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Discussion Starter #1
I was putting Bilstein 0929's on the rear. Stripped the threads on the lower mounting bolt when torquing it down.

I used the FSM spec of 63 ft-lbs. There was no insert with a spec in the Bilstein boxes. Only saftey info in 12 languages...

My thoughts are:
1. Ok, I did torque it a little past 63 ft-lbs. I was going after the "2nd click" b/c I had a small extension on the torque wrench and didn't like the angularity and "twist" I felt. But, I mean, like 1/16th of a turn on the 2nd pass and the thing just gave way. Doesn't seem like the spec should be that close to failure.

2. Maybe my torque wrench is off? I was using a smaller one up near the high end of its range.

3. Specs for the Bilstein's are different that OEM shocks. (Doesn't makes sense, since they are exactly the same size fastener...).

BTW, the bolt and nut were definitely clean and dry. It isn't like I had oiled it up, so that I was "fooling" the torque wrench.

Anyway, experts please enlighten me. This was an expensive mistake.

P.S. Any fix aside from purchasing a new shock?

-- Dan
 
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Nevermind. Call me mechanically challenged.

I put on the undamaged Bilstein 0929 I had. Torqued it to 63 ft-lbs. This time it was MUCH less effort to get there.

We'll just chalk it up to pilot error.

-- Dan
'95 9C1
 
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Dan, I just had the same problem with my Bilstein 0929 rear shock. I've owned Bilstein shocks for many cars and I have never encountered this problem. To me, the hardware seemed softer than my previous Bilstein shocks.

I would contact Bilstein and let them know about your problem because that's what I did. If you want to avoid the wait for a shock replacement, go to your nearest parts store and buy a P30 shock bolt kit. I bought the P30 shock bolt but I could not install it into the original Bilstein rubber bushing without damaging it. I finally sent the shock back to Bilstein for repair or replacement. This stripped shock bolt cost me a lot of time and pegged the frustration meter.
 
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I'm starting to realize what a good design HAL used by using a removable (i.e. replacable at the hardware store) bolt there instead of an "embedded in the bushing" stud......
 
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Discussion Starter #5
Goldmember,
Thanks for the tip on the shock bolt. Since I didn't want to wait for a new shock, I went that route.

The guys at the local parts place were confused by what a "P30 shock bolt kit" was. They put me in touch with the local Bilstein distributor who said it was a Bilstein part, but that they would have to order that. (Not sure I believed them, either).

Over at PepBoys the counter guy looked through some catalogs and the finally directed me to a Motormite (aka "Help") part -- which was a Universal shock bolt replacement kit. $4.95 and comes with its own rubber bushing, so I was able to get rid of the Bilstein bushing.

Bolt diameter is exactly the same as the stud in the Bilstein. Spacer was a little bit thicker, but it's good enough for government work.

I'll post some pics when I get a chance.

-- Dan
'95 9C1
 
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I'm glad the shock bolt kit worked out for you Dan. I wish I was able to reuse the original bushing instead of the HELP split bushings. I could not press in the new bolt without damaging the oem bilstein bushing. Oh well, I'm still waiting for my shock to come back.
 
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