Issue with Bilstein 5100s?

Installed Bilstein 5100 (BE5-C477-T1 (24-280785) from Wheelers) front shocks with Dobinson C59-302 (586 lb, 1.6in lift) springs. Also installed Deaver single AAl from Toytec.

I have a ridiculous amount of bounce when driving and it seems like no damping. If I hit a bump at about 20mph the truck bounces and rocks (front goes up and down about a foot) and I have to pull over to wait for it to stop bouncing up and down. Seems to me like this would be an issue with the shocks not damping well. Hoping someone here a little smarter/more experienced can point me in the right direction of what needs replaced in this set up to make it driveable. Could it be that these are the older model of 5100 in that have a different valving? Haven't replaced rear shocks yet. Was going to order 5100s for the rear but it seems like I'm having major issues with their damping in the front. Seems like everyone I could find has loved their 5100s so wondering if I got a bad batch?

 

Maybe post a pic of the setup? Are the coils on the bottom perch? I have 5100s with headstrong coils on the bottom - 2” - and the ride is great. I’d guess something isn’t setup right so maybe post a few pics and others will chime in ...

 

Welcome to TW
We are going to need to see the truck and suspension pics to help you out.
Otherwise we are flying blind.

 

Coils are on bottom perch, will post pics first thing tomorrow

 

It could be that the coils are too light at 586#. The word is the stock springs are 700#. It's more work, but you could try putting them back on the stock or aftermarket 650-700# coils.

 

remove them and replace with BILSTEIN 4600 ASAP!

 

OP's 2nd gen didn't come stock with 700 lb springs In any case a lighter spring wouldn't cause an underdamped behavior. Just the opposite actually.

 

You need to tighten that top nut more. The bushing should look like this when tightened. Did you check the lower bushing inside the mount as well?

I have the same C59-302 spring on my 2.7L with the Dobinsons MRR.

 

Ended up having to put the stock suspension back on as I needed to drive the truck to college. Shocks and springs are sitting in my garage. Any suggestion for how to figure out which part was the issue while they're off the truck? I don't have the tools at school to test out stock springs on the 5100s but cant think of any other way to test. Better off sucking it up and going the 6112/5160 route? Its going to see mostly highway driving so I dont think I need these but willing to spend the money on something that works

 

rock the 5100's with the stock springs. Been running 5100's on the 1.75in setting with my from the factory TRD OR coils and the ride is great.

 

Also that top hat assembly doesnt look to be fully seated in the top perch either.

 

looks as maybe the bottom rubber bushing under the hat itself might have been left out since the threaded stud is overly protruding up at the top, shouldn't be sticking that far out

 

21-15

 

Replaced the top hat, with stock shock in I think it sticks even farther through but drives fine. Bottom bushing was in there. Toytec spacer for the lean probably why it looks like it isnt seated all the way. Stock springs seem to have a lot of sag in them so would think it would be best to replace. I think the suspension is original so after 194k that seems fair.

 

I agree with this. I think you may have missed the bottom washer. Therefore the shock pushes through and does not engage when the spring is cycled. I would recommend disassembling the whole thing and reassemble.

 

that would be the only thing I could think of, unless the coil spring is short, WHEELERS offroad sells a bushing/cushion kit for $30 I always buy one when I do a BILSTEIN front strut replacement the BILSTEIN strut kits don't usually dont come with new stud bushings and say to reuse the old cushions, I certainly wouldn't drive it with that stud sticking out so high

 

I thought that was a possibility too because it did feel like I was just riding on springs no shocks. Had my brother jump up and down on the bull bar so I could watch the suspension, and the shock seemed to move properly. Wish I had a go pro so I could have watched while driving. As far as I could tell they were assembled right- washer, bushing, top hat, bushing, washer, nut. Also it was a lift spring so wouldnt think it being short would have been the issue.

 

who did the work?, it kinda sounds like a cushion might be missing,

 

I did it myself. My guess would definitely be that I messed up something in assembly but I cant figure out what. Stock shocks now assembled on the truck the exact same way the 5100s were and I do not have the same issue. I assembled them once with a washer out of place, but realized before putting them on the truck, so I did a good amount of research on how the they should have been assembled before i put them on the truck. Problem is that top hat assembly is really the only thing I could have screwed up.

 

ah yes the lean spacer would be why it looks not fully in there. Carry on.