How 'bout this ****. So, some of you guys may remember my "lift" adventure.(Bilstein HD Order HELP!!!) Skip to the bottom of the post for the gist

I upgraded my old worn out springs and monroe sensatracs to some brand spankin new 99 tall coils and Billstein HD 4600 series on all 4 corners. Well, this was a couple weeks and about 2000 miles ago. Needless to say the improvement was night and day, I have been loving every minute of it. Well last weekend I took ~900 mile trip up to Hot Springs, Arkansas to quickly renew my passport(long story). Great trip, had tons of fun-brought a buddy with me so the ~14 hour adventure went by quick.

When I got off the interstate in my home town I heard this subtle hard to describe noise. Something between a "clunk" and a "rattle". I was cussing like a sailor for a while because I just got done saying how proud I was of my old girl, after all these years she still never lets me down, blah blah on and on I was going. I turned a few more corners and the noise was much worse taking turns at city speeds. (still cussing at this point)

Anyway, got home climbed all under the 'runner (this is at about 9 at night, I'd been up since 3am after being up till midnight the night before) and couldn't find the source of the noise. ( I sure was reminded of how badly I need to change my VC gaskets though--lost quite a bit of oil after running that long) So, I went to bed for the night(after many beers) and got up the next morning and started again. I spent 6 hours under my runner, stuck a wrench on every bolt I could find, tore the steering rack apart, greased everything, checked heat shields, check dust shields, checked drums, checked calipers, check engine mounts, tranny mounts, etc., etc. I checked it all and still couldn't find ****.

Still laying under the 4runner, 'bout whipped. I lit a ciggarette and just laid there for a minute. While I was on this smoke break a buddy of mine(same buddy that took the road trip with me) pulled up and walked in the garage and asked what I was doing. I started hollering and cussing explaining myself and how much bull **** this was, and while I was *****ing my buddy jumped on my back bumper and BAM. I remembered the only thing I didn't check. I blame toyota honestly. I didn't check the top shock mounts. This is partly because I looked at the rear shocks and all seemed good. Sure enough, my passenger side rear shock ate **** on me and sheared the **** off at the top mount. So, I got back to cussing and *****ing again all the way to Orilley's to buy the cheapest piece of **** shock I could find to get me by till I can get a replacement. (hopefully under warranty)

After I figured out what the noise was I had it fixed in about 30 minutes. Lesson learned-lazy buddies that spectate more then help are still good for something.

Anyways, thought you guys would get a kick out of this. I know billsteins are nearly coveted around here and I still love mine--but **** can happen at any time, no matter how respectable the brand.

Here's the Pics that I know you guys have to have.

Wow. I can't believe that happened. It's such a clean break I can't believe it broke under the truck. It almost looks like it broke when tightening the upper bolt during install. Never seen that before but glad it didn't cause anymore damage or worse.

yeah PB. It wow'ed me, too. I didn't think a shock would see enough lateral movement for a failure like that to occur. I think that I've concluded that this must just be a manufacturer defect because of how clean the shear was and the manner in which it occurred.
(as far as it breaking under the truck-i guess I can't really say 100% it did but I am as sure as any logical being could be. I didn't use a torque wrench on the top mounts(i'm impressed if anyone can get a torque wrench up there) but I know I didn't break it when I mounted it.)

Really glad you posted by the way PB, if you didn't I was probably going to send you a PM. Just because I know you have the same Billstein love that I do.

One has to remember that the oe style shock mount is designed for very little flex. Look at your suspension geometry and see if when flexed, it twists that thing in the bushings more that the hole in the mount will allow. I remember back in the day a few guys broke stuff just changing from rubber to the stiffer poly bushings when used in compliance situations (rather than pivot about an axis) because the bushing was to stiff and fatigued the part....or it's possible that after all these years and the millions of shocks bilstein has produced...they finally had a defect. It happens.

Yeah, I remember posting in your other thread about the part #'s. Sucks man. Have you contacted them about return/refund yet?

No, I haven't contacted them yet. I haven't even looked into it yet. This is a hell week for me at school right now(although im wasting time right now), so I won't have time to ship it out and I don't know if I will have to send it to billstein or deal with AJUSA. still need to figure that out.

AJUSA's customer service seems to be pretty good. I know they're on the forum too. I bought two sets of these from them and I think I referred you to them. Tell them all that when you call. I'd be very surprised if they don't handle it for you themselves.

I think I understand what your saying, but it seems like guys on here put these same shocks through a lot more hell then I do still using the stock top mounts. (I know some guys make their own mounts and relocate them) Also, I know billstein is a good brand/company but I'm sure that they have had a few defects besides mine.(yeah just googled it and it's not all that rare from a cursory glance) But, when I get some time I will go climb under the runner with a floor jack and check out what your saying.

I think thats where I'll start. I was very impressed with their service when I made my order. Let's see if they continue to impress me.

Good luck brother. Keep us posted.

I sheared one of those too at some point. At the time I figured I was barely 2 weeks off my new rear lift, and I managed to find the top nut and threaded stud stuck in some mud in the top plate so I had a friend weld it back on. 1 - 2 weeks turned into almost 6 months and it held solid as new. Get out the welder!!

interesting...this happened to me twice w/ the right rear shock as well, however mine was a billy 5150 resi shock...top nut/bolt or whatever you want to call it snapped right off the shock....coincidence?
don't mind the markings on the shock, had to compress/wiggle/curse/pull/push the shock to get it out from where it was stuck


this is what it looked like the first time I found the problem

I had factory coils and stock OEM shocks when mine sheared. Happened that at some point (during the trail run when it sheared off) my coil got hooked on the frame when I drooped and over extended with no shock, and was bent 90 degrees from the base cup to horizontal under the frame rail.

Good luck with the next shock and finding a replacement. Good thing installing those top nuts is a ergonomic and relaxing job

This is my first post, and I really don't know much about 4runners yet.
But I have been doing a lot of research, as I am planing on lifting my 3rd Gen. Correct me if I am wrong, but it is my understanding that this is a symptom of not having a panhard bar extension.
As I said I am about 50% on this.

Mine came out of the top mount ripped through the top washer and bushing but get this, The nut was still attached to the shock. The mount was perfectly fine too. No damage to anything but the bushing and washer. And the damage the shock did to the area it was scraping against.