Bilstein 6112 Front Lift Issue

About 3.5 months ago I installed the Bilstein 6112 front suspension kit on my Taco (2010 Access Cab). The past couple of weeks I have heard a clunk from the front suspension if I hit a bump/pothole, so I decided to take a look at it this morning.

This is what I found:


Look at that gap!! It was definitely not like that when I installed them. Maybe the springs settled causing the gap. The worst part is there are no threads in the gap so I can't just wrench it down.

Has anyone experienced this before? I'm thinking I need to get a new (or additional bushing) to fill the gap. I'm open to any suggestions.

 

Here are the install instructions from Bilstein:


All the parts are installed according to the instructions.

 

Driver's side is not as bad, but the metal washer and bushing are still loose.

 

you put the bushing on upside down it looks like. Big bushing should of gone on the bottom side of the top hat.

 

The install instructions in the second post make it look like the bushing should be between the top hat and the nut. Unless I am reading them wrong ...

 

There should be two rubber bushings. on one the top of the top hat and one on the bottom.

The lower isnt shown in that picture as its typically stuck to the inside top of the top hat and is part of the "top hat assembly"

http://toyteclifts.3dcartstores.com/142467--Front-shock-replacement-bushingwasher-kit_p_35.html#

 

Make sure that washer underneath the top hat is there.

 

There wasn't a gap like this when they were first assembled. If the inner bushings weren't there, would there have been a gap during the initial assembly?

 

Found a thread on an FJ forum where a guy had the same issue I am having. This was his final conclusion: "They had left out the bottom bushing and washer after all."

Looks like I am going to have to do some investigation when I get home from work tonight.

 

Ill bet either the lower washer isnt there or the bushings have been flipped and the smaller top one has been crushed / non existent now as its being used on the bottom.

 

I have ordered new top hats with all bushings/washers from Amazon (will be here Saturday). In the meantime I will pull these off the truck to figure out what is going on. Didn't think I would have to pull the struts out this soon

More practice is never a bad thing though, right? LOL

 

After checking out the stock shocks I had in the basement, the issue was pretty apparent. The installer forgot to put in the washer that goes between the Bilstein rod adapter and the bushing on the shock tower mount. I ended up purchasing new upper shock tower mounts so I just had those installed by the tech at Sears. I figured it was better to go with all new parts rather than try and salvage the old ones. All is good for now!!

 

Didja get em back on the truck

 

Yup, took them out and put them back in on Saturday. So far so good.

 

So I had this same issue, took mine apart, put back together with new bushings and washers, got it all in the truck, and there was still a gap! I made sure the proper bushing was on the top and bottom, as well as the washer that goes between the rod and the bottom bushing. The threads on the top don’t go down far enough, the bushing and washer move around. I guess I’ll just add a second bushing to the top? Is anyone else having this issue?

 

Found the same problem on my front shocks because of this thread.
Can you provide the eBay link to the top hat and bushings/washers?
Trying to find a good deal.
Thanks!

 

$29 KYB SM5640 - Mount Kit

https://www.amazon.com/gp/product/B00C7S0KA8/ref=oh_aui_detailpage_o02_s00?ie=UTF8&psc=1

 

^^ Yup, that is what I bought. Holding up well so far.

 

OK. Thanks guys.
Ordering it now.

Edit:
Clunking fixed