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Old 08-12-2015, 09:12 PM   #1
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03 Dynasty replace Bilstein with Koni FSD problem

Our 03 Dynasty is just under 100,000 miles so I thought I would provide it a birthday milestone present by replacing the factory Bilstein shocks with Koni FSD shocks. This evening, after the temps cooled a little, I started with the front shocks. Got the first Bilstein off without a problem. Compared the two shocks before installing the new FSD and notice that the top mounting hole was larger than the old shock. Bottom hole measures 5/8" which is the same as the old shocks. Top hole measures just a hair under 3/4", old shock is 5/8". These are Koni 8805-1004 which is what Koni and others state are the correct shocks.

I am considering finding a steel sleeve to reduce the hole size but the hardware store was closed by the time I notice the difference.

I will call Koni in the AM but was wondering if anyone else has had this issue and if so what was your solution?
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Old 08-12-2015, 10:10 PM   #2
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Thaws an old Monaco requirement for having a bigger bushing for better ride insulation.
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Old 08-12-2015, 10:16 PM   #3
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Quote:
Originally Posted by Mike Canter View Post
Thaws an old Monaco requirement for having a bigger bushing for better ride insulation.
Sorry, I do not understand. How would a hole larger than the bolt help? Seems to be the slop would cause a weak link and eventually cause the bolt to snap off.
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Old 08-12-2015, 10:25 PM   #4
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I guess I misunderstood what you were saying but I know on older Monacos the had bigger top bushings. Are you sure they gave you the correct replacement shock?
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Old 08-12-2015, 11:00 PM   #5
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I guess their could be a mistake but I looked at multiple sites and the 8805-1004 was what they had listed for a 2003 Monaco Dynasty Roadmaster 10 bag chassis... I believe our coach is a very late 2003 as the Dynasty Countess, as I can't find a Countess listed for 2003. The first Countess I find documented by Monaco is 2004.

Both eyelets have a rubber bushing with a steel bushing inside of that. The bottom eyelet hole ID is 5/8", the top is 3/4". The old Bilstein's have a 5/8" on both eyelets and the eyelets only have a rubber bushing, i.e. no steel inner bushing.

I would just change the top bolt but since they are welded to the frame that would be a major task.

So, a call to Spartan Motors, where I purchased them, and maybe a call to Koni in the morning will solve the mystery! I purchased them via eBay from Spartan as they had the lowest price on Koni's that I could find, which was $131.24 each!!!!

If the shocks are valved for the front then I believe all I need is find a sleeve with the correct ID/OD and I am in business.
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Old 08-13-2015, 11:23 AM   #6
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Look for a bearing supply company in your area. They normally have lots of bushings. Many are oiled bronze but some steel as well. Maybe they can source the right ones if needed
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Old 08-13-2015, 08:33 PM   #7
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I did find some bronze bushings at a hardware store today. They are not a tight fit in the shocks eyelet but a lot better. The ID is too small so I will need to drill them out to fit. However, I called the supplier today and he is in touch with Koni to find out what the suggest. It appears there was a design change done at some point. I will wait until tomorrow and find out what Koni says before I proceed. Since I only have one shock off it won't take long to put it back on if the don't have a quick solution.

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Look for a bearing supply company in your area. They normally have lots of bushings. Many are oiled bronze but some steel as well. Maybe they can source the right ones if needed
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Old 08-13-2015, 09:06 PM   #8
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Good hunting, if the supplier comes up empty be sure and take a shock and bolt for size. I have an old piece of conduit in the garage I just measured and it measures pretty darn close to what you need. Ifyou find something like that works just cut off the right lengths. The other thing about oiled bronze is wear. Good in a closed environment but not so long lasting once it gets dirty
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