4600 Front Install Error / Issue

Boy I did something massively wrong (I hope).

This is one of my poor fleet trucks, they run down dirt wellpad roads daily.
It's been maybe 2-3 weeks since I installed 4600's up front.

I swear that I followed the directions but you can see what happened.
I will admit, I did not pay super close attention to this 'clocking' part. I just made sure the upper coil sat flat into the isolator and the coil bucket(?) lined up with the coil to not add some weird twisting force. I have replacement upper mounts, so there's nothing to refer to..? The Bilstein instructions are rather vague.

It's far from my first time with suspension work, and I am genuinely baffled what the heck I did wrong!

-- Also, given the gouge in the upper shaft - I think I need to replace these even if they're only couple weeks old.

 

something was missing during the assembly to allow the shaft to slide constantly on the top mount. i would replace them now personally even tho it sucks they are still new

 

I wouldn't have any qualms continuing to run those on my own truck (after replacing the top hats & stuff)... I'd probably be more hesitant to put those on a vehicle other people would be regularly driving though (would need to examine them in person to know for sure).

 

The clocking doesnt really matter, this is usually a case of a missing cushion/rubber or the bolt wasnt tight enough, or the washers werent in the right order.

You could use these still, but they'd be time bombs for failure.

 

I am still 100% uncertain of what or how I goofed.

I put in new shocks and uppers, I do know they went back in with much less struggle.
I do not know, but I certainly hope I didn't goof up again. This poor truck is out in the battlefield and rarely checks back in.

 

Your original picture shows only metal, there is no rubber in the picture at all - that I can see. There are other rubber pieces in that assembly. It was never meant to be metal against metal which to me appears to be what happened.

 

maybe this will help

 

I *think* the factory mount plate (which has the 'lower' bushing) was completely destroyed when I put the 1st set on.
There in fact WAS an upper bushing when I put it all together, but boy oh boy it was destroyed and gone.

With the new mount plates I think this one should be good to go.

 

In my opinion you need new shocks as well. Are those notches on shock shafts don't look normal? Looks like they were chewed up

 

Oh, I very much put in new shocks and new plates. Even if it were my personal vehicle, I wouldn't risk that.
This is a fleet locator truck.

 

This diagram ignores the rubber under the top hat. It is technically part of the top hat and glued in place but often falls off when removing shocks or can get over compressed or disintegrate. My guess is that piece was damaged or missing.

 

I do believe you’re entirely correct.

Seems to be doing great!