Broke a Fox Shock

What to do next?





UPDATE:

I was able to reach out and speak to Will in warranty claims at Fox. He informed me that as of May 5, 2014 (last year essentially) there was a major revision done on these shocks to address the stem problem, but he did say that the new design was much more stout and was now designed to be a serviceable item. He emailed me a PDF while on the phone of the new design and he also went on to inform me that they have since not had an issue whatsoever with the design revision. He also did mention that the previous design was inferior and was asking for issues the way it currently sat just because of how it was designed (thick stem welded into a thin steel body tube). There is currently still the old design out there in circulation so those looking to order some of these better make sure and identify they are receiving the updated shocks and not the old ones to avoid the hassle I'm currently experiencing.

-The new design is now a top cap made of solid machined 6061 aluminum and the stem is threaded into the cap (or there is an internal nut in there).

-The overall thickness of the stem was not a problem because it never broke, it was its mounting point on the shock because it was just welded to thin steel where the weld broke and now lets it hang in free suspension. Once broken, there is no real way to repair it other then to TIG weld it if you are a welder or good at it.

-As of currently there are no reported issues with those running these revisioned shocks, which is always good news, the fact that it's serviceable now simplifies the issue if they ever break again, making life easier for the at home mechanics if they are ever able to break the new design.

He informed they were out of stock of these at the moment so he is going to have their race department custom build two new shocks for me on the house with better valving for what I do (because the compression on these is fairly light), as well as install new CD adjusters (to allow for further adjustability of compression settings) for a discounted price because of the situation and the minor inconvenience it is causing. So the only thing I will pay them for is new CD adjuster reservoirs which I will have in about a week and a half. A stand up reply and response from a company which I love. The only thing I have left to request of him which I forgot to ask was to have the shock shaft upgraded to a 7/8 as well since they are building new ones for me because the current one is a 5/8.

Those looking for the new design, here is what they look like. Much better then the previous model.

-I also should note the new shocks have a new Extended height of 25.88". Collapsed height of 15.88" so make your bump stop and top out limiting adjustments accordingly if needed:

 

Break out the credit/debit card.

 

LOL, OP- How did you manage to do that?

 

Lol, yeah no.. I don't intend to just yet, because it's pretty obvious it's a manufacturing defect based on where the stud literally came out of. There is about 1/8" worth of stud sticking out from where it normally goes in. I originally bought them from ORW, if it's going to be warrantied or not, I'm wondering who would be the best to go through, ORW or Fox.

Problem is, I'm wondering if this'll happen again.

 

I was actually just driving city and took a normal sized bump, next thing I know I hear flop flop flop all over the place. Pull over and find that.

 

Agreed. Pass that over.


My favorite part is that it happened right at about 4:55PM. Right about the time everyone closes shop for the day. Just my luck.

 

How old are they?

 

About 2 years old I want to say, About 20K on them.

No actually. The springs are the limiting factor for these. They are bumped out at the correct height as well.

 

Same shit happened on my runner. Normal driving. Called allpro where I got them from and fox sent me a replacement.

 

Shoot... The more I search about it the more I run into this same thing on FJ Cruiser's as well. I'm starting to wonder if the factory upper mount is actually causing the stem unnecessary side to side torsion under compression and extension of the shaft?

 

When I got these shocks I gave all pro the set up I was running. I ran their 3.5 springs and this was the shock they recommended for the length. I forget the numbers.

 

That was ALMOST my initial thought until I realized that I knew for a fact that my shocks had never overextended before except for when they were fully extended in their original packaging, lol.

I still have to wonder about the stock mount location and whether or not it is causing binding at the bushings which is in turn putting further stress on the shock stem. Ideally, you would really want the shock shaft threaded in by an internal nut through a hole in the shock body then fastened and secured by a locking nut for better strength. Hell maybe even a hardened shaft. I know Icon uses a 4130 stem on theirs.

 

Is this a common problem with rear Fox shocks? I'm thinking I should go with Icon now.

 

I've seen the Icon's fail as well. Course this was back in 2008 and they have since rectified their issue, but I'm going to have to talk to both Fox and ORW tomorrow and see what they can do for me or something. I like the shock but I do want a stronger stem if the stem is indeed what the problem is and I would be willing to pay some money to get custom ones installed, a better way as well instead of the standard stuff.

 

These are 10" travelers. They were originally meant for a first gen Taco. 25.19 ext. 15.19 collapsed

The FJ's I believe are a touch over 9 if I remember correctly. 9.1"

I know brand new Fox piggyback's for the Tacoma are inverted and mount the shaft at the upper mount and uses that as a stem. I wonder if that give's the mounting point increase in strength? (From the shock stem mounting point, not the actual upper mount itself)

 

That's what I was thinking, it looks stupid the way the stem sits there. ANy suggestions as to what to do as a solution to it?

Yeah. I don't think the numbers really matter. As Jberry mentioned it appears the stock mount is to blame for this problem. What a horrible design.

 

Lol, dang I had a feeling you would say that. That would let me run a 12" shock as I am aware of. My big question though is could I retain the current pack I have in there? 2.25" of lift total on the pack.