Peugeot 84 505 strut assembly question

From: kenneth parker (elkeni@mac.com)
Date: Mon 05 May 2008 - 06:59:22 EDT

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    I am in the process of changing the seals on a fairly new, leaky
    strut on an 84 505 STI sedan (less than 2 years old). I took it
    apart today expecting to see a badly worn seal or broken spring, but
    all the old parts looked pretty good. The chamber looks good and the
    piston shaft doesn't appear to have any defects. The top of the
    spring-tensioned grease seal was a mess, dirty and greasy, though,
    when wiped clean, the seal and spring looked fine.

    As I think back to the time I did the job I remember when I filled
    the first strut with fluid, that I poured some fluid into the innards
    of the insert with the insert on my bench and not in the strut
    assembly chamber. Some leaked out of the valve on the bottom of the
    insert. I didn't realize that the insert had would leak fluid and I
    lost a few tablespoons of fluid by the time I realized what I had
    done. I put that side together with only the remaining fluid left in
    the individual can that came with the insert assembly, a few
    tablespoons short. On the second strut I knew better.

    I have a few questions and would appreciate any feedback offered.

            Should I have noted something obvious (more than just grease and
    dirt) when I removed the seals?
            Is 12 ounces of fluid the correct amount of fluid per strut?
            Is there a specific technique for filling the system (clearly not
    with the insert outside of the assembly chamber)?
            Could the fact that I shorted a strut a few T. of fluid have
    accounted for its developing a leak?
    Thanks,
    Ken

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