OK, 2 years ago I purchased and installed a set of Bilstein shocks front and rear. Shortly after, I started to hear a rattle in the front end. I traced it to a thick washer (for lack of the correct word) that is on the shaft of the front shock under the boot. The washer is below the c-clip on the shaft. When ever you go over a bump this washer jumps around on the shaft and makes a rattle.

So I think to myself: You dumba$$, you installed the shocks incorrectly. Of course, all the Bilstein instructions come in German and they are so generalized, your only option is to install the shocks just like the ones that were in the car.

Of course with my car sitting all winter, I decide to order another set of front shocks because I obviously screwed something up the first time and I worry the chrome shaft is probably scratched up from this washer bouncing all over.

So..... today my new Bilsteins show up in the mail, I open them up, and guess what...... there is still this big washer between the shock body and the c-clip on the shaft...................what the hell?

Can anyone tell me what the washer is? Do I just remove the c-clip and slide the washer off the shaft before I install the new shocks, or is there some function of this washer that I am not aware off? I know the c-clip keeps the boot in place, but I cannot figure out this washer and if it even belongs.

Has anyone else ever had this happen to them? Any input would be greatly appreciated! Thanks

 

Well at this time it looks like 104 people viewed my post and no one replied, so I will add an update to my findings. I was a huge fan of Bilsteins, until I actually took my oem "Z51" shocks out of storage and compared them to my Bilstein sports.

I must say going forward, that the Bilsteins took away about 80 to 90% of my wheel hop issues at the track. The car rides like a truck though until the suspension warms up.

Comparing the original shock to the Bilsteins, the OEM shock is so much better design. The attaching hardware you get from the Bilsteins is so generic and cheap compared to the oem. With the money you pay for the bilsteins compared to the oem, you think you would get better hardware.

The noise that I was hearing comes from a metal washer bouncing up and down on the shaft of the shock. Bilsteins uses a generic rubber bump stop and installs a metal washer on top. It's the washer that is the culprit! The GM shock uses a foam injected bump stop that fits tightly on the shock shaft. The oem dust cover actually has the washer as part of the boot assembly.

I removed the c-clip on the Bilsteins as well as the washer and bump stop. I then installed the gm bump stop and reinstalled the c-clip. The original boot is then used instead of the bilstein boot. The shock was installed with no issues and fits just like the oem.

I have not been able to test drive the car yet is we are just finishing up winter here in chicago, so I will let everyone know the results when I drive the car.

I was shocked that no one replied to my post as clearly, this has to be an issue with every bilstein front shock installed on a c6. I have a new opinion of Bilstein now (generic). I was also disappointed as I actually talked to 2 different engineers at Bilstein and was told they have never seen this problem before.

Sorry as I do not have photos of my work as I have never been able to post photos properly on the forum.

Thanks to all that read this and good luck if you are installing new Bilsteins!

 

I did the replacement a few years ago as well. I do remember using the rubber bushing and washer from the original shocks and placed them on the Bilsteins.

 

thanks for posting your finding and comparison. Nice to hear when someone buys something and admits its not the "WOW, best bang for the buck" on everything they buy.

 

I will be back in a few minutes from a parts run. Posting for a reminder for myself.

Randy

 

Sorry for the later then expected reply.

I didn't get a chance to snap a picture of the setup, so hopefully I can explain it well enough.

On the shock shaft there is a group of items as you know. It's pretty simple but I will take the time to go over it again.

1. Bump stop
2. washer
3. c-clip
4. dust boot-washer
5. washer
6. bushing (male end should be up)
7. this is where the frame goes
8. bushing (male end should be down)
9. washer
10. Finally the nut

You are having a issue with the number 2 washer. The washer is there to retain the bump stop from going into 4-10. The main reason for the bump stop is prevent shock damage if you were to run over a curb, into a ditch, or etc. If you move the bump stop all the way to the top of the shock shaft it will hold the #2 washer from going up and down.

The shock shaft is made from a very hard steel, the washer shouldnt have been a issue.

I think we spoke on the phone earlier today, I was a bit busy, so I came back and found this thread.

Randy

 

Randy, I originally installed the Bilsteins 2 years ago. (5,000 miles). My original thought was on the new shock I bought (exact replacement) the bump stop was indeed strong enough to hold the washer up at the top of the travel. When I removed the 1st Bilstein I installed, I found the bump stop was worn out and the hole was oblonged. Granted, we have some pretty crappy roads here in southland of Chicago, but I am the only driver and the car was never bottomed out. I probably have 12 runs at the drag strip on the 1st set I installed.

I actually found the bump stop from the Z51 shock would work better as it was an injected foam and really seamed a better material for the job. I was also able to then use the oem boot cover which actually has the washer integral to the boot itself.

Proabably will be another week before I get the car down off the jacks and get a chance to drive it. Might be seeing 70's next week

 

Now I need to go see if mine are installed right.

 

Bludog,

Sorry to hear about your issues with the Bilsteins. You mentioned that they reduced your wheel hop, I was curious how/if they helped any with rough roads? Down here in NC the roads are terrible and after a couple hours of country road driving the harsh ride can be a little taxing on the back.

 

My feeling is the shocks make it harsher than a normal Z51 shock setup. I have just started driving the car again this season and really haven't been over any harsh roads since I re-did the front shocks. One thing I know for sure..... No more steel washers bouncing around making noise!

 

I just recieved my shocks for the ZO6 today. I went outside just to play with one of them, and this washer puzzled me as im thinking every bump i hit, im going to hear this thing rattling around in the boot. I wont do this install quite yet, it looks easy but i dont feel like doing it twice.

 

only way to do it. gotta use OEM bushings for the front, the bilsteins dont fit and are not the same size or shape...

 

i used all the stock stuff when switching to my bilsteins hd's. no rattle

-carl

 

Carl so what your saying is you used just the shock and new boot from Bilstein. Bushings you used oem.
Thanks

 

Sorry for the late reply. Just got back from the Mecum auction in Indy. You want to use the oe boot and bushings on your Bilstien front shocks. The oe boot has the washer that is integral to the boot. The bushing from the oem is a much better design. If you have any questions, send me a pm with your phone number and I will call you.

 

Thank you.

 

I did the same, in fact I was so disappointed in the hardware I went with the Koni's the next time out

 

You are absolutely right. I installed bilstein sports this weekend and when I looked at that bumpstop design with the metal washer above it, I thought to myself, "this bumpstop design will make noise out on the road! The metal washer just above the bump stop is not secured in any way and thus left to jingle/rattle around while you drive."

Since my car isn't low, and it's never bottomed out, I pulled that metal washer and bumpstop off and reinstalled with no bumpstops.

I don't expect any issues and so far so good. If it ever does bottom out, I will install bumpstops but NOT the Bilsteins.

As I found out after my install, the right way to do it is to use the stock bump stop with the wider stock boot. This eliminates the metal jingling washer that causes noise out on the road.

Shame on you Bilstein for your cheap bumpstop approach. Unbelievable.

 

which bilstein did you buy, HD, Sport or DRM?

never mind I just noticed this post is from march 2010..... 4 years old. lmao.