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  #1  
Old 01-15-2005, 11:33 PM
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Shock absorber install nightmare...

Just installed two new front Bilsteins today and had a nightmare getting one on. I broke one of the bolts installing the shock to the control arm on the driver's side. This was one of the NEW bolts that came with the shock. I was using a torque wrench to torque it to 33# as specified in the Haynes manual when it simply broke before reaching that torque. I couldn't believe it. Is Bilstein packaging some cruddy bolts with their shocks these days, or what?

Well, luckily I had an EZ-Out on hand that fit the bolt, and got it out without too much trouble. Then I reused one of the old bolts and torqued them all to 25# instead without further trouble. But this turned a simple job into a pain in the ass.

One of the shocks also did not come with a new nut for mounting the shock shaft at the top, so I had to reuse the original pair that I took off.

Is all this a sign of declining quality at Bilstein, or am I over-reacting?

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  #2  
Old 01-15-2005, 11:50 PM
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Yes and No

Quote:
Is all this a sign of declining quality at Bilstein, or am I over-reacting?
Yes and no. The missing nut is not the end of the world, just a packaging error. Complaining to the company or the dealer should yeild a nut post -haste.

A bolt that breaks at less than the specified tightening torque is a big deal. Notifying the company should result in an immediate recall of all shock absorbers packaged with bolts from that purchased lot.

Document your results, take photographs of the broken bolt, your wrench, and the package in which the shock was received (with emphasis on any lot numbers or packing dates). Send all this, with a copy of your receipt to both the company and to the NTHSA. Send them simultaniously, so that you won't have to resist the temptation when Bilstein offers to keep you quiet.

Best of luck,
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  #3  
Old 01-16-2005, 12:07 AM
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Quote:
Originally Posted by WannaWagon
I was using a torque wrench to torque it to 33# as specified in the Haynes manual when it simply broke before reaching that torque.
Well, I can certainly believe it. The screws that hold the shock in place are relatively small 6 mm. screws. I don't have the torque limits handy for metric fasteners, however, the limit on a 1/4" socket head cap screw is only 14 ft.-lbs. If you exceed this by much, you will definitely snap the fastener.

Just for a comparison, a 3/8" socket head cap screw (slightly less than 10 mm.) is limited to about 42 ft.-lbs.

I cannot tell you why the Haynes manual specifies 33 ft.-lb., but, it is definitely wrong.
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Old 01-16-2005, 05:24 AM
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The spec is 25 newton meters which is only 18 pounds. You are also supposed to tighten lower shock nuts with the wheels off the ground and tighten the top with the wheels down. My front bilsteins only came with one self locking nut for the top.
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  #5  
Old 01-16-2005, 06:20 PM
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I checked the haynes, 33# is for the rear shock absorber lower bolt. It says 14 pounds for the front lower shock mount, which aligns with what Brian said. 18lbs was for my 115.
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  #6  
Old 01-16-2005, 08:11 PM
DENNIS
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I instaled two on my 300td, took about 1.5 to do it i did not use a torque wrench, only feel. Dennis
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  #7  
Old 01-17-2005, 03:14 PM
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Quote:
Originally Posted by joshhol
I checked the haynes, 33# is for the rear shock absorber lower bolt. It says 14 pounds for the front lower shock mount, which aligns with what Brian said. 18lbs was for my 115.
Cripes, looks like I read the wrong number in the bloody manual.

Oh well, I guess I learned one of those "lessons the hard way!"

Anyway, the new shocks are great. The car is much more solid and sporty now, dives a lot less in braking and is much flatter in corners.

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