My E250 shock saga, Bilstein warranty and vs KYB

[MarinBlaine]

Hello friends,

I started this on a generic shock thread a couple of weeks ago and got one reply, but thought it warranted its own thread after some new data.

My rig: 2001 E250 EB50, 5.4, 169k mi. 2WD, stock suspension

When I got my rig in early 2018 with 129k mi, as part of sorting it out I replaced all the shocks with Bilstein 4600/B6 shocks all around...not the RV versions, just the standard shocks. I'd had bilsteins previously and was very happy, plus the "lifetime" warranty was a big plus of course. These shocks worked great for about 4 years.

In 2022, one of my rear shocks broke, the top mount snapped off after about 26k mi. This was after some moderate offroading on a trip to the San Juans. TireRack was gracious with the warranty replacement. The process was to buy a replacement and then send the old shock back and they gave me a credit for the 2018 purchase price...which was quite a bit less than the 2022 price but I thought that was fair. My trusted local shop installed the new shock.

This past summer, after some more moderate offroading in the Eastern Sierra, the other rear shock broke in the same way as the first one, snapped at the top mount. This time, a rep (who shall remain nameless) at TireRack told me to pound sand, that the damage looked to be from "installer error". Not responsive at all, but she did offer to sell me a new shock for 25% off. I pushed back for a while, told her it broke in the same place as the one they replaced in 2022, and that the shock had worked fine for 6.5 years. To no avail. I also contacted TireRack via twitter/X, and they referred me back to the same woman. Pretty unresponsive, didn't return my phone call, and frankly she quit responding to my polite emails after some lengthy delays in response. I won't be working with TireRack in the future.

The front shocks were purchased through Amazon via 4WheelOnline. The driver side shock seems to have lost one of its bushings and it's been banging around, and as a result the threads in where it attaches at the top have been damaged and my mechanic says it needs replacing as well. Bushings seems to be specifically exempt from the lifetime warranty, so I'm resolved that this won't be replaced. But just as a note, Amazon referred me to 4WheelOnline, who told me that "the vendor they get the shocks from is out of business", so I need to deal with Bilstein directly for any warranty claims. Which is strange since both Amazon and 4WheelOnline are still in business, with these same shocks available from both...but I digress.

I need to replace at least two shocks that are broken. The remaining rear shock has ~14k mi on it, and the remaining front shock has ~40k mi.

My mechanic has recommended KYB shocks as "holding up better" than bilsteins. Reading online reviews of these shocks I don't know that the internet agrees with him. Also, not sure whether MonoMax or Gas-a-just shocks would be the right solution. MonoMax sound heaver duty, gas-a-just sound more comfortable...not sure if that's synonymous with Bilstein RV vs "comfort" shocks. I've been very happy with the Bilstein ride and performance.

I've been generally pleased with the Bilsteins except when they break . I'm not a massive offroader, but I do get fairly deep in the back country from time to time, crawling over some rocks as my ground clearance and LSD will allow. And I've done things like 60mi each way over washboard to the North Rim. Online reviews say bilsteins better offroad. But lots of highway miles as well.

So my options are as follows:

1. Get 2 new Bilsteins to replace the broken ones.
2. Get 3 Bilsteins to replace the broken ones plus the other front one that has 40K mi. I think the rear one with 14k mi should be OK
3. Make a change and get new KYBs all around, but need to decide which ones.

In the previous thread, the only reply suggestion I got was the do a forensic analysis of the shock travel on the rear and determine if the Bilsteins are simply too short and get something else. My suspension is rock-stock, other than 169k mi. I'm reluctant to go for anything custom...I'm a simple creature with this van's suspension.

Oh, and I'll be buying locally so any future warranty replacements will be a little more face to face.

Would love any comments and feedback for my predicament...

Thank you my friends, and Happy Holidays!

 

[doublevan2]

Just asking on this - what is the weight of your van - front and back GAWR - when loaded for bear ? If overweight on either - could that have negative consequences for your shocks and suspension overall ? NOT a shock expert -

 

[MarinBlaine]

Just asking on this - what is the weight of your van - front and back GAWR - when loaded for bear ? If overweight on either - could that have negative consequences for your shocks and suspension overall ? NOT a shock expert -

Good question. I've not weighed it. Other than the stock SMB EB50 buildout, there's really nothing extra in there. The first set of stock ford shocks seemed to have lasted 129k miles.

 

[carringb]

I’ve been running the KYB MonoMax on my van now for the nearly 20 years I’ve had it. The Shock bodies have been completely trouble free. They do wear out after a while and eventually will leak. I think I’m currently on my 6th rear set and 5th front set but the fronts have now lost much of their damping. Damping properties are fantastic, and it seems to be about midway between the Bilstein comforts and HDs.

6 sets may sound like a lot, but keep this in mind: I bought them from Les Schwab so they have a lifetime parts AND labor warranty. Swapping them out has been completely hassle-free. Van is at 518,000 miles now and I bought it with 105,000 so I’m averaging about 80,000 miles a set. That’s under a duty cycle that might be rougher than just about anybody else up there. Gross weight can exceed 16k. Combined weight can be around 26k. Off pavements miles is probably at least 15% of the total miles I’ve put on. Van has been airborne multiple times, with one of those landing hard enough to spit the carrier in it’s former Dana 70 rear axle. So consider all that, I think the lifespan of the KYBs has been completely reasonable.

One of my friends had a shop put the Gas-A-just version on his van. Those were completely underdamped for the weight of an Econoline. Laughably so. So I can’t recommend those.

 

[bigriver-SMB]

I’ve been running the KYB MonoMax on my van now for the nearly 20 years I’ve had it. The Shock bodies have been completely trouble free. They do wear out after a while and eventually will leak. I think I’m currently on my 6th rear set and 5th front set but the fronts have now lost much of their damping. Damping properties are fantastic, and it seems to be about midway between the Bilstein comforts and HDs.

6 sets may sound like a lot, but keep this in mind: I bought them from Les Schwab so they have a lifetime parts AND labor warranty. Swapping them out has been completely hassle-free. Van is at 518,000 miles now and I bought it with 105,000 so I’m averaging about 80,000 miles a set. That’s under a duty cycle that might be rougher than just about anybody else up there. Gross weight can exceed 16k. Combined weight can be around 26k. Off pavements miles is probably at least 15% of the total miles I’ve put on. Van has been airborne multiple times, with one of those landing hard enough to spit the carrier in it’s former Dana 70 rear axle. So consider all that, I think the lifespan of the KYBs has been completely reasonable.

Now THERE'S a testimonial!

 

[Adventure4us]

In 2022, one of my rear shocks broke, the top mount snapped off after about 26k mi. This was after some moderate offroading on a trip to the San Juans.

This past summer, after some more moderate offroading in the Eastern Sierra, the other rear shock broke in the same way as the first one, snapped at the top mount.

In the previous thread, the only reply suggestion I got was the do a forensic analysis of the shock travel on the rear and determine if the Bilsteins are simply too short and get something else.

If you are damaging the mounts this sounds like good advise.

 

[arctictraveller]

Im at a loss to understand why you keep breaking shocks. Despite having stock suspension, i have to wonder if the shock application is correct. Its pretty simple to measure the required fully extended length (droop) by first removing the shocks and then jacking up the frame till the diff is hanging freely. The distance between the upper shock bushing and the lower bushing is the minimum extended length. Anything less will cause the shock to be the limiter, putting undue stress on the shaft and internals. Then measure from the bump stop landing pad to the spot where the rubber will be fully compressed to determine the minimum amount of shock travel required. If the shock is limiting the bump travel rather than the bump stop, its likely the issue and the shaft will try to bend and eventually break. After cycling my suspension and choosing an appropriate model, Ive been running Fox 2.0s with zero issues in front for over ten years. The rears wore out (lost dampining) within about 5 years of heavy off road use and were rebuilt, but nothing ever broke. I recommend taking an hour or so to measure the required travel and then comparing it to the available travel of any shock you consider. Im reasonably certain your issue is caused by too little shock travel.

 

[Twoxentrix]

You would limit the potential suspension travel, but if you are comfortable with what you currently have then you could consider a quick fix by installing 'limiting straps' for the differential and/or larger bump stops (like sumo's) to take weight stress off the shocks. ***You would still need to investigate shock travel to get a measurement for the length of the strap needed.
You may not need both, but again you'd have to diagnose if the upward travel or downward travel is causing your suspension drama (assuming this is the culprit).

https://www.amazon.com/Suspension-Limit-Straps-Shocks-Blackout/dp/B0851TW76G?th=1

 

[carringb]

You would limit the potential suspension travel, but if you are comfortable with what you currently have then you could consider a quick fix by installing 'limiting straps' ]

I think his issue is actually the opposite which you also hunt at. His rear end looks kinda saggy (on the van!), and when the rear end is approaching the bump stops, the stems can be put into slight bending especially if they were over tightened. It’s slight, but I could see it causing fatigue if the typical ride height is nearly compressed. Easy fix for this is adding a lead and/or sumo springs.

 

[carringb]

I should add…. The stock length KYBs seem correctly sized. They definitely aren’t constraining bump travel, and if that’s are limiting droop, they don’t seem to care.

 

[Twoxentrix]

I think his issue is actually the opposite which you also hunt at. His rear end looks kinda saggy (on the van!).

Yep, Tried to offer both sides of that equation since I didn’t see any pictures (at least not that I noticed) for reference - from your comment it appears you have ‘visual’ benefit I must have missed.

 

[MarinBlaine]

If you are damaging the mounts this sounds like good advise.

Not damaging the mounts…I don’t think…damaging/breaking the top of the shock where it attaches to the mounts.

I think his issue is actually the opposite which you also hunt at. His rear end looks kinda saggy (on the van!), and when the rear end is approaching the bump stops, the stems can be put into slight bending especially if they were over tightened. It’s slight, but I could see it causing fatigue if the typical ride height is nearly compressed. Easy fix for this is adding a lead and/or sumo springs.

Thanks carringb, I think at this point both my van and my own rear ends might be a bit saggy…

I thought all these stock vans had a saggy rear end. Yours is an interesting hypothesis. Maybe I need an extra leaf…I was just worried about a harsher ride. Maybe the right move would be a visit to the spring shop…

As to carringb’s report on the KYB monomax, the good luck you’ve had with them is on a much bigger and heavier rig than mine…but I’m intrigued. Anyone else running KYB’s on non-monster E450?

And finally, arctictraveler, I agree I need to figure out my shock travel, thank you for that advice. I just continue to be baffled that my stock suspension is killing “stock” shocks…

And thank you everyone for the ideas and feedback.

 

[carringb]

Yep, Tried to offer both sides of that equation since I didn’t see any pictures (at least not that I noticed) for reference - from your comment it appears you have ‘visual’ benefit I must have missed.

Extracting what i can from the tiny thumbnail:b1:

 

[HIGHCOUNTRYMIKE]

I had Bilsteins all around. Front failed.........removed and replaced with Monroe Mags.
Removed rear Bilstein and replaced with KYB.
Beautiful ride on and off road. Not a Bilstein fan.
HIGHCOUNTRYMIKE - 2003 Ford E350, 4X4, 7.3, Sportsmobile 330,000

 

[moorefc]

Hmmm. I've had bilsteins on both my Sportsmobiles. Second one had KYBs that were about 10k miles used, and I replaced them with bilsteins (not the HD ones). I like the bilsteins better...First van bilsteins lasted about 100k, second van they are getting tired at 80k (it is a heavier van E350 vs E250). Currently in baja and when we return we'll chat with bilstein about replacement. First time I sent in the rears to bilstein and they sent me replacements for all 4 with the comment please send in the fronts when you can. That was in about 2013...From memory there is some rocking of the rear studs in the top with full travel and maybe if they are overtightened? that might have an effect. Part numbers for the "standard and HD" are the same for the 90s thru 2007 I believe. I did have the HDs initially on the E250 and when they were replaced they shipped the standards....more comfortable when not fully loaded.

Bottom line have driven these for about 300k+, lots of baja time, on sportsmobiles and I like them; except replacing the rears is a bit of a pain due to the upper stud location/access...
Maybe for you fox or old man EMU might be worth a try if upgrading.....

 

[fordsarefun]

I have a 2011 2wd and yes i use the Bilstein shocks, but I will mention that I have had the suspension upgraded with heavier coils in the front and new leafs in the rear. The reason was the the originals aren't all that great especially after 10 plus years. I thinking that you're suspension was probably flexing too much and causing the shock mount to crack and break?