Broke a Fox Shock

I might just have to do that then. You would have to get extended brake lines as well too though wouldn't you. I was really hoping to avoid going this route only because I didn't want to do all this fabbing and readjusting of everything. Shoot. At least I can keep the pack though.

EDIT: I just thought about it. I think it would actually work out perfectly because I would then have a 50/50 ratio assuming I get 6" down, 6" up. I currently have 6" of exposed shaft. It would work perfectly because I would still have my 6" of shaft showing so in theory I wouldn't have to do any readjusting of the bump stop.

 

you sure your hitting bump before the shock is fully compressed?

 

This ^^^

Go eye to eye with heims.

I think folks expect too much out of the OE replacements. Stem tops suck and when the top and bottom bushing are smashed there's really very little movement and a whole lot of strain on a stem that's sized to fit through the factory hole.

You doing enough to constitute the need for hydros, you might as well put the money towards a setup that’s adequate for the intended use

 

this.

BAMF relocation kit and and then you can run at 12 inch shock!

 

Positive. I've spent a lot of time perfecting this setup and I know for a fact that they are indeed being utilized at their very most possible.

I had a few options when making a decision what to do. The first one was to contact Fox and have them send me replacements of these shocks and cross my fingers that they made a design change to a smarter design, or B have Fox send me new 12" eyelet upper and bottom equipped shocks and then have fab work done to make it all fit.

While I would love to run 12" shocks there are a few things not allowing me to do that. Jerry at BAMF is backlogged for months because of his current shop relocation situation and it is highly likely he has no stock of shock relocation kits. The next problem is he is the welder of the area who knows how to install these properly and can do it without taking all day due to measuring. Others will not. I needed a fairly immediate solution and since Fox came out with a revision which is exactly the one what I was hoping for, I see no need to further put myself under extra headaches and attempt to source parts from different locations and find a welder who is as competent as Jerry is.

Update in the next post.

 

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:

 

That is the old design where the stem was welded on. The new design utilizes a solid 6061 aluminum top cap and the stem gets threaded into it or a nut on the inside.

Either way, it is repairable at this point is my point if it ever is to happen again, not rendered useless because of busted welds. Though I believe they revised the stud as well using a stronger metal on it. If I was to take a guess it would be similar to the route Icon went on their rear shocks, which have yet to have a reported issue since 2008.

 

That's crazy, really? I think a lot of it might have to do with the warranty claims handler.

Though in retrospect, I did inform him my limiting and bump out factor was in check via the air bumps/ leaf springs. I also provided him the build serial number engraved on the bottom cap as well as the mileage put on these. 20,000 miles on a set of rebuildable shocks is not a lot. Also coupled with the fact that the damage occurred on a non serviceable piece. I think it was really hard for him to refuse this claim. Either way. I'm really glad they stepped up to the plate and addressed the situation correctly instead of half assed.

 

no problem bud. I've spent a lot of time researching about these shocks and to have them ultimately fail me was a big let down. I feel it was only important and right that I pass this on to the guys who have bought these in the past to make their life a little easier if they ever do run into this situation in the future.

 

Tell you the truth in the entire time I have had these I never had an issue with contact of the stock upper mounts onthe hose fittings. I may actually end up trimming it as you mentioned for good insurance but I do plan on sticking to remote reservoirs simply because I like the design better where the body of the shock faces upwards and not the shaft. I just like the flexibility of being able to mount the cans away from the shock itself.

 

It wouldn't hurt to see if they would swap you out a new set if this is a known issue, and avoid having it fail in a remote spot etc. I could see potential for this to cause even more damage if the shock got kicked into the wheel somehow as well.

 

Performance wise they are great. I love them. They are really everything I could need and ask for in a shock. Well thought out design and good manufacturing. It just so happens they overlooked a small design flaw which in theory should be ok, but because the upper mount is so damn weird it creates other problems unseen overtime. The thing is there really was no way to for see this until the real tester, the consumers, ran them.

The short hose would had been an easy fix man. I guess when it comes to warranty claims and return policies a lot of the outcome solely relies on your presentation of the facts and the conviction you have behind your voice. Lol 'Merica for you!

That one could be a crap shoot and can go 50/50 only because his shocks are still whole. They could say kick rocks because its not broken yet or the flipside they could honor them seeing the impending failure especially due to my recent mishap and the warranty claim guy now knows what the situation is with these Tacoma's and their history with the old mounting style shock.

 

I received an email back from the Fox claims rep. He told me that a 7/8 shaft would not work due to the CD adjuster's inability to handle the fluid displacement of a shaft that large. So the build will continue as slated, custom valved, CD adjusters only with a standard 5/8 shaft. I'd rather take adjustability over a stronger shaft. The rear end being as light as it is a shaft that size is not needed anyways.

 

Fox is a contender for my new setup, (icon, fox, king, OME BP-51)
Customer service is a big part of my decisions. Nice to see Fox has helped you out.

 

Apparently fox is out of stock on the CD adjusters (I know they are a popular seller so it's understandable). I may have to go and install them myself once they get them on the 13 or March. Not exactly what I was wanting to hear but I am happy enough just to get 2 new free revolved and revised shocks on the house.

 

Exactly, never hurts to ask.

 

Wow. Glad to here fox is taking care of you. Did you do this saturday?

I have these 12" waiting to be installed to replace my current 10" icons

 

No this actually happened just yesterday while I was just driving not offroading!

You are good with those man. Fully hard threaded eyelet designs both top and bottom. The load seen by those is strictly up and down only, any side to side play is kept at bay with those spherical bearings.

Fox redesigned the shocks as of mid last year and haven't had any issues since. Any issues that are to arise if so are now serviceable. A quick stop on the polyperformance website will let you get either a replacement stud and/ or top cap if needed so it's no longer a big deal unlike these where if they break they are done.

Presentation man