So what did I manage to screw up (Bilstein 5100 w/ Mevotech UCA's)

[BigDogg795]

So last night my brother, his friend and I installed the 5100's into my truck. Everything went fairly straight forward except for two issues. First is I had to cut the shocks out with a sawzall because we couldn't get the top nuts loosened to get the shock cap off. When I reinstalled it; everything went back in and I reused the applicable hardware and reused the (partially cut) rubber boot that fits over the top (between the cap and the coil, the part contained within the red square in the attached pic). Now whenever I hit certain bumps it sounds like a clunk as though something is loose. I brought the truck to a mechanic to have them do the alignment and asked them to take a look at everything to make sure it looked good and they advised it was...so now I'm wondering if the partially cut boots are whats causing the noise. When I compared the assembly to the the Rancho Quick Lift replacements they don't have anything in there as far as I can see; do I even need them or can I cut them out?







Attached are obligatory photos lol

 

[SOKY_RAM]

Where did u put the washer when installing 5100?

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[BigDogg795]

Where did u put the washer when installing 5100?

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Forgive my ignorance but as my brother and his friend did most of the labor I wasn't paying as much attention as I should have. Which washer are you referring to so I can ask him in the morning...?

 

[Csanders1992]

The shocks come with a washer. Common sense tells you to put it under the nut, which is wrong. It goes on the rod under the upper seat. The rod is a smaller diameter than the hole in the spring seat so the washer keeps it from going through


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[jknappen]

The shocks come with a washer. Common sense tells you to put it under the nut, which is wrong. It goes on the rod under the upper seat. The rod is a smaller diameter than the hole in the spring seat so the washer keeps it from going through


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Uhhh no. The washer goes under the nut it will be the second to last part that you put on before you secure the nut. Refer to the bilstein instructions as well as your old strut. Make sure your mevotecs are on the correct side as they are side specific

 

[sriley531]

Uhhh no. The washer goes under the nut it will be the second to last part that you put on before you secure the nut. Refer to the bilstein instructions as well as your old strut. Make sure your mevotecs are on the correct side as they are side specific

Sorry, but "uhhh no". The washer goes under the spring hat. I thought it went under the nut too (as is conventional wisdom) and now I'll be pulling my bils out and apart just to move a damn washer. This can cause the strut rod to pop up through the hat, causing a clunk on bumps. Here is a pic of the instructions. Although I feel they should've stressed this washer location more, if you read how they were written, its apparent it goes under the top spring plate, not above it under the lock nut.

 

[jknappen]

Mine is directly under the nut and everything is fine


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[SOKY_RAM]

Just fixed mine today. Washer definitely needs to be under plate. You could tell where the rod was already beginning to wear on the plate. I also added mevotech's since I didn't feel like tearing all that apart for just a washer.

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[jknappen]

Just fixed mine today. Washer definitely needs to be under plate. You could tell where the rod was already beginning to wear on the plate. I also added mevotech's since I didn't feel like tearing all that apart for just a washer.

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Is this just something new or is this on all of the fourth Gens?

 

[charonblk07]

I had the same issue with my Rancho installation. I had to redo both struts to get the washer under the spring cup.


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[SOKY_RAM]

Is this just something new or is this on all of the fourth Gens?

I would think it's on all but can't say for sure. I would look at the bilstein instructions for your year. Can't really see that they would be any different. The instructions really did a poor job of calling this out in my opinion.

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[AustinB]

Mine didnt even come with instructions.

IMO

 

[fordtech90]

Sounds like you either have the washer in the wrong spot or didn't tighten the upper strut nut tight enough. That will cause a clunk. It will look fine while its in you hand but as you install it and let the trucks weight on top of it the strut will compress some.


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[jknappen]

Mine is not clunking altho i do not want any issues down the road


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[iam_canadian22]

Mine is directly under the nut and everything is fine


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For now, id get that fixed as soon as you have the time

 

[smoothee]

I didn't have any clunking issues either, until the strut mount hole eventually bored out, blowing out a strut in the process.

 

[R.L.K.]

For anyone leveling their trucks with Bilstien's here is a couple links that are well worth reading . These post are very informative.

Hope this helps !


https://tapatalk.com/shareLink?url=...&share_tid=79370&share_fid=17770&share_type=t

Alright guys.. BILSTEINS post your pics!!!



https://tapatalk.com/shareLink?url=...&share_tid=70918&share_fid=17770&share_type=t

Guide to Leveling & Wheel and Tire Sizing for 06+ 4wd Ram 1500's

 

[R.L.K.]

Mine is not clunking altho i do not want any issues down the road


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Helo Sir , check out the link below , more importantly see step #8 and notes # 5& 6 for the bilsteins 5100 install .

Hope this helps you Sir .


https://tapatalk.com/shareLink?url=...&share_tid=79370&share_fid=17770&share_type=t

Alright guys.. BILSTEINS post your pics!!!

 

[jknappen]

Well went ahead and changed the location of the washer. Wonder y bilstein made the shaft smaller in diameter from stock. Oh well problem solved also installed my 3/4 inch rear spacers. Now its level


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[BigDogg795]

So an update...In the school of thought to try simple things first, I decided to make sure everything was in fact tight. Given that we were rushing towards the end as it was cold and wet with several thousand dollars getting soaked I thought maybe we didn't button everything up the way it should have. So I went and used SOKY's recommendation on the craftsman ratchet set and went to town. Everything was nice and tight except for...wait for it...the nut on top of upper assembly. That had quite a lot of turns to go before it even began to get tight. Used an Allen key to hold it in place and snugged it up nicely. Then I took a look at the zerk fittings on the new UCA's and realized the shop never actually greased them for me when I asked. So $20 for a grease gun and some grease and did it myself. Took it for a test drive and the clunk is gone! I asked my brother about the washer and he told me he assembled it in the correct order too so I think I'm good!!!