3rd gen + ICON 2.5 Coils - front end clunk over speedbumps

Here's a vid showing the driver's side shaft, and then the passenger's side shaft for comparison:

 

Since your shock is leaking the dividing piston isn't were it should be in the reservoir so as you go over bumps the piston hits the end of the can and cause a clunk. That's my bet where the noise is coming from.

 

Very newbie question:

If it comes down to removing the coilover and shipping it off to ICON, can someone sanity-check the following approach?

- loosen lug nuts
- jack truck up
- set on stands
- remove wheel
- loosen & remove bottom shock mount bolt (19mm)
- loosen & remove three upper shock mount bolts (14mm)
- take shock out
- put wheel back on and hand-tighten lug nuts

Reverse the process when the rebuilt shock arrives.

Sounds simple enough, but am I missing anything? Anything to be aware of?

 

You'll have to also either. Disconnect the tie rod. Or upper ball
Joint or lower control and to finagle the coilover out

 

I'd disconnect the upper ball joint and sway bar from the spindle. Otherwise, yes that will work. But the truck will be sitting on the bump stops until you get the shocks back.

 

Man hate to say it but i'm starting to be a little suspect of Icon myself. Sent my 2.5 coil overs back to be rebuilt and they replaced the Pistons and seals and didn't address the thread locking nut that was rusted in place, after I requested it. Received them back and called them and they informed they couldn't even find me in their system. After providing my info, they did say to send them back, but I said screw it because It would have taken another week or so to get them back. Now it hasn't even been been a year and 350 bills later you guessed it, clunking back and found they are leaking. So what now, drop another 1500 bones? I'm Seriously considering another vendor, just not sure what options are best because my rear shocks our ICON also!!! Frustrating for sure

 

Tried to get this rebuilt at an Icon-suggeted shop 3hrs away, but the folks at Icon could never reach the shop (despite them picking up on the first ring every time I called - on the phone number Icon gave me), so two days were wasted in endless calls to Icon for status updates. Took the coilover off today and shipped it to Icon. Now it's a waiting game with no vehicle to get around in. Frustrating to say the least.

 

I was going to say your shocks are topping out. Like the OME 885 issue. Then thought LCA alignment cam bolts or sway bar link or brackets. Now that you know you have a leak I'd say the topping out caused the leak, I don't think the leak started the symptoms

 

If they were topping out I'd have known about it way, way before the leak started. I was feeling a change in front-end comfort (getting rougher) for a few weeks prior to the start of clunking. The other side is perfectly fine, too. It all started with the leak.

 

www.iconvehicledynamics.com, if you guys are listening "Customer Service Is Everything" and the sub par service you're providing is getting old quick!!!

 

Finally got the coilover back (two weeks downtime). Installed, no more clunking. Glad this nightmare is over.

 

That's Good to hear man and glad they finally squared you away and hope they hold up for ya! As far as I'm concerned though, I'm really considering purchasing the Fox shocks because they stand behind their product 100%. Really sucks too, because I love everything else about ICON.

 

I'm really hoping these shocks last a reasonable length of time between rebuilds. I've read about people going 5+ years without issues. Really, really hoping I just got very unlucky and it won't happen again. Rebuild kits are cheap, so after the 1 year warranty ends I'll be keeping a few of those around just in case. Any future rebuilds (out of warranty) will be done locally.

FOX sounds like a very good option. Let us know how they work out for you!

 

Will do

 

I now have a horrible squeak from the front suspension - driver's side, where the new coilover is. It happens at all speeds, over seemingly minor road imperfections (but not on larger ones like pot holes). Happens when stopped and turning wheels, too. Squeaks even when parked and I push down on the truck with my hand. Loud enough to turn heads on the street.

I just re-torqued every bolt I touched. Still squeaking. Anyone have an idea of what to check next?

 

For what it's worth, here are the installation instructions that came with the coilover: https://www.iconvehicledynamics.com/wp-content/uploads/2015/06/I58735_REVA1.pdf . As far as I can tell, I did everything according to the instructions.

 

Maybe the spacers in the lower shock mount need to be greased? I don't think (?) they were greased originally, but that's all I can think of.

 

Drove around for a bit after re-torquing and the squeak went away - guess things "settled".

 

Celebrated too soon. Squeak is back.

Here is me pushing down on my sliders and the resulting noise:



There is also a cyclical nocking noise when driving, and resulting "thump" felt in the pedals, dead pedal, and steering wheel. Seems to be correlated to speed, but not to road imperfections (at least the bigger ones that I can spot/see).

 

Chatted w/ ICON - they say to put some miles on the truck. Apparently this happens once in a blue moon (my luck just keeps on going) and ~200miles or so should sort it out. They say it's the seal making the noise? I forgot to mention the nocking when talking to them...