1600e front suspension inserts

[colin.o 0]

Hi, any help appreciated. I have removed complete front suspension strut and unscrewed top of leg and removed piston and drained off fluid with intention of replacing with nos insert. But the insert does not seem to go in far enough for the top to screw back on ?  There is metal seal in the bottom of the leg does this need to be knocked out ? I have 2 pair of inserts one being a mk2 and the other lotus speck mk2 1600e. Neither seem to go in far enough to screw retaining  cap back on . 

[Dave A 17]

not sure if this will help. in the picture the top strut is early series 1(67)  the orange one is later series 1(68)  the next one down is series 2 and the bottom one is Capri.

I'm not sure if 1600e is the same as we didn't get that model in my country. I assume you got the compression valve out of the bottom of the leg when you removed the rod and cylinder.

cheers.

[colin.o 0]

Hi Dave thanks for your info, the problem I had was caused by not having the top screw parts that hold the insert into the leg. I bought some inserts years ago ,got them out an put them into the leg but the original top fastener won't go back on . Luckily I had bought another set and when I opened them they included the top bit , problem solved . Tried to upload picture but site won't let me. So anyone buying inserts check the top screw fasteners are included unless replacing existing inserts. Cheers Col 

[G.O 20]

The internal length of MkII legs can differ by quite a large amount, which means some inserts can be too short and will need some packing shims in the bottom of the casing while others can indeed be too long and the cap won't be able screw down.

 

Inserts are pretty hard to find today and more than likely are old stock so seals can already be degraded before use.  Best answer is to send the legs to GAZ who will rebuild a full wet leg to whatever spec you want using all new parts, most of which they machine themselves on site.

BTW, don't forget when fitting inserts to put some oil between the insert and the leg casing - partly to stop the casing from rusting from the inside out, but also to help the heat transfer away from the insert.