Bilstein 5100 rear install issue! Super confused!

Installed the rear 5100’s on Friday, took a 4 mile test drive, ran well, drove 40 miles today and heard a loose clanging sound. I thought it was the ladders on my roof rack, but turns out the drivers side shock somehow came loose! I am at a loss. it seems that the nut on the top side is secure, the washers are in the correct order, bushings in the right spot, but something just gave way. Thoughts? Manufacture defect maybe? Something I totally noobed? I’ve installed shocks before, an really took my time trying to get this one right the first time, and felt pretty confident that I did.

 

Sure looks like that lower washer in the pic goes under the frame. Nut/top washer/bushing/frame/bushing/lower washer.

EDIT: I was wrong about the number of washers on those - but two washers have smaller dia holes per side. Looks now to me like the washers are in wrong order.

 

Yep, installed incorrectly...

 

I followed the diagram.

 

Try to re-tighten to spec and use a little bit of blue loctite and do another test drive. Maybe it wasn’t torqued correctly the first time?

 

Looks like it's the wrong shock length.

 

Could this be remedied by adding a riser block between the leaf spring and axle?

 

Something doesn't look right, but the shock length looks correct though. Here are mine. Also, you should have purchased 2 of the Gabriel suspension mount kits. See video of post 17 of the following thread for additional help.

https://www.tundras.com/threads/rear-shock-replacement-video.48014/

 

I can also easily just slide down the boot away from the top end….. not sure if that should be the case…

 

Oh. You have the silver barrel in the wrong position. It should be under the frame mounting ear.

 

When I got my 5100s I did not have to purchase any additional mounting hardware and everything fit accordingly

 

I believe I did that, I am wondering if the new washers are the wrong size, allowing the silver barrel to slide up past them? Maybe I need to use hardware from the original shock prior to this install?

 

If the old hardware was in decent shape, yes.
Also in the future take a few pics of whatever you are taking apart for reference in putting it back together..

My 5160s look like the @BlueCrushSC16 pic..



https://youtu.be/RhRCxyxLOgg?t=494

 

You put the wrong washer at the bottom

 

The install video done by Overland Tundras shows them using the OEM washers and hardware.

 

IIRC, from the bottom up: flat washer > rubber > cup washer > barrel ]mount[ cup washer > rubber > flat washer

 

The shock shaft went through the bottom washer and the rubber bushing, now the right size washer is stopping it going all the way through…

 

^^^This...

 

These are the pictures I took of the old shocks before taking them off. Only difference I see is on the old shocks, there is no metal washer between the lower bushing and the receiver cup.

 

Also, I can just pull down the boot, which seems weird. I’m not seeing anything that should be stopping the shock from traveling up further than it should.

 

I highly recommend that you test fit the washers and bushings OFF the truck, the spacer CAN'T go past the first upper flat washer

 

Your bottom 2 washers are installed reverse

 

Starts at assembly.

https://youtu.be/726wxGS_lLM?t=188

I've installed 5100 rears and then 5160s.
They both used the OEM bushings..

 

The washer with the smallest diameter hole is always on the bottom then rubber bushing, what’s stopping your shock going all the way through is the washer that you need on the bottom.

 

Yep, all mine came with was the nut.

 

Thanks for all of your responses! I really appreciate the help!

 

Where have I seen that before?








































https://www.tundras.com/threads/bilstein-5100-rear-install-issue-super-confused.111901/#post-2887514

 

Did the shock break??let go on the inside??

 

I ran into this after my install and after noticing I fixed the one side in the pouring rain and made it home without the other side popping and jacked it up and fixed it.

I followed the instructions provided but something was wrong. Can't exactly remember but switch around the washers.

The retaining ring attached to the actually shock assembly near the top is resting inside the bushing and held up on something. The diameter on the bottom washer is wrong. Just swap em around and you'll be good.