1st Gen Shock Problem

Hey suspension gurus, looking for some help. Working with a popular vendor, I've installed OME CS019R Dakar leaf springs on my 96 Xcab. No extra leaf. Since truck has previous suspension lift of about 2.5", the springs went in OK, and the rake looks good - slight angle up to the rear. The problem came when attempting to fit the Bilstein F4-BE5-D559/560-TO 5100 series shocks sent with the springs.

Fully extended, the shocks aren't long enough to reach the mount pins with the truck on the ground. Vendor suggested the springs would settle but that doesn't seem right. Plus, that would leave negligible length for droop. All the mount locations look normal? Spring shackle length is 3.5" (stock). Frame spring mount eye to eye is 49.5". I did use a 3 deg shim but it's pretty thin. All u bolts are tightened evenly. The Driver Side shock pin to pin distance while resting on the ground is 22.5 inches. The PS is 23.5 inches.

To rectify this, vendor sent a set of

$94 Bilstein 33-186542 Bilstein Shock, B8 5125 Series, Monotube, 15.12 in Compressed / 24.35 in Extended, 46 mm, Steel, Zinc Plated, Each

Bilstein 33-186542's 5125 series. They're long enough but I'm doubting their 15 mm bushing will fit my 19 mm mount pins.

Any advice oh wise ones? I am aware of the bump stop issue associated with longer shocks.

 

A bump, update, and gripe. The vendor now claims I'm doing something wrong, they sell thousands of these parts, and nobody else has a problem. They say it's normal for the shock to act as a limit strap. I think the shock should allow for droop. So, I could jack the first shocks into position and drive around hitting extension limits every time the truck bounces up.

They also think all I need to do to make the second shocks work is "swap out the bushings." But, they haven't told me swap out with what bushings. If they had sent new bushings with the second shocks or would respond to my inquiry about that, we wouldn't be having this conversation. Plus, we're going for new parts here.

They don't return my inquiries until I call them days later, and we're getting irritated with each other. They're resisting agreeing to take the shocks back, making me feel like a nuisance to them. So I've got $360 worth of two sets of useless shock inventory here. I'll get the shock problem resolved, go Amazon! But, I am disappointed that a supposedly reputable vendor is, IMO, providing poor service. This is supposed to be fun. I had hoped for more support from a popular vendor here. I'm not posting their name because I've seen that turn threads into flame fests. I want to focus the solutions on the shock issue but also vent a little.

Has anyone installed these springs on a 1st gen and been able to fit shocks? Does my upper shock mounting point look normal in the picture? I can't image my lower point is moved from stock.

In other news, my CBI sliders are set to arrive today! Some email advance shipping/tracking notice would have been handy since they want someone here to accept them, but oh well.

 

Just to close this off, new Skyjacker H7027's are mounted up. These extend from 15" to 25" and so mostly fit my range as determined by jacking wheels. It would have been nice to know why "normal" shocks didn't fit. The vendor I was dealing with finally shared that they've been short handed. I can understand that, just say so.

The CBI sliders are also mounted up. The wider brackets go in front.

 

The shock itself SHOULD NOT act as a limit for down travel OR up travel. Bump stop should limit up travel and leaf pack or limit strap should limit droop. Any way else and you will have issues

 

Realize I'm resurrecting an old thread here, but I'm having the same problem with the Bilstein 5125 bushings not fitting the shock mount studs on my 2000 TRD. Just put on some Allpro expedition leaf springs. It seems the holes in the bushings are too small.

Should I spit on them and jelly them on there??

Should I swap the bushings from my old shocks? (OME nitro sport)

In a bit of a time crunch and don't want to wait for more parts to arrive before I can drive the truck.