Rear hatch strut nightmare
 

When I purchased my 85 300td it came with two new, still in there package, support struts. A week ago I decided to replace them thinking this would be a quick job. After removing the overhead panel to get to the bolts I made a trip to a store to get a large torx bit. I did not fit properly. Too sloppy of a fit. I called the local dealership to be told that a metric allen wrench should fit it. It did not. I called again, spoke to someone else who told me it takes a m8 triple sqaure bit (12 points). After a hour of phone calls I finally had one on the way . $25 after shipping and handling cost. Ouch!
When the tool arrived I went to work. Fisrt bolt no problem. Second bolt the tool just turned inside removing little pieces of metal. Now what. I called the dealership to get a new bolt because I was going to destroy this one getting it out. They wanted $16 for a bolt that was going to have to come from Germany. No thankyou.
My solution. I welded a nut to the bolt using a mig welder. Then backed it out with a wrench. While I was at it I welded a nut to the other (not stripped out ) bolt.
After fighting to get the new struts back in place. I lowered the hatch only to hear a hissing noise coming from the left strut. I then proceded to let out a string of expletives that sent my dogs running for cover.
If anyone needs this special tool let me know and Ill ship it to you. I'm going to have to replace one of these new struts, but now I can do it with a wrench.

85 300td





85 300td

txpo
 

I meant to say "first".

my mom's td is a bit saggy, I may take the wrench off your hands.
John

I did mine with little to know problems. But I really hate messing with anything with an allen wrench. The metal is to soft on the bolts....

Hatch strut ramblings, etc
 

Before you do anything, check your particular model to see if they used allen hex bolts or torx (make that triple square) bolts. Early TD's differ from later ones in this respect.
I also discovered the fuel expansion tanks are metal in the '79 TD and plastic in later years. Found that out when my '85 started smelling strongly of diesel fuel in the cabin, then tried unusuccessfully to patch it with hot glue and epoxy. Finally got a metal one to replace it now it should last a hundred years.

What pisses me off about the hatch struts is they don't seem to last very long! I've replaced both sets in my TD's and the one I changed 5 years ago is now unable to hold the hatch up on a cold day. On a hot day they work fine. They don't get used but once or twice a monoth, its not like I use them a lot but I think they are under pressure while the hatch is closed, so that may explain it. Changing them is no fun either! I have a 2X4 of the right length to prop the hatch up, its a calibrated MB tool :rolleyes:

Its a bad deal, but OTOH I remember a friend's ricer, his gas pistons for the hatchback only lasted about 5 years, so maybe its an industry-wide problem?

m8 triple square bit
 

John if your strut bolts take the triple square bit I will gladly send it to you and any else who needs it.

i picked up a triple square set at nortern last time i was in there. haven't used it yet, but i know i will. under $10, i think, for 3-4 bits?

I went through the same thing. Didn't look in the hole just stuck and allen wrench in there and stripped the first bolt. Had the M8 triple square wrench in my toolbox and the second one came out with no problem. I started drilling out the first one but never finished. Put in one strut and it is working fine.

Bought some parts from Germany and included that bolt on my list. I got it used for $5. Bought my struts from an eBay place in Miami. Sent me the wrong ones the first time and it took a month to get it right, but they did send me the correct ones the second time.

TORX and triple square (XZN) are NOT the same thing.

Neither INHEX (allen) or TORX wrenches work for XZN screws.

Don't blame the car for not using the correct tool.

Wonder if that Miami place was Mercedes991?
http://toolhaus.org/cgi-bin/negs?User=mercedes991&Dirn=Received+by

I have warned people on this forum about that ebay seller, I had a very bad experience w/ them!

There are two wagons in the yards here- I just pulled a set of bolts that are allen headed from one of the wagons with good threads and pretty good allens. First one to PM me gets the set for $20 delivered to their door. Not many wagons in the yards... and if this is too much then I'll keep them myself- I do have two wagons....:cool:

Did you pull the heads from the wagons? They'll be worth a premium since they have the hydraulic pump feature. I stupidly forgot to do that some years ago when there was a wagon in the local pick and pull.

If you want one I'll pull it. The wife may not be real pleased with a wagon head in the laundry room...:mad:

Wagon parts?
 

If they are pre-82 they should have metal fuel expansion tanks, behind the spare time.
People with wagons are having leaks in that area (theres a thread running about using Bio in a wagon and the resulting leak at the exp tank) Someone will someday want a metal tank if their plastic tanks are cracked and I'm sure they
would pay dearly for one if they need it because the dealer price will be astronomical for another plastic tank :rolleyes:
Clean spare tire covers are nice to have also and BTW I need a nice palomino or brown one. If there happens to be a clean example grab it for me!
kerry edwards is right, don't let the heads go to the crusher!
I remember pulling a head with no pin puller for the chain guides, all I had were some hand tools. Someone had already taken the IP but there it was, a free head beckoning for me to remove it. I was all by myself and I finally took a small hacksaw to the chain but then I had to lift off that head, what a SOB! You need a strong back to DIY (which I don't have!)