BILSTEIN 5100 FRONT SHOCK INSTALL, OEM TOP WASHER DID NOT FIT OVER POST.

Sup guys, thanks for taking the time to read here. I just installed some 5100s on my 09 Tacoma to level out and stop the slight rub from my new wheels and tires. The top bushing was loose and the nut would not tighten any more, so I took off the top nut, washer, and bushing. Here I found that the washer did not fit over the shank of the post. There is a lip right at the end of the threads, so I drilled out my oem washer and added 2 more washers so that it fit and pressed the bushing. I called Bilstein and they said they never heard of this, and that the 5100s are made to fit all oem components. I also pointed out that there was slightly more threads showing on passenger side than driver side, but they said that's common due to worn suspension. They are great though, no more rub, looks better leveled out (went with the .85 lift) and the drive is a lot more smooth as well. I was just curious if any of you ran into this, or have heard of this. Heres a pic of my custom washer job, lol..Have a good one folks.

 

It sounds like you didn’t put the inner washer on the shock before installing it.

It should go washer-bushing-top hat - bushing - washer - nut. There’s nothing on the inside to keep the shock shaft from continuing to slide upwards.

Or maybe the inner bushing is just super shot. Did you reuse the top hats?

For reference, the top hat is the top part of the coilover with the three little studs in it.

 

you didn't use the bottom bushing under the hat

 

There is no bottom bushing. The bottom bushing is part of the tophat. It goes plastic boot- washer- tophat- bushing- washer- nut.

In the pic, the plastic boot is missing. Also, it's best to install new tophats with the new shocks.

 

There is a bottom bushing. It is part of the top hat but can come out as it’s it’s own piece. It’s just wedged in there and typically stays put.

 

OK, I just know on my new KYB top hats the bottom bushing appeared to be molded to the tophat. I didn't try yanking it loose.

 

I did reuse all original components, and we followed the directions, the plastic sleeve is there you can see it in the bottom a little. The bottom bushing and washer are also there..everything was for sure done right, the top of that post has a lip before the top threads, it was that lip that made me question since the bushing wasn't getting compressed.

 

Well, somethings wrong under the tophat. The plastic boot is supposed to be setting on the step that your bottom washer is against. When everything is installed correctly, you shouldn't be able to see the shock shaft.

 

i used the BILSTEIN 4600 and mine compressed I used new WHEELERS stud bushing kit for the install, unless you got the wrong model struts it should work reusing the existing bushings

 

looks like the spring or shock isn't compressed??

 

Yea I noticed the boots are just there, what exactly do the boots connect to? Were they supposed to be mounted some how to the top hat? And I noticed the bilsteins for the new tacomas dont even come with dust boots on the front. And that still doesnt explain this lip at the bottom of the threads. I'm looking everywhere for pics and none have a lip where the threads meet the post.

 

There is a steel spacer about 3/8" thick in the top part of the plastic boot. That spacer goes against a shoulder on the shaft. Then the washer goes on top of that spacer. Maybe you're missing the spacer. On my 5100s, that spacer/plastic boot came already on the shock with a tight fitting white plastic washer holding it together.

 

https://www.tacomaworld.com/threads/problem-with-front-bilstein-shocks-help.463515/https://www.tacomaworld.com/threads/problem-with-front-bilstein-shocks-help.463515/

 

based on some threads it seems the bushing under hat is shot that causes the protrusion at the top stud, you can get a whole new replacement set of bushings upper and lower from WHEELERS offroad about $30-$35 https://www.tacomaworld.com/threads/strut-upper-bushing.427649/https://www.tacomaworld.com/threads/strut-upper-bushing.427649/

 

https://www.tacomaworld.com/threads...washer-kit-assembly-one-bushing-extra.207581/

 

Yes I noticed that washer, and the boots were on fine on the install, just like this guys video, he didnt do anything with the boot...www.youtube.com/watch?v=nqzy3U7yYsQ

 

glad I paid somebody to do this job

 

WOW! The guy in the video is a goofball! He should stick to making hamburgers at Burger King.

 

This is what you should have:

 

^note in the above pic there is a bushing thats stuck on the underside of that tophat. Its likely what OP is missing.