How to replace camper shell and tonneau cover gas struts

Replacing gas struts on a camper shell door, truck cap window or fiberglass tonneau cover takes about ten minutes and one tool. The only real risk is a heavy lid coming down, so the first step is always to support it.

What you need

• A pair of replacement props that match your old extended length and force (how to measure)
• A small flat-blade screwdriver
• A helper or a sturdy prop stick (a 2×2 cut to length works)
• Safety glasses

Steps

1. Open and support the lid. Hold the door or tonneau fully open with a helper or a prop stick. Never remove both struts from an unsupported lid.
2. Release the top socket. Slide the screwdriver under the metal retaining clip on the socket and lift it about 1/8″. You only need to loosen it, not remove it. Pull the socket straight off the ball stud.
3. Release the bottom socket the same way and remove the old strut.
4. Check the ball studs. If a stud is loose, bent or rusted, replace it with one of the included ball mounts.
5. Install the new strut rod-down. With the thin rod pointing down, press each socket onto its ball stud until it snaps into place.
6. Repeat on the other side. Change one side at a time so the lid is always held by at least one strut plus your support.
7. Test. Remove the support, close the lid and open it fully a few times. It should rise smoothly and hold at full open.

If the new struts don't feel right

• Lid won't close or springs back: the force is too high, or the extended length is too long.
• Lid won't stay open: force is too low, or one strut isn't fully seated on its stud.
• Lid twists: the two struts don't match. Always install a matched pair.

Common questions

Do I need to remove the clip completely?

No. Lift the retaining clip just enough for the socket to slide off the ball stud. Removing it fully makes it easy to lose.

Which way up does a gas strut go?

Rod down, cylinder up, whenever possible. This keeps the internal oil on the seal and makes the strut last longer.