New toyota 4 pack leafs... defective?

Posted here for the most eyeballs/opinions.

I purchased a TRD off road dblcab shortbed new in 2009. Had Eibach 620 front coils, Bilstein 5100's all around and a Toytec Add-A-Leaf installed within about 4000 miles. Truck has driven perfectly for ~ 7 years.

I got the recall letter for leaf springs, so arranged to have my original leafs(3-pack + Add-A-Leaf).Replacement took place Monday and the dealer also returned my Add-A-Leaf(not installed) per my request.

Because of schedule, girlfriend picks up truck and reports that the rear is much lower(rear is now back to stock height without Add-A-Leaf) and that it rides a bit rough/firm. Ok, I'll check it on Wednesday.

Upon driving, it is immediately obvious that the rear is bottoming out on the shocks over very slight bumps or dips in the road. Had my mechanic friend confirm while I jumped on the bumper while he observed. Leafs appear flattened out and the rear is bottoming out the shocks, not hitting the bump stops.

Sorry about the long backstory...

The Bilstein 5100's(part# C478 or C476) are direct replacement for factory shocks. Same length?
Is this correct?

The truck has 48,000 gentle, old man, mall crawling miles. The shocks may be worn out a bit but are not leaking and appear to be in good condition. But even if they were shot, the rear would still be supported by the springs.
Is this correct?

My thoughts are that something is wrong with the replacement leaf pack.

I already have a call in to the service manager at the dealer but am seeking expert opinions.

Thanks guys, and I'll post this to the suspension forum shortly.
I've forgotten an awful lot in 7 years since I last researched suspension/lifts.

I welcome any comments, opinions or suggestions.

 

IF those shocks were direct replacements it should still never bottom out the shocks and should hit the rubber bump stops long before the shock bottoming out.

The leaves are designed to be near flat anyway.

 

Curious - if you were happy with the setup you had, why did you take it in for the spring swap?

 

ive heard they are longer then stock shocks for lifte applications. so im guessing the collapsed length is also longer. could be possible that without the aal it is bottoming out. ive heard and read lots of stories of 5100 blowing out or leaking on stock replacement. i could be wrong. but if they were designed for up to 2" of lift could be an issue

 

Jimmyh- According to Toytec, 5100's are direct replacement for factory shocks, but since they are bottoming, maybe they are too long?

glwood6- The leaf recall was for a safety issue and my set qualified, so I had them changed. Plus, free new springs were free and new.

VLocos24-This is what I'm trying to confirm, and from memory, they are stock replacements along with Toytec confirming that yesterday.

To me it seems that the shocks may be too long. But doesn't the truck basically ride on the leaf springs and the shocks role is to absorb the harsh bounciness of the spring?

The springs don't appear to be carrying any of the truck weight at all, which makes me think they might be defective. On the other hand, if the shock is too long and then the springs aren't being allowed to carry any of the truck.

Uhg, still not sure what to think. I don't want to pester the dealer if my issue is a shock that's too long, but I do not think they are.

Thanks for the input guys, appreciated.

 

https://www.tacomaworld.com/threads/new-toyota-4-pack-leafs-defective.432853

 

The leaf springs carry ALL of the weight of the truck always.

Regardless if the springs are defective or not IF you have the stock rubber bump stops you should hit those before you bottom the shock.

The Only purpose of the shock is to absorb sudden impacts to the axles. Shocks should never carry any weight with the exception of Air Shocks which are special and made differently.

I think you have an assembly issue or the shocks are too long causing them to bottom out.

Post up some pictures of the setup from different angles.

 

From their web site:

BILSTEIN B8 5100 series are designed specifically to help your lifted truck, Jeep or SUV reach its pinnacle in ride performance, while supplying the correct tuning and length for your specific lift.

Specs for rear: I'm not sure what the stock shocks are for the collapsed length.

However Bilstein says from a zero to 1 inch lift.


B8 5100 - Shock Absorber

Part Number:

$91 24-186728 5100 Series Shock Absorber

24-186728
Old Part Number: F4-BE5-C476-H0

Series: B8 5100
Drive Type: 4WD
Position: Rear
Descriptor: Rear Lifted Height: 0-1"
Quantity Per Vehicle: 2

Collapsed Length (IN): 14.02
Extended Length (IN): 22.94
Collapsed Length (MM): 356
Extended Length (MM): 582.7

Finish: Zinc Plated
Reservoir: No
Body Design: 46mm ID Smooth Body (Non-Coilover)

 

I have a 2" lift in the rear and those are almost my exact measurements for my icons and my icons are considerably longer then my stock shocks. If the problem started after they installed the leafs I would go back. There is still a slight possibility they did something wrong

 

The new "HD" leafs are a joke. I was not happy with them at all. I ended up adding air bags to my truck. I put a 400lbs wood stove in the truck with just the "HD" leafs and road on the bump stops all the way to my moms house. I had the stove over the rear axle too. With my old leafs i could have a heaping bed full of fire wood and not be on the bump stops.

 

so then new leafs are much weaker? id ask for my old leafs back

 

I would say they are. But my old ones are gone with my old frame.

 

Thanks Jimmy, you are right. After a bit of email tag with Toytec (who supplied the shocks, springs and add-a-leaf, I think they gave me the answer.
Bilstein 5100's are factory sized replacements, unless you have the add-a-leaf and then they come with shock extenders to accommodate the add-a-leaf.


So I just need to remove these for now because the new 4-pack leaf has not lifted the truck to where the height that the 3-pack+add-a-leaf ended up, resulting in the shock being too long for the current stock height.
For now, I'll remove the extenders and run the rear at stock Toyota 4-pack height, since the add-a-leaf from the 3-pack is not compatible with the new 4-pack, until the new 4-pack leaf arrives from Toytec. Hmm, after 7 years maybe I should get some new shocks while I'm at it.

Thanks all for the help and suggestions.

 

Your images are not showing up.

Glad we could assist.

 

not sure about the images but will try again.

thanks again Jimmy

 

I had not seen any extenders previously. Interesting...