I've watched a number of videos, including Mod Mini, of front struts being removed (2004 Cooper S). Pinch bolt came out just fine and the strut is loose in the knuckle but when I try to drop the hub assembly it will not fall far enough to clear the bottom of the strut. Hence, I can not remove the strut from the knuckle. All the videos I've watched, folks simply hit the knuckle with a hammer and it moves past the bottom of the strut and creates an easy removal. I still have an inch or two of the strut still in the knuckle preventing removal. And, I've removed the three bolts on top and attempted to pull the strut out of the knuckle but because the knuckle is not moving down far enough that's not working either because there's no clearance at the top. I have not removed any suspension or brake components because it doesn't appear to be necessary from the videos I've watched. What am I doing wrong?

 

Have you disconnected the outer ball joint and the steering tie rod end?

 

I don’t remember disconnecting the outer ball joint for the struts, but I did pop the tie rod loose. Then I was able to push the knuckle down and rotate it forward and out. There’s just enough play to get a stock height spring and strut out with some mild cursing and maybe a pry bar. Lowering springs are way easier.

 

Have you disconnected the swaybar...that will allow more movement.

 

I did disconnect the sway bar link. I also tried cursing but that didn't help either. I have not disconnected the tie rod or ball joint because Mod Mini doesn't do it on his video. But, maybe he did and just didn't include it but that would be unusual since he's normally very detailed with his instructions. I'll pop the tie rod tomorrow and see if that allows the space I need. Thanks for everyone's help.

 

Disconnect the anti-sway bar link and just PUSH..!
Mine (2005 S) took a little fighting, but both sides came apart when I put adjustable upper mounts in place. I didn't take the whole car apart. Just the obvious and anti-sway bar link.

Mike

 

Could also try putting some compact
spring compressors on to shorten
the strut assembly if there’s room.
Also, use one of the spreader tools
in the hub to make things easier.
(a 1/4 in drive adapter can do in a “pinch”).

https://www.ecstuning.com/b-schwaben...-tool/scw3435/

 

Ended up dropping the suspension which was the only way to get the necessary clearance. Should have just done it to start with. Finished this morning and what a difference. I removed the Sport Plus struts/springs (front and back) and ride quality is MUCH improved.

 

Congrats! will be tackling this tomorrow to replace the strut mounts. Hope I dont have these issues, but I know I will... This car seems to be nothing but more difficult than anticipated. I must be a sadist. >.>

 

Did you mean masochist, or do you
just enjoy beating up on car parts
with BFHs, etc.?

 

Strangely, the passenger side control arm would not bend down far enough for the strut to clear and remove (until I dropped the suspension). The driver's side practically fell out by itself (with only the ball joint disconnected) which was a good thing since I was pretty frustrated by that time. All's well that ends well!

 

masochist indeed, but beating up on car parts is fun sometimes... Anyways, took my steering knuckles to a shop and it took all of 2 mins to get both the ball joints and the stuck axle out with an impact hammer. Got everything back together, although after replacing both axles, it sounds a bit sandy when turning full clock left and just doing slow donuts. Wheel bearings? Maybe low on transmission fluid?