Help! Front Strut Replacement - Bushings rattling!

This suspension project of mine has been nothing but chasing my tail... it's been ongoing for several months, seems like everytime I get one thing buttoned up, the next thing goes.

Anyway...

I recently replaced my stock struts with the Bilstein 5100's. I've got them set on the lowest (stock) setting. When I assemble them, the inner rubber spacer and washer (the ones underneath the main top hat assembly that are on the inside of the spring/shaft) are loose! The lower washer (that supposed to mate up with the small shelf on the main strut shaft) has room to wobble and shake.

I didn't notice this initially with the assembly until tonight when I decided to swap springs as well. When I removed the struts, there's some definite wear on the strut shaft where this washer has been in contact because it's not seated firmly against the shoulder.

Anybody have any idea on this? I'm scratching my head. And a little worried about the wear on the shaft!

 

Here you can see the play...

 

Add a washer. My OME's were the same way.
Maybe someone else has a better answer.

 

You may be missing a piece. I had the issue as well and was missing an alignment spacer.

 

This helped me out.

 

Mechanicjon,

Where did you add the washers?

 

Ok. That makes sense. Mine were missing to start with.

I added one to the bottom. But it has to sit on the ledge like the other one.