New Bilsteins shocks won't fit on top mount

[97windsor]

I bought 8 Bilsteins to replace the Monroes on my 97 Windsor. I bought Bilstein part# F4-BE5-F664-HO (new part# 24-187336) Both part#s are on the shocks.
I have it at a truck repair shop installing them and they are telling me the stud on the top mount is .003 larger than the hole in the shock mount and they wont fit. The shop also says the lower mounting hole (bolt not stud) is larger than the Monroes. I've called Bilstein and they say these shocks are the correct part for fitment on a 97 Windsor. Any one have this problems with Bilsteins and what did you do. Thanks Jim

[Triker56]

Your chassis is a?
Ford
Workhorse
Freightliner
Other

[Thorp]

97Windsor,
I just went through this on my 02 Windsor. Your shop is correct. I ended up sending my shocks to Bilstein West Coast (1-800-537-1085) in Poway, CA to reem the upper bushing from 3/4 ID to 18mm. They they changed out the bottom bushing from a 5/8" ID to 1/2" ID. You need to speak with Kevin O'Keefe at Bilstein, ext 5904.

Based on what Kevin figured out, I'm betting your coach was built in Indiana. The shocks you have might fit if it was built in Oregon. Anyway, this will slow you down a bit, but Kevin is extremely helpful and you will love the ride from those new shocks.

One big hint for me was the shox.com website where they show a 3/4 and 18mm difference for the Koni shocks.

http://www.shox.com/appguide/shoxsho...ctsdisplay.php

You're saving a lot of money with the Bilsteins and they do perform very well.

[jimkate]

97 Windsor has the all steel RR8S semi-monocoque Roadmaster Chassis. Built as solid as an army tank.

[86 Cavalcade]

97windsor, I have a 2001 Diplomat and it came with Monroe shocks. The top mount for the Monroe's had no inner steel sleeve, Monaco just installed these using a thick rubber bushing. Over the years some of the top rubber bushing had transferred some rubber to the stud and I had to get this old rubber off before my 8 new Bilsteins (24-187336) would fit on the top. I think my new Bilsteins were supposed to be 9/16" on the bottom mount and I measured them and they were pretty close. I called Bilstein and talked to their customer support and was told these shocks should not be bound when they are mounted to allow for some side deflection. I had mounted one shock on the front and had used the big Monaco washers (one washer on each side of top mount) from the old Monroe shocks. I removed the washer that was on the frame side and used one washer on the nut side. The top stud on my coach has a shoulder that the washer will just barely fits over and I am happy with how mine mounted. I installed these myself because I could not find anyone that was interested in doing this. One truck repair place said they would do it and then never called me back. George R. 2001 Diplomat

[97windsor]

Quote:

Originally Posted by Thorp 97Windsor, I just went through this on my 02 Windsor. Your shop is correct. I ended up sending my shocks to Bilstein West Coast (1-800-537-1085) in Poway, CA to reem the upper bushing from 3/4 ID to 18mm. They they changed out the bottom bushing from a 5/8" ID to 1/2" ID. You need to speak with Kevin O'Keefe at Bilstein, ext 5904. Based on what Kevin figured out, I'm betting your coach was built in Indiana. The shocks you have might fit if it was built in Oregon. Anyway, this will slow you down a bit, but Kevin is extremely helpful and you will love the ride from those new shocks. One big hint for me was the shox.com website where they show a 3/4 and 18mm difference for the Koni shocks. http://www.shox.com/appguide/shoxsho...ctsdisplay.php You're saving a lot of money with the Bilsteins and they do perform very well.

Thorp Thanks much for the info. I am sure you are correct. My coach has the same problem you had. The top stud is to large to fit the shock and the bottom bolt is to small for the bushing in the shock. I will call Kevin at Bilstein. Thanks again to all who responded and another big plus to the forum.

[97windsor]

Quote:

Originally Posted by 97windsor Thorp Thanks much for the info. I am sure you are correct. My coach has the same problem you had. The top stud is to large to fit the shock and the bottom bolt is to small for the bushing in the shock. I will call Kevin at Bilstein. Thanks again to all who responded and another big plus to the forum.

I got my coach back yesterday after the shocks were installed. It was a 2 1/2 week project because the Bilsteins top mounting bushing were to small, and the bottom were to big. After 4 or 5 calls to Bilstein I spoke with Kevin in the special install dept. He was aware of this problem with Monaco. If the coach was built in Oregon the shocks would have fit but since mine was built in Indiana the mounting points were slightly different. He told me to machine out the top bushings and he would send the correct bushings for the bottom.
The process was pain but the good news is the ride is wonderful. The shocks that were replaced were the yellow top and bottom Monroes, that I think, were the original shocks from 1997 and 54k miles.
When I picked it up I could tell after the first mile or two there was a big difference. I drove it about another 15-20 miles over some rough roads and concrete expansion joints. The difference is amazing. With the old shocks the bumps would resonate through the entire coach and uneven roads would roll and bounce it pretty bad. It is a completely different ride now. It feels like I have a new coach.
If I had known there was this much difference I would have done this the day after I bought it.
Anyone who has worn out shocks shouldn't hesitate to do this, it's worth every penny that it costs to get these shocks installed.
I have 6 new tires (last fall) and 8 new shocks and I'm super happy with my new shocks and can't wait to drive it more.
Anyone thinking about new shocks, my advice is replace them ASAP.

[Thorp]

Quote:

Originally Posted by 97windsor He told me to machine out the top bushings and he would send the correct bushings for the bottom. The process was pain but the good news is the ride is wonderful.

Thanks for reporting back with the outcome. I guess Kevin w/ Bilstein West wasn't quite as generous with you. I was able to send my shocks in and then Kevin sent me new ones that were set up correctly with the top bushing reamed out the 3 extra mm and the bottom one at 1/2 ID.

Anyway, good to know your coach rides well now. I am also pleased with the performance of the new Bilstein comfort shocks. I will be going with Source Engineering's sway bars and steering stabilizer also. I have placed my order.