The only part that seems odd to me is if this is caused by a design flaw, why did it take over 17 years of this front end design or even going with just gen 4 its been 10 years of people running these and just now a couple newer trucks have an issue . One had loose hardware but it just seems odd to me . I don't use them personally but have installed many for people with never a problem plus many of the drop bracket type lift kits use a really large spacer which I have no clue to the size of the lower hole in it . I do use a torque wrench more often as I don't trust my strength at 65 as much as I used too. Look at how much force is put on the little snap ring on a 5100 and it holds the same amount of weight and holds up to the forces from what I have seen . This whole thing has just made me curious
So take my reply with a grain of salt, as this is based off of what I've seen on my 2 personal trucks with ifs and "coilover/struts"
Spacers aren't a bad thing per se, they just need thought and supporting mods specific to each application. Our strut top hat requires the center bushing for the shock shaft be supported from above by the mount itself as the shaft is only retained by a bushing with a small metal ring, which over time unsupported will push through. My f150 had a fully contained upper strut hat and didn't need a solid shock mount as the nut and washed sandwiched the shaft inside it. Basic premise works, but the variables are different.
On our ram our bump stops for compression are shaft mounted, and it seems that they designed the shock to be the droop limiter. So in that case, that's where our BJ issues arise because in stock configuration that's what limits droop, or fails prematurely trying to limit it.
On Toyota's, the bump stops are frame mounted, and without relocation they are prone to fully compressing the shocks and actually destroying them.
But like you said, properly installed and with supporting mods they can function fine. It's all about the details, and like we religiously warn new guys here looking for the cheap way out, cheap cost more in the long run, so buy s comprehensive kit once and you're better off.
That's just what ive personally seen installing parts with my own hands, so that's where I get my info that I trust, I've seen much more on the internet, but than again, the earth is still flat to some and samsquatch still exists so I heed that info accordingly.
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