Bilstein Fail

[sharkcaver "2000"+ Valued Contributor Find all posts View Profile Close sharkcaver]

So I'm hearing a few reports now of the boots on Bilsteins failing eventually leading to shock failure due to chopping out the rod seal. I see some are coming out with a sleeve rather than a corrugated boot. I would love to hear your reports if you have had a fail.

To date, mine (about 50K old) have been superb. Recently I note the front boots are starting to split. That is a pita....

I have had no issues high speed driving, heavily laden over some of the crappiest dirt roads. Then I do some low speed, high flex work and the boots fail.

The shocks have got so hot, the boot has melted to the shock body. How does that happen?



Left:






Right:






The melted boot and shock body:


















Love to hear of any negative experiences of your billies.

[Ian Sharpe Valued Member Find all posts View Profile Close Ian Sharpe]

mate even my el cheapo monroes don't do that, must be design fault?

[nj swb Resident Find all posts View Profile Close nj swb]

mate even my el cheapo monroes don't do that, must be design fault?

Yes, in that Bilstein chose the wrong plastic - not necessarily that the dampers did the wrong thing.

When a damper is working correctly, they generate heat. A quick google suggested 170 degrees C isn't unusual, and the Bilstein's monotube design means the outside of the tube can reach that temperature. Not too many plastics can handle temperatures like that.

At a guess, I'd say that damper did its job properly, but somebody in Bilstein didn't when they chose whatever material for the boot.

At the very least, the boots should be replaced, as I'd say they clearly weren't fit for purpose - the new "sleeve" design is evidence that Bilstein came to the same conclusion.

Arguably, the failure of the boot has exposed the shaft seal to wear, which could lead to premature failure. Jump up and down, and demand replacement damper(s) - not just new sleeves.

[Aussie_Dan Valued Member Find all posts View Profile Close Aussie_Dan]

Was it your trip across the desert that killled the boots Shane?

[HSV Rangie Valued Member Find all posts View Profile Close HSV Rangie]

sadly my Bils on the rear of the paj failed. 130k 3.5 years.

replaced in a hurry with way less efficient shocks, no where near as good as the bis were, bils going back on soon.

Michael.

[MSF Valued Member Find all posts View Profile Close MSF]

I've had Bilsteins on 3 of my 5 Pajeros as well as my Twin Turbo Cressida - None of them had any problems whatsoever.

Current Pajero has done about 110,000km on them - still going strong
Previous Pajero had done about 145,000km
Previous to that did about 90,000km on them before I sold it
The Cressida did about 75,000 before I sold it 4 years ago, two subsequent owners have done about 60,000 more since then...

[sharkcaver "2000"+ Valued Contributor Find all posts View Profile Close sharkcaver]

Was it your trip across the desert that killled the boots Shane?

No, they survived those rigors splendidly. As I mentioned, they have taken the punishment of lots of high speed, corrugated gravel with lots of load placed on them.

The boots failed last weekend. A pissant couple of hill climbs, virtually unladen.

[sharkcaver "2000"+ Valued Contributor Find all posts View Profile Close sharkcaver]

Arguably, the failure of the boot has exposed the shaft seal to wear, which could lead to premature failure. Jump up and down, and demand replacement damper(s) - not just new sleeves.

I highly doubt that'll happen. But I know where you are coming from.

The new sleeve design leaves the rod seal exposed, just like standard metal shroud covers. Where you get into strife is on the sealed corrugated boot. Once dirt gets in, it cant get out. That is what will test the integrity of the rod seal.

[Jords Valued Member Find all posts View Profile Close Jords]

Now that's shocking (pun intended) could be a combination of Aussie temps slowly degrading the rubber then the high temps from off roading the rubber just fails wonder if there's a recall with an upgrade to fix?

[Maximage Valued Member Find all posts View Profile Close Maximage]

That's very surprising, as I can't think of any section of our trip last weekend that could have been considered remotely testing on the shocks for any length of time. Yes they were obviously being used, but hardly any torture test.

[MSF Valued Member Find all posts View Profile Close MSF]

Prior to this last trip where this occurred, were they in perfect condition prior, ie, had you inspected them before you left ??

[sharkcaver "2000"+ Valued Contributor Find all posts View Profile Close sharkcaver]

Prior to this last trip where this occurred, were they in perfect condition prior, ie, had you inspected them before you left ??

I had inspected them a few weeks prior when I had returned from the desert as I knew the fronts were split before I left, so I have been watching them closely. In the mean time, it had done very little road work. It had to occur on that weekend.

I agree, they got a workout, but only for such a short duration. I was staggered when I looked underneath Sunday arvo.

[MSF Valued Member Find all posts View Profile Close MSF]

I'd definitely be sending them a few photos and description etc - They shouldn't do that (yeah yeah, Captain Obvious I know). in such a short persiod of time..
They may want to have a look at them internally to find out what happened...

[nifty Valued Member Find all posts View Profile Close nifty]

G'day shane,

http://www2.pajeroclub.com.au/forum/...ht=boot&page=2

Experienced the same problem and posted it on here abut a year ago. Notified Bushskinz, who said they were not aware of the problem at that time.

Performance is good, but the boots are a let down. They split, then let water in onto the seal. They also grab the shaft seal cover on compression, and then pull it up off the seal on extension, eventually "walking" it to the top of the boot. Both back ones failed, not sure of fronts yet, as they are much harder to inspect.

Wouldn't buy or recommend until they change their boot design.

[nifty Valued Member Find all posts View Profile Close nifty]

I'd definitely be sending them a few photos and description etc - They shouldn't do that (yeah yeah, Captain Obvious I know). in such a short persiod of time..
They may want to have a look at them internally to find out what happened...

Did that too, but to no avail.