gap and spreads enough to get the strut out. Little trick I learned in the field when you dont have the special spreader.

That looks like it should do it but practically any auto parts store should have a 7/8 plug socket on the rack.

What Koni's are you putting in?

Plan on replacing all of the other hardware associated like the strut bearings and such...

macmatic said:

That looks like it should do it but practically any auto parts store should have a 7/8 plug socket on the rack.
What Koni's are you putting in?

Click to expand...

Thanks. None of the local auto parts stores had it in stock, but I did just found a 7/8 plug socket online in the NAPA warehouse in Richmond.

I bought these: http://www.koni-na.com/street.cfm Koni was running a good sale through 8/31. Fronts and rears for $282 shipped.

I bought the suspension refresh kit from Bora last year for the TT LCA bushings, but kept all the other stuff (bump stops, mounts, etc.) for this job because I knew i would be doing it eventually.

Edit: Do you have a grinding wheel? I think I'll try to DIY a spreader again tomorrow from a 14mm bolt with a 19mm head. After looking at a few pictures I'm fairly sure I can make one that will work with a bench grinder.

Ah, so I missed the Koni sale again... Let me know what you think of them on the wagon, I'm also thinking about the STR.T's on the '03 wagon I just got.
In the meantime I'm going to run some very fresh looking VW OEM shocks and struts I just pulled in a parts yard from a 2002 1.8T along with the rear springs. Poor car looks like it got new suspension and brakes about a month before it met a telephone pole face first.

I bought a set of 2004.5 GLI springs on craigslist and I've got to see how much the butt droops with the sedan sport springs so I may have to used those poly rear spring boosters or try the normal 1.8t rears.

macmatic said:

Edit: Do you have a grinding wheel? I think I'll try to DIY a spreader again tomorrow from a 14mm bolt with a 19mm head. After looking at a few pictures I'm fairly sure I can make one that will work with a bench grinder.

Ah, so I missed the Koni sale again... Let me know what you think of them on the wagon, I'm also thinking about the STR.T's on the '03 wagon I just got.
In the meantime I'm going to run some very fresh looking VW OEM shocks and struts I just pulled in a parts yard from a 2002 1.8T along with the rear springs. Poor car looks like it got new suspension and brakes about a month before it met a telephone pole face first.

I bought a set of 2004.5 GLI springs on craigslist and I've got to see how much the butt droops with the sedan sport springs so I may have to used those poly rear spring boosters or try the normal 1.8t rears.

Click to expand...

I had the Koni reds wagon specials on the 02 wagon and they were a great handling and riding suspension. Replaced them @ 90k miles as they had rusted out.
Now have STR.T's on it and it still rides and handles fine. They are also rusting.

I had a deep well 13/16 socket that I ground two flat places on the sides of it. Put a 15/16 wrench on it and it works perfectly. Been using it for several years

Dirtracr95 said:

You can use a 1/4" extension and ratchet as a spindle spreader. The 1/4 drive bare fits in the gap and spreads enough to get the strut out. Little trick I learned in the field when you dont have the special spreader.

Click to expand...

Good tip, I'll try this! I'm going to try rolling my own spreader from a big bolt too though.

Oh the Metalnerd tool is sweet. I put in Koni Yellow FSD's last spring and it was cool: tap it in the skinny way rotate 90 degrees. It is true that you will want to put some PBlaster or equivalent on as even spread I ended up using my 3 foot pipe wrench to get it to move.

Just for giggles when I was installing the new strut and it was sliding down nicely I released the spreader tool and man it stop dead.

I like to support Metalnerd as he is a good guy. http://www.idparts.com/metalnerd-strut-spreader-tool-a4a5-p-400.html

Curious Chris said:

I like to support Metalnerd as he is a good guy. http://www.idparts.com/metalnerd-strut-spreader-tool-a4a5-p-400.html

Click to expand...

I'd like to also but I've got to be pretty thrifty right now so 15min with a grinder beats $15 on a tool I can probably make. I'm definitely planning to buy all the new parts I can from supporters of this and other forums.