2nd Gen Non-Engine/Transmission Rear shock broke and other Misc stuff

[erobb]

Maybe this post is premature as I haven't had much time to do research yet. But this weekend while replacing my rear brakes and axle seals, (a job I haven't had to do for quite some time) I was laying under my truck looking at the condition of things when I noticed my right rear shock was completely busted, broke, kaput! Now I don't abuse my stuff, yes, I do use it for work as I am a contractor, but I rarely haul any load that a half ton truck couldn't handle. The shocks were Bilsteins from Geno's, so I went back and looked at my log book and I installed them in '07, so yes they were 4 years old. But I have never seen a shock rod completely break. Just wondering if I have something else going on that I should be worried about? Also I placed a call to Geno's and they claim they have never seen a shock completely break, and they don't feel Bilstein will honor the lifetime warranty, they will say it has been abused. I called the local NAPA store to see what they offered for shocks and the counter guy said he has seen broke shocks and its not that uncommon, just wondering what the truth might be?

Also, I noticed the arm/lever thingy that goes from the rear end housing to the brake proportioning valve is completely gone as well. I called a couple junkyards in the area and they say good luck finding one as every truck they get in is missing it as well. I think it may be possible to build something out of a chunk of strap metal or threaded rod and some swivel ends or something but I would have to know the exact length. I didn't call my local dealer parts yet, but I figure the part is most likely no longer available new. So if anybody can give me any ideas I would appreciate it. Thanks



98. 5 2500, 4x4, Reg Cab, 5 spd, 3. 55's, 322k, RV275's, Van Aaken box, 4" turbo back exhaust, Fuel pressure gauge, FASS DDRP, Vulcan relocate kit, Amsoil in all gear boxes, Amsoil air filter in stock box.

 

[CAPTPHIL]

EROBB,
Call Bilstein Customer Service and talk to them. I had the same thing happen to me about 7 years ago, they replaced it no charge. You are the only other that i have ever heard of. I have been using their shocks for over 30 years. They even sent me new bushings at 500000 mi. no charge for the truck in my sig.
Good Luck Capt Phil

 

[erobb]

I will find Bilstein's web site and their customer service phone number, I might as well give them a call. The guy I spoke with at Geno's was skeptical that they would do anything about it, but since I have an unexpected day off today, I will call them and see what they say, I will report back.

 

[erobb]

Well, I looked at Bilstein's website which is less than helpfull. There was no mention of thier customer service number on the site anywhere that I could find. After a couple google searches I was able to find the number and a list of warranty requirements on website that sells Bilstein products. After reading through the warranty info, I have decided its not even worth wasting my time, it says a broken or bent rod will automatically disqualify the shock for warranty replacement. Also you have to have your original purchase reciept, date of install, blah,blah,blah what a PITA. Plus then I gotta wait for it to be shipped.

I'm headed to my local parts house, I have either a NAPA and the guy there is bragging up their 'Gas Grande' shocks made by Tenneco (Monroe) or CarQuest who sells KYB but they say it is a great shock but very stiff ride when empty, I'm not sure I want that. But whichever I decide to go with, if they go bad I can go back to the store and smack someone upside the head with the faulty part.

Call me old fashioned but I still like to have a store to go into, I really dislike all this mail order stuff, and I'm not convinced a person saves that much money. That's just me. Still no response from anyone on the brake lever thingy????

 

[rotohead]

... Still no response from anyone on the brake lever thingy????

I know many people have bypassed the proportion valve altogether either by removing it and using brake line to reconnect or positioning the lever to where you get full brake effect, I think it's the arm all the way up... either cut the rod connecting to the axle and zip ty it to the frame somehow. If yours is just broken off and hanging there then the rear brakes will never get full brake effect even when you have a big load in the bed or hauling a heavy trailer. You must've hit something to break that unit.

 

[erobb]

OK so I got the NAPA shocks and I was irked because one of my Bilsteins was broken, but upon further examination I have quite a bit of damage back there. As I mentioned before my brake lever arm is gone, busted shock, right emergency brake cable is smashed flat, which probably explains why my emergency brake doesn't work all that great anymore.

Anyhow upon replacing the shock something had definitely hit it because it had a big ole dent in the side facing front, but anyhow I replaced them with the NAPA Gas Grande' at $52. 00 each and they even said Made In USA right on them. The Bilstein that wasnt broke was still a good shock, very stiff after 4 years, I could have just ordered 1 Bilstein to replace the broke one but I figured its best to replace them in pairs. But I think the truck rides a little better unloaded with the NAPA shocks. Oh well, I saved a little money compared to the Bilsteins and the job is done and I didn't have to wait for parts to be shipped in.

I will try to figure out some way to zip tie the brake lever up, right now its hanging staright down. Thanks.