Koni strut replacement issues Options

[Cvrguy]

I replace my very old Koni front strut inserts with new adjustable Koni inserts. All went well until I was tightening the top nut. When trying to get the required 59 lb/ft on it, the alignment tab on the washer sheared off. I replaced the washer and tried securing it with large channel-locks while torquing the nut to no avail. The same thing happened again. Yes, I lubed the bottom of the nut in both instances.

It seems to me that the washer material isn't hard enough or it requires a tool that I don't have. How critical is the torque? What tool might work?

[rjames]

What do you mean by ‘alignment tab’? Are you talking about the tab on the lock washer that gets bent upward after tightening the nut? Are you bending the tab up before tightening the nut? If so, that’s the problem.
No lube on the nut should be necessary.

[Cvrguy]

What do you mean by ‘alignment tab’? Are you talking about the tab on the lock washer that gets bent upward after tightening the nut? Are you bending the tab up before tightening the nut? If so, that’s the problem.
No lube on the nut should be necessary.

When looking at the large washer that goes on top of the rubber top bushing, there is a rectangular notch on the outer rim. There is a corresponding tab on the inner rim that slides into the groove in the strut shaft. I presume that this notch and tab pairing, when secured by holding the outer rim while tightening the nut, fixes the shaft of the strut. This should allow the correct torque to be set.
It seems as though the material used for this large washer is too soft, as it shears off pretty easy when the nut is turned. I have now viewed about 10 YT videos of how these strut inserts are done and in all of the, the nut is simply installed with an impact gun. What's up with this??? The nut is supposed to be torqued to 59 lb/ft.

[L-Jet914]

I used a spanner wrench (aka coil over adjuster wrench) to hold the upper large washer that sits on the rubber strut bushing and was able torque the upper retaining nut to the proper torque of 57.9ft lbs or 58 if you want to round up. No lubricant at all. Then staked the lock washer to the nut like the old one that was on the vehicle before replacement.