OME Strut Assembly Issues

[OldManKamps]

Hey guys,
So my buddy bought OME suspension(OME881 with 90004 Nitrocharger shocks) and we had trouble assembling it last night. Spring compression went great with the compressors and we easily had enough clearance.
Here's the issue, the shocks need a washer a bushing, top plate, bushing, washer, locknut.
The top plate has a built in bushing which is slightly skinnier than the spindle of the shock. Pressing it on is difficult but it slides down until the washer and bushing underneath the top plate.

The issue: There isn't nearly enough room for the bushing and washer and not on the spindle on top of the top plate. The bushings would need to be compressed roughly an inch for the nut to be able to thread at all. These bushings are robust af. We put them in between blocks of wood in the vice and they compressed holes in the wood. We put them directly in the vice and they compress to 1/4 inch and then pop right back into form. We tried to get a C-Clamp in their but it doesn't fit and it's awkward.

We're at our wits end here, no information can be found online and the included directions merely state the order and torque specs. We watched Mtbtim's video on installing it but he didn't see to have this issue.

Can anyone offer insight or aid?

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[turbo8]

Post some pictures.

 

[MStudt]

Somethings off somewhere. Those are pretty common to see used to together on both 4runner's, and Tacoma's.

Post some pictures or what you have going on. I sounds like you may have the wrong bushing set. You should be able to get the nut started without having to compress the bushing at all.

 

[JayRolla]

I have the same front setup. It was a tight fit but it works. I didn't have an entire inch to compress.

 

[OldManKamps]

UPDATE:

So in frustration, my buddy took it to his mechanic and they shaved the bushing down a few mm with a grinder, pushed the top plate as far down as possible with penetrating oil. That left a thread or two on top and they got it on!
Thanks a lot for the quick replies guys.

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[99 Problems]

Weird how the struts couldn't be assembled without having to shave the bushings down! At least they're assembled now!

 

[Tyler James Inc]

So, you're using two bushings on the bottom of the top plate?

 

[99 Problems]

So, you're using two bushings on the bottom of the top plate?

Nope, one on the top and one on the bottom. There weren't enough threads on the shocks to get the top nut started. Really weird issue, unless I was totally missing a step.

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[Tyler James Inc]

Nope, one on the top and one on the bottom. There weren't enough threads on the shocks to get the top nut started. Really weird issue, unless I was totally missing a step.

Are you the buddy of the OP? I was asking because he said-

The top plate has a built in bushing...

"Built-in" implies- to me- it wasn't removed. If that's the case, you would end up with with two bushings on the bottom, yeah? Or did the OME strut only come with one bushing for each side? Or included two, but only one(the top) was used? That would make [MENTION=119226]reelamin[/MENTION] bushing issue with Bilstein make a lot more sense(they only include one bushing).

 

[99 Problems]

Are you the buddy of the OP? I was asking because he said-

"Built-in" implies- to me- it wasn't removed. If that's the case, you would end up with with two bushings on the bottom, yeah? Or did the OME strut only come with one bushing for each side? Or included two, but only one(the top) was used? That would make [MENTION=119226]reelamin[/MENTION] bushing issue with Bilstein make a lot more sense(they only include one bushing).

I am yes!

I think by top plate bushing he meant the rubber footbed of the top plate itself. The OME shocks came with 2 bushings (along with instructions) which say to put a washer - bushing - top plate - bushing - washer - top nut on top of the shock.

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[reelamin]

I cant tell from the pic...but it really looks like there is a huge distance from the bottom washer to the underside of the plate. Not saying it is but it looks like there are two rubber bushings under the plate. My KYB top mounts had a lower bushing properly fitted inside the rubber isolator for the bottom.

Bilstein did not include jack crap with my front shocks....well I take that back they provided a BULL SH$% explanation with them. I did get a normal rubber band on the top threads holding the plastic protector on if we are splitting hairs. haha

 

[Tyler James Inc]

I am yes!

I think by top plate bushing he meant the rubber footbed of the top plate itself. The OME shocks came with 2 bushings (along with instructions) which say to put a washer - bushing - top plate - bushing - washer - top nut on top of the shock.

Okay, gotcha [emoji1360]
I'm still thinking you- effectively- used two bushings on the bottom of the top plate. My OEM coilover had never been taken apart. When I took it apart, the bushing on one side stuck to the bottom of the top plate, and the other side came off- so I know exactly what you're referring to. That said, there was only the bushing below the top plate; no "rubber footbed". Wait, you're not referring to the rubber coil isolator, right? We're just talking about the hardware that actually slides onto the piston/stud, yeah?
I'm wondering if KYB(or even the OEM top plate, for that matter) top plate has a built in bushing, and that's why you couldn't get the nut threaded on. It would definitely make sense.

I cant tell from the pic...but it really looks like there is a huge distance from the bottom washer to the underside of the plate. Not saying it is but it looks like there are two rubber bushings under the plate. My KYB top mounts had a lower bushing properly fitted inside the rubber isolator for the bottom.



Bilstein did not include jack crap with my front shocks....well I take that back they provided a BULL SH$% explanation with them. I did get a normal rubber band on the top threads holding the plastic protector on if we are splitting hairs. haha

Exactly what I'm thinking happened. So did you not use an addition lower bushing? Lower washer, top plate, upper bushing, washer, and nut?
Oh, gotcha. I guess I should know that by now [emoji23] Well my Tundra's came with two washers, one bushing, and a nut. In your case(with the KYB top plate), and possibly 99problems's as well, the one bushing would completely make sense.