Rear Bilstein shocks breaking at the shaft

[virafp]

I was wondering if anyone else has had this issue. In 175K miles I have replaced the rear shocks three times. The rear shock shaft breaks, right at the top mount. Bilstein has been great replacing them under warranty, but my truck has never been off road, so am surprised.

Any thoughts?

Thanks.

 

[3rd Cruiser]

Didn't break, but on one of my rear shocks the top mounting point came unscrewed from the shaft. No problems with the fronts.

 

[2000UZJ]

I have broken/blew quite a few shocks. I haven't actually had one break in two, any pictures?

 

[99toylc]

I had my pass side brake at the shaft after 40k miles and replaced, the drivers side 1k later...

 

[virafp]

Bilstein

Im glad I'm not the only one. Bilstein said they had not heard of this issue.

Thinking about it, it happens every 40K. I now keep a new spare shock at home, and actually carry it on long road trips.

 

[ENGINE er]

Given how the shock mounts inside an oversize hole and relies on the bushing to stay centered, I wonder if there is a method of installation to keep something like this from happening?

 

[Sledhead800]

Both of my Bilstein rears shocks broke at the top of the shaft right where it's welded to the eye. Bilstein would not cover it. I noticed my new Bilstein part # had a extra digit at the end? What a PITA the upper rear bolts are, a 19 MM racheting box end wrench will help ease the pain.

 

[virafp]

Options

With my fronts being at 175K, I'm thinking of changing the shocks out.

Any other shock ideas for a stock suspension, not used off road, but driven on windy hilly roads?

 

[LCHardriver_02]

Just out of curiosity, but why not go back to OEM? Mine have 134K and have not broken. I need to replace them, but I have never been stranded or worried about breaking and I do off-road.

 

[virafp]

Shocks

I replaced the stock shocks at 15K, just felt that the dampening was inadequate, as I like a stiffer ride. Still love the ride quality of the Billy's, so really don't want to go back to stock. Any other shock out there that has the firmness and ride quality of the Bilsteins?

Thanks

 

[virafp]

Pictures

I have broken/blew quite a few shocks. I haven't actually had one break in two, any pictures?

Unfortunately no pictures

 

[arich]

Just happened for the second time and you k ow what it's about 40k. Really strange. I have a call into Bilstein.
As soon as I heard the rattle I knew exactly want it was this time.

 

[AutoCraft Aus]

The 100 washers and rubbers are extremely big diameter, so the leverage over the shaft is ALOT if you over tighten them, and there is no flex left for the shock to swing around when the diff moves around on the panhard rod.

The correct method is to do up the lock nut 2-3 more flats after you cant turn the rubbers or washers with your fingers any more.


To stop them coming unscrewed [also caused by side loading from over tightening] we tack weld every set we install to prevent them coming unscrewed, but can be ground off if ever need to be disassembled.


The Bilstein shaft is small dia, this means more oil, and less displacement when compressed, and is why they are designed this way.

 

[stonepa]

I replaced the stock shocks at 15K, just felt that the dampening was inadequate, as I like a stiffer ride. Still love the ride quality of the Billy's, so really don't want to go back to stock. Any other shock out there that has the firmness and ride quality of the Bilsteins?

Thanks

Big fan of Old Man Emu. Nice and firm, no issues. I have them on my rock crawler Disco 2 and my 100.

 

[99toylc]

Just happened for the second time and you k ow what it's about 40k. Really strange. I have a call into Bilstein.
As soon as I heard the rattle I knew exactly want it was this time.

Call this number : 800-537-1085 - when my both sides broke and Bilstein dealer told me to piss off I spoke wit a very nice Lady at Bilstein Warranty Service and she took care of the problem (didn't event have to send the old pair in...)

 

[SupraTuRD]

Blistein replacement shocks top out because they are shorter than OEM shock. Shocks limit down travel on our 100's.


The fix? Don't use Bilsteins on 100's. It's unfortunate because they are wonderful shocks on every other vehicle.

 

[AutoCraft Aus]

If you would like some that are longer, and better controlled, I know where you can get them.

I cant say I have used the U.S 100 Bilstein version.

We have been using a 650mm long Bilstein for the rear, and we have just worked out a 670mm long 50mm lift shock to release soon with Icon [same for 80's too]

 

[petrotk40]

I think Just Differentials has a Bilstein 5100 for our trucks if you want to stick with them. I love my fox's more with every mile I drive.

 

[Musky]

Yes, this happened to me also. I thought my mechanic didn't install them right but after that I went to the OEM shocks that were absolutely dirt cheap and they haven't broke in over 2 years. The front billes seem to be fine but the backs snapped like toothpicks.

 

[arich]

Bilstein is sending me new shocks for the rear, no questions asked. I was in the system from the previous break.
I hope there are no problems with the shocks on our 2011 200.
Anthony