Anyone had a Bilstein failure?

Myself (3rd gen), and 2 buddies (5th gens) have had similar issues. We came to the conclusion on ours that the shocks were maxing out and snapping. Bilstein didn't warranty any of ours. Switched to icon and no more issues. The problem is those Billy's should really be put in with extended bump stops to keep this from happening.


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Myself (3rd gen), and 2 buddies (5th gens) have had similar issues. We came to the conclusion on ours that the shocks were maxing out and snapping. Bilstein didn't warranty any of ours. Switched to icon and no more issues. The problem is those Billy's should really be put in with extended bump stops to keep this from happening.


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I have extended bump stops on mine & the driver rear just started leaking like crazy this past weekend on a mild trail this past weekend in Joshua Tree. I was extremely suprised for 1, I just installed these things 2 weeks ago, & 2, the trail I was on was extremely mild as noted earlier. I have the 2" Toytec Super Flex coils, bump stop drop, & 5160's (which I gather are a little longer & offer a tad more flex over 5100's). Currently in talk w/ Wheelers regarding a replacement pronto.. fingers crossed
 

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I had this exact thing happen Saturday. Ground the sh*t out of the inside of my rim. It seems like the shaft came unscrewed from the mount a bit then wiggled until it stripped the mount.
FWIW a OEM equivalent Monroe shock rides almost identically to the Bilstein. That's what I had to throw on in the meantime
 
I recently discovered that this same shock had started to leak. Finally gave in and replaced the rear shocks with OME from Total Automotive Performance (forum vendor). Works great with the ToyTec rear springs. Honestly I think it feels the same as the Bilsteins. I haven't really put enough miles off road to really comment on the durability.

Next up is to figure out what to do with the fronts...and no I wont replace them with Bilsteins:-)
 
I’ve had great experiences so far with mine, and I wheel more than anyone I run with. Now granted, I’m not in MOAB, but I have put them through their paces with not a single regret yet.

Maybe I’m wheeling wrong and should be way more aggressive.


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I have extended bump stops on mine & the driver rear just started leaking like crazy this past weekend on a mild trail this past weekend in Joshua Tree. I was extremely suprised for 1, I just installed these things 2 weeks ago, & 2, the trail I was on was extremely mild as noted earlier. I have the 2" Toytec Super Flex coils, bump stop drop, & 5160's (which I gather are a little longer & offer a tad more flex over 5100's). Currently in talk w/ Wheelers regarding a replacement pronto.. fingers crossed

I really don't see how bump stops would be a factor in a shock failure assuming that you have stock lower control arms. In a lifted suspension or stock ride height, the suspension travel is the same and therefore the bump stop would only prevent larger tires from rubbing by reducing suspension travel.

If anything, the seals/ fittings may be faulty and/ or downward travel are probably the culprit. That said, how a shock designed for off road can have a problem with forceful downward travel is beyond me.

On a high note. my 5160's haven't failed yet, though I still have my stock shocks just in case.
 
5160 failed after 4 days, replacement set damping performance deteriorated after few months.

6112's in the front was installed same time still going strong.
 
not that I am off roading any....well that is still dissapointing.

thanks for the post, i will periodlically check the rears for signs.
 
I had a nissan titan before my 4runner. BEAST of a truck. Replaced the shocks and struts with Bilstein (ordered from approved vendor) due to their reputation. Less than 1k miles later and with zero off roading, the front driver strut blew out and was leaking badly. Bilstein customer service SUCKED. Told me to send pictures which I did that obviously showed the problem. Then they told me I had to remove the strut, ship it back to them and await decision on if it was going to be a warranty repair. This was going to be a 2 week process for me to ship and have them render a decision. In the meantime, I needed my truck so I had to order a new strut from an online vendor (only place that had them in stock due to 6 week national backorder at the time). It was a manufacturing defect that caused the failed strut. The initial place I ordered it from could not refund me the money because the fine print in that they offer a "warranty replacement".

So I paid for the initial strut and install. I also had to pay return shipping. Then I had to pay for a new strut and install while awaiting their decision and finally after almost 2 months got a new strut that I had to sell at a loss on an online forum to recoup some of the costs. due to all this, I won't ever order Bilstein's again. Crappy product (at least at the time) and awful customer service.......
 
I really don't see how bump stops would be a factor in a shock failure assuming that you have stock lower control arms. In a lifted suspension or stock ride height, the suspension travel is the same and therefore the bump stop would only prevent larger tires from rubbing by reducing suspension travel.

If anything, the seals/ fittings may be faulty and/ or downward travel are probably the culprit. That said, how a shock designed for off road can have a problem with forceful downward travel is beyond me.

On a high note. my 5160's haven't failed yet, though I still have my stock shocks just in case.

That's good to hear about your 5160's not failing yet. Do you have stock coils back there tho??

*I think this is just a case of a faulty shock from the factory. I really don't see any other reason this would have happened.. especially only on the driver side.
 
That's good to hear about your 5160's not failing yet. Do you have stock coils back there tho??

*I think this is just a case of a faulty shock from the factory. I really don't see any other reason this would have happened.. especially only on the driver side.

I have Icon 2" lift coils in rear and keep the stock shocks in the garage just in case.
 
I have Icon 2" lift coils in rear and keep the stock shocks in the garage just in case.

Okay, good to know.

I guess I'll take the 5100's off the market then & just hold on to them for a leaky day then.

I'm not mad at those 5160's...look damn sexy in that wheel well

Thanks dude!
 
tacoma 5100's

I had one of the rear 5100's come apart like the OP, bought them from Wheeler's , Dan was great and replaced it for free, he said he would have just welded it back together but honored my request :thumb3:
 
I had one of the rear 5100's come apart like the OP, bought them from Wheeler's , Dan was great and replaced it for free, he said he would have just welded it back together but honored my request :thumb3:

That's pretty rad of them. I have to wait for the distributer to OK the 5160 being sent back, then get a return slip, then send in my broken shock, then have them inspect it, then see if I can get a refund, then once I get a refund I'll have to re-order another one. Kind of a PITA but it's what you get when you dont order from a shop that'll warranty it on the spot. At least I got a spare to keep me truckin until then... womp, womp...
 
I don't get under my truck as much as I should. Today when swapping my rear springs I found that both shock boots on my 5100's had come off of the shock body and are torn. I zip-tied them both back on but there are giant holes in both of them. Wondering if it's worth it to order new boots and replace them. Anyone else had these fail or run without them? I've been pretty happy with the 5100's, had them on my 3rd gen before.
 

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