I moved this question over from the suspension forum due to lack of browsers there. I know the 1st gen guys will come through.

My new (slightly used) Tokico Blue strut cartridge is a little longer than the OEM part it's replacing (1984). Does that sound right? Well, it is. So the problem is that the large nut that holds the cartridge in won't seat well enough to get the threads started.

Looking at the seal inside that large nut, it seems that if I could get the top of the new cartridge into the groove in the seal, it would work. However, the fit is too tight to allow that to happen. Perhaps if I put the seal on the cartridge first, but I can't get the seal out of the nut. Is there a secret to this? Do I need to purchase new seals and just rip out (destroy) the old ones? Or can I get them out in one piece and reuse them?

Also, the factory service manual mentions using a "pilot" to put this nut on. I assume this is a special tool, used to guide or center things as they go together. However, the parts guy at my local Mazda dealership has not been helpful. Allright, he was downright rude. Is this "pilot" really needed, and if so where can I get one? Or am I misinterpreting the term?

Gotta be someone out there that can solve this problem. If so, thanks in advance.

 

BUMP....anyone?

 

IIRC, when I installed a set of Tokico Blues on my 1980LS, I came into the same problem that you're experience, which is that the threaded 'locknut' (for lack of a better term) does not thread all the way down flush with the top of the strut housing. The net result is that the threads can be seen at the top of the strut housing. On my 80, that didn't affect the threaded locknut's ability to hold the strut cartridge in place fully.

I assume that you added the proper, pre-measured amount of motor oil to the strut housing before placing the shock strut into position, as the strut cartridge is supposed to be submerged in a bath of oil to aid in heat transfer. If you added too much oil to the housing, you may be compressing the oil in the bottom of the housing which will prevent proper seating of the strut cartridge in the housing, i.e., not allowing the cartridge to drop far enough to start threading the locknut.

Normally, what would happen is that the oil will overflow the housing and you'll make a mess, but the cartridge will still seat properly.

Also, recheck the part numbers on the Tokico Blues that you purchased, as I know that they list a different part number for the fronts on my 84SE than the 80LS, this is likely due to different housing lengths related to spring tension higher and height being lower on the 84SE - if you find that the part number is different, you just need to get the right cartridges for the job - no other way around that.

BTW, rear shocks are interchangeable between all 1st Gen cars. HTH,

 

sort of on topic, how much oil and what weight do you add to the strut assembly? the haynes isn't too clear on that.

 

Fill it until it starts to overflowl. Rather then make a big mess, I slowly added the oil after fully inserting the strut into the housing. Then tighten the large nut to hold it in place. From what I've read, you can use any type of oil as long as its lightweight. I was going to use some 5w-30 I had laying around, but I used ATF fluid instead because it was thinner.

 

so just put the strut in and fill it to the top with something thin? sounds easy enough.

 

225cc of "shock absorber fluid", according to Haynes. The purpose is to transfer heat away from the cartridge body, to the strut, and eventually to the air. I suppose any oil would serve this purpose.

actually, my problem is that I can't get it to thread at all. Longduck, do you recall if the top of your cartridge fit into the slot in the seal? Did you put the seal on first, then the nut? If you got it to thread, you got it to go down at least 1/8 inch lower than I can.

yes, 79-80 are different from 81-85. SE is no different from base models. The ones I'm having a problem with are from an 85, going in an 84. I'll double check the numbers to make sure.

Anybody else have any ideas?

 

You didnt leave anything down in the bottom of the housing did you? Maybe an old spacer? And does the tokico come with its own nut? or do you reuse the stock nut? I cant remember now, getting older sux big time!

 

I hope you can reuse the nut cause the set of used tokicos i got didn't have any nut with them.

 

I got mine used as well, and did not receive a nut. Am attempting to use the factory nut. Am going nuts!

Has anyone bought new Tokicos and received anything besides the cartridge in the package?

I'll look in the tube for a wayward spacer.

 

My Konis had a nub on the bottom that was to be filled off to make it fit. This was even addressed in the instructions.

Hey, have you emailed the Tokico Techline and asked them?

 

my tokico's have a nut + a set of spacers + some instructions ... I'll try and dig them out as they're still unfitted (damn weather ... its snowing today!)

 

Kill No Cone: Great idea. What is their address?

MikeLMR: I would appreciate any info you could forward to me. Check your PMs.

Thanks.

 

the instructions :-

 

the parts :-

 

That's the answer!

The stock nut is replaced by the Tokico-supplied unit.

Now to contact the seller . . . .


Thanks to everyone for their help.

 

Seems I will have to do the same....