Bilstein 5100 Trouble. Please help!

So on Wednesday, I installed bilstein 5100's on my 07 model. I went to have an alignment done at firestone and they informed me that I had too much play in my passenger side front wheel bearing assembly. They kindly quoted me $700 to repair it. I bought the new assembly and a buddy helped me do it. However, leaving firestone, I noticed an odd popping sound on the drivers side whenever I went over a bump. Further inspection revealed that the top of the new shock is hitting the top of the wheel well (pictures below). As you can see, the bushing is not compressed at all as it was when I installed the shock.
Drivers side



Passenger's side



While the passenger side isnt hitting the wheel well, It is definitely not as tight as I made it when I installed them. Any insight here is greatly appreciated. I have the shocks set on the 3rd setting (1.75 inches). My working theory is that it took a couple of days for the coils to settle in and that the new ride hight is too much for them. What do yall think?

 

Just looking at the picture a couple things come to mind that could be wrong. First of all do the threads on the top stud appear to be stripped? Did you install the bushing under the top cap? Did you use the correct washers with the bushings. Did you assemble the 5100's yourself or were they pre-assembled. I installed my stock coils on my 5100's on the third notch. I remember that the washers for the top stud, that sandwich the bushings on top, were much thicker than the factory washer. No matte what you are going to have to disassemble the shock and make sure you are not missing a bushing or that it is defective. Good luck to you.

 

I bought them directly off the bilstein website and the shocks arrived with the hardware (Washers, bushings, and nuts) in little baggies in the boxes. I am very confident I installed them correctly and the threads arnt stripped which is what lead me to believe the stock coils weren't prepared for the extra height. Does that sounds like a plausible answer?

 

Its installed incorrectly. A washer then a rubber go under the top hat and then rubber and washer on top

 

This is everything the kit came with. There were only four bushings. I assumed this was one for each shock?

 

This was my thought as well. Either the washer or both the washer and bushing are missing on the underside of the top hat.

 

Alrighty. I suppose thats good news in regards to not having to shell out for new springs, but bad news in the sense that I might be an idiot. Another dumb question. What is to stop the washer and bushing on the underside of the top hat from just falling down the shock to the plastic cover?

 

The lower washer sits atop a stop on the rod which prevents the washer from sliding down. Here is a diagram showing the assy components and order...



It's been a few years but if I remember right, I believe Bilstein provides the two lower washers and the lower rubber cushion, as well as the upper washer and nut with the new shocks. I seem to recall I had to re-use my old upper rubber cushion because one was not supplied by Bilstein.

In the picture below, you can see three washers, one rubber, and a nut.

The dust cover slides on and hits the stop on the rod (as shown in the picture below). Then the first lower washer slides down and rests against the metal sleeve molded into the top of the dust cover. The rubber cushion goes next and then another washer. At this point the shock assy goes into the top hat. The upper rubber cushion (not supplied by Bilstein) slides on above the top hat, followed by the large diameter upper washer and the nut.

 

as others have said.....missing the bottom washer. its a special size to stop this exact thing from happening.

 

Y'all are awesome. Thank you.