Stripped strut rod, need suggestions
 

I was torquing my ST Coilovers rear to nut to 41 lb ft to fix some clunking noises. One side did it fine, other stripped. KW customer support said it should be 15 ft lbs but I doubt that will help my noises because I fixed front clunk by going beyond their 25 ft lbs front spec. Before resorting to warranty repair which will cost a few hundred, I'm going to get a tool to re-thread it.

Anyone have success re-threading a strut rod before? Anyone happen to know the thread pattern and size for the ST kit? Top nut is 17mm.

You would have to go to a smaller size you can't just rethread to the 17mm. I would be afraid of it failing when stressed. Not something I personally would mess with to be honest.
Why would it be a warranty repair if you went past their spec? It wasn't defective so will they cover it?

They sent me the form to cover it. I've been emailing them these past few weeks about the noises so maybe they're being lenient on those grounds.

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Then do the warranty repair before they change their minds?

Im with tcoat id just sent it in not mess around with it. Not likely you will be able to safely repair it. How long did you drive it with the clunk?

Odds of success: uncertain, possible, maybe even probable
Odds of them denying a repair after you fuck with it: high
Cost of just buying another damper, what, $150?

KW clarified it is not a warranty repair so they would charge me $135 to rebuild it plus whatever work to take off the stripped nut (I will try to DIY that off) plus shipping both directions.

Buying a complete replacement damper is $459 and it has a revised wet valve insert and male hex rod (opposed to dry insert and female Allen in mine which they discontinued).

:eyebulge:

Well, thanks for the info at least, hope you find a good solution.