2009 X5 35d Front Strut Rebuild DIY

[FunfDreisig]

Yesterday I began rebuilding the front struts on our 2009 X5 35d with standard suspension. I used SeanC’s excellent DIY post for the R&R

https://xoutpost.com/bmw-sav-forums/...ive-drive.html

These are some notes/photos of the strut rebuild.

The upper Guide Support on the right side had been completely pulverized allowing the large “Articulated Disk” (AKA washer) to impact the Support Bearing Flange on rebound.



The lower Guide Support was still there but on its last legs.



Strut rebuild station. Note blue paint on spring and flange that indicates the side which faces outward when installed.



The top coil of the spring is captured by the upper spring pad, which is inside the Support Bearing Flange. So as the spring is compressed the Support Bearing Flange becomes more and more angled to the strut shaft. Gently prying the top coil of the spring out of the upper pad straightens the Support Bearing Flange eliminating the bind and making it much easier to extract the shock absorber.



Extracted shock absorber with the remains of the guides and bump stop.



Rebuilt Strut. With the Support Bearing Flange removed from the spring, the shaft could be inserted through the Support Bearing Flange without it binding. The Bilsiteins, at rest, are several inches longer than the old shock. So the shaft fit through the flange before the lower spring pad touched the spring. The extra length provides clearance for aligning the top of the spring in the upper spring pad and positioning the lower spring pad during assembly.



Rebuilt right front strut installed.



Funf Dreisig
2009 X5 35d std suspension