Strut upper bushing

Well knowing that the factory top hats also have the bushing integrated into them, I don't see anything obvious from your pics that points to faulty installation. Everything looks like it's in place. It could be that the bushing(s) just failed.

Or maybe (at least on the driver's side), it was just the clip on the shock shaft that failed.

The one thing I would check is the driver's side. See if you can see the washer that's supposed to be below the top hat bushing. I can't see one in the pic. If they forgot to put that in, I could see the shock eating away at the lower bushing fairly quick, and causing a failure.

 

Then why arent my top bushings compressed like it should be ? Driver side and passenger side

 

I just edited my last post, and added:

I would expect to see that washer sitting on top of the dust boot. It could also be stuck to the under side of the bottom (top hat) bushing.

 

Here's what happened : They inverted the lower bushing and the washer.
Top hats are shot but shocks are fine
Driver side hat :

 

expected, this is common when bushings are not installed correctly or compressed down to prevent stem travel, your stems are probably damaged too from this rubbing and you need completely new struts and hats.

 

Just found a similar issue on my passenger side strut mount. The rod on the strut was about halfway worn through. Glad I caught it before it failed. Replacing the Bilstein with Rancho struts and ordering a new mount from Rock Auto.

 

Just finished swapping out the top hat and the strut. The old strut rod had almost worn through. Glad I caught this when I did, if this failed while driving on the highway, I imagine I would have come to an abrupt stop.

 

I read this can also be caused by failing to install new top hats during a shock change. Because supposedly the shock stem can naturally wear into them like this, and people will continue using a worn old part for another cycle of new shocks, instead of buying new top hats for ~$30/ea

I don't get what people mean by the bushing is not supposed to be on top.
New shocks come with multiple bushings, to isolate metal from rubbing against the top hat and squeaking. So that rubber can wear out and get replaced.

Probably rubber, then the top hat, then another rubber, then a washer and nut because the washer helps distribute force from the nut.

Here is a picture of OEM ones that look similar, but their rubber is older and a different shape. But it is still visible.



So I can't tell if this is an install failure, or simply someone being too cheap to get new top hats during a shock change. (I admit, I just did the same. Re-used top hats with new 4600's at 130k)

If the OEM top hat has a rubber bushing integrated into the center of it (rubber piece not easily replaceable on it's own without new whole top hat), then maybe a hole wore into it over time

Not the only post I've seen of this. Others have mentioned "do not re-use top hats that look like this":

 

Looking for some advice somewhat like the OP!
I noticed my bushings on top of my top hat look a lot different on my driver vs. passenger side. Driver looks a lot looser than passenger. To the touch, both are smashed pretty well. Would love a comparison pic to someone else with a 5100 setup. Should I take it apart? Which side is messed up? I hate to say it but I can’t remember what they looked like when I put the whole suspension in. Pics below.

driver side^^

passenger side^

Thanks in advance! And sorry for how dirty!