Anyone successfully replace old worn out Bilstein 5100s under the Lifetime Warranty?

Has anyone successfully traded in old 5100s for new ones?

My 06 4wd access cab only had front 5100s and the stock 4600s in the rear. The 5100s have now failed after ~40k miles and the stock 4600s are still fine at ~90k miles.

I checked with ShockWarehouse and they said i bought them too long ago and Bilstein will just say they're normal wear and tear.

Anybody have any experience with this or recommendations?

I've also just gotten a Four Wheel Camper and am thinking it might by time to upgrade to reservoir shocks anyway. I still have the stock 4600s from the front and might just put those back on till i figure out the full plan for the suspension. But, if i can get a free replacement on the 5100s, well that would be better.

 

Well, I started "the process" and it looks like it's likely not going to pan out. You have to contact the original distributor according to Bilstein, so I did that. They said, (paraphrasing) "your shocks are old, they're worn out from normal wear and tear" I thought, well how do you know without evaluating them? Also, the rear shocks are the original 4600s with about twice the mileage of the 5100s up front and are not warn out (seemingly).

So then I contacted Bilstein and they said normal shock life is 8-9 years (no statement about mileage) and if you want to have them evaluated for "defects" you have to request a RGA from the distributor.

Well, the distributor seems pre-disposed to label them as wear and tear...they're also on the other side of the country so packing them up and shipping them is likely just a waste of money.

I think it's a bit sad that "lifetime warranty" is used to trick consumers into thinking they're buying their last set of shocks for the vehicle. There is no statement that I can see of the expected "lifetime" in either miles or time and nothing saying what wears out as normal other than "normal wear and tear (including bushings, bearings and valve shims) unless attributable to a defect in design, material or workmanship"

Maybe I'll take the shocks off and see if I can tell if any of those are the problem, but i think in most cases you have to destroy the shock to determine that?

 

I undergoing the same situation right now but for my 1.5yr old B8 8100s, just sent Bilstein an email regarding a warranty. I have one shock that is leaking bad leaving oil pools and the other that has begun to leak... I don't have my hopes up seeing what everyone else is saying but it is a premature seal failure so who knows what they'll say.

Only difference between my case and yours is the place I bought them from says I'm to email Bilstein directly, according to the guy I spoke to and their warranty page.

 

https://offroad.bilstein.com/en-us/understanding-bilstein-warranty-procedures-and-policy/
https://offroad.bilstein.com/wp-con...ermarket-warranty-North-America-v.-2020.1.pdf

 

Yeah been reading all of the warranty stuff they have posted, they also boast that the 8100s are owner rebuildable on their website so if they don't honor the warranty I'm planning on asking them about that. Just need to know what grade hydraulic oil is used and the precharge presssure.

Looks like you've got about the same setup as myself, I should have gone with the deaver leafs and not dakars though

 

Here is what Galileo Africa of Bilstein told me about swapping the rear 8112 damper wrench adjusters to the clicker adjusters, "Yes you will need to recharge the shock before use. 200psi is a great start but can be bleed to reduce spring force." I paid $450 for all four after an employee told me that they were an easy swap.
I asked, "Would any of you be willing to email me the overhaul service procedures/documents for the 8100 dampers?"
Mr. Africa said, "We so not have a service procedure manual for 8112/8100. Service would not be any different that an 8125, I have added that. This will not have info on bypass adjusters, springs or check pistons. https://productdeskapi.cart.bilsteinus.com/media/products/bilstein/B8_8125_Tech_Manual.pdf "

 

Well damn thanks man, I seen those clickers and am thinking about it. If I end up doing my own overhaul I definitely will add them, if Bilstein warranties them I'll ask if they could possibly do it while the shock is open, on my dime of course. There was a video I came across on youtube that a guy had posted of a full disassembly procedure of the shock for installing the clickers, it fairly straight forward.

But yeah thanks again