Front Upper Shock Bushing Failures

[Trail X]

Mine are finally starting to go after nearly 5 years.

The indicator for me was that I get a sound like a small bell being rung once whenever I top out now.

It seems to be coming from the fact that the top washer has been beaten up now so that it looks upside down.

After 5 years though, I think I'll just replace it with more BDS parts. It will be interesting to see if they survive as long - if they don't last as long, it would indicate that there was some sort of bushing change at BDS at some point.

[TBYODA]

I have been following this post with great interest and have some food for thought.
Maybe this has been over looked maybe not (have not seen it discussed anywhere so far) but one thing I see different between the BDS front upper mount and Mark's 3" front mount is the third bolt on the outside of the strut mount. It seems like more brushing failures are with Mark's 3”, which do not utilize that extra outside bolt. As Jason stated there is a lot of side load as you go up in lift. Based on the failures my guess this side load is towards the inside. Now could having three bolts holding down the mount counter act that side load somewhat? I am no Mech Eng but I am thinking that only having two bolts would not limit the possible movement in the y plane as the strut travels. X would be front to back of TB, y is side to side and Z would be up/down. Without the third bolt, maybe there is just enough movement over time to cause this type of failure. In addition, does Mark’s front mount have the sleeve between the bushings? It kind looks like it does from his picture on his site but since I have not seen them first hand it is hard to tell. Mark needs to send me a prototype lift with a third bolt for testing for the benefit of the community.

Edit: I could be off in orbit with this.

Mikekey when you installed your BDS did you use that bolt? I would think so but just asking because I have not see any picture of it in any post. BTW, a few pictures in your build thread are missing or broken link...

[navigator]

I think the BDS stock photo shows 3 bolts but from what I recall, I don't think the actual lifts have 3 bolts.

I have the Rough Country lift (but only wheel mildly) but have had no bushing issues as of yet. I don't recall anyone having a bushing issue with the RC lift. If anyone has had that kind of issue it would be Donny.

[TBYODA]

I think the BDS stock photo shows 3 bolts but from what I recall, I don't think the actual lifts have 3 bolts.

Hmm. Would be interesting if James uses the bolt and other do not.

[JorDaneeKey]

I specifically remember installing all 3 nuts on the bolts to the BDS mounts. It was a pain as the third was harder to access without the body lift, but we used all 3.

[Trail X]

I had all three until more recently, when I took it out because it's pretty useless.

I'm pretty sure though, that it isn't the cause of the failures. Hasn't Mark seen bushing failures too?

[mikekey]

I had all three until more recently, when I took it out because it's pretty useless.

I'm pretty sure though, that it isn't the cause of the failures. Hasn't Mark seen bushing failures too?

PAGE 2

Heres what happened to me with Marks 3" 89s and No armor. Bushing gone and spacer damaged. having it repaired locally and should be back in business by next weekend.

[drburke]

Hasn't Mark seen bushing failures too?

From the first post:

ADMIN NOTE:

This discussion has come up before in random threads. This will become the definitive thread on the failure of aftermarket lift upper shock bushings.

I suppose this should probably be replaced soon...

that is the Markmc 3in kit, It has all the components that normally come with it.

[Trail X]

Hm, I guess those posts are directed my way eh.
I read Robert's post backwards, thinking that he was implying Mark's lift had less failures.

I still don't think the bolts have much of anything to do with it. If mark's fail more, then it's probably due to the 1/2" of extra lift, which puts the strut 1/3" closer to topping out, assuming that the max downward articulation is set to the same location on both lifts.

[v7guy]

well, this shit don't look right

[mikekey]

Dang, that does not look fun.

[TBYODA]

Hey I got question, so do you think that all these failure are because most of you that have failures are using 88 or 89 springs which are putting to much compression / pressure on the upper mount.
Sorry my lame question just trying to understand behind the computer screen with out any real experience.

[The Roadie]

The failure doesn't happen on compression. We have a bump stop to reduce the shock stress. But on EXTENSION with stiff springs AND heavy oversized tires and wheels, that's where we have the problems. The mount's not designed for that. It's also the mechanism that broke my Icon coilovers. We have no bump stop for extension.

Limiting straps are the right countermeasure.

[mikekey]

Hey I got question, so do you think that all these failure are because most of you that have failures are using 88 or 89 springs which are putting to much compression / pressure on the upper mount.
Sorry my lame question just trying to understand behind the computer screen with out any real experience.

I can only offer you my personal experience. I was running stock springs, and almost stock tires 30.5 Grabbers. I don't think I was wheeling too hard, but maybe I was. We experienced the bushing failure while on an ORV trail in Capitol Reef. I do believe that v7guy (Jason) mentioned that the problem seems to be related to the small sized washer. The top washer on my strut literally sheered the bushing. With no spare bushings, by the time we got back to FL, the bushing was completely obliterated.

[v7guy]

Yeah, the quick and dirty explanation ( it's covered a lot better in the previous pages) is like Bill and Mike said, the small washer destroys the bushing by cutting it, a larger washer quickly smashes into the strut bucket when there's just a smidge of wear, so it doesn't really work either... I bent a shock rod like that. In addition there's no internal bump stop, so on extension the internal valves slam into the shock body. In my case it ripped the threads on the shock rod internally letting the whole assembly come apart..

I'm thinking the solution might, maybe, possibly be a solid bearing mount in marks spacer (I got some parts on the way) With the washers and a stupid heavy bumper I don't appear to be having any more topping out issues. The only real problem seems to be the bushing part for me.


Or you could just get radflos and be done with it.

[Trail X]

Jason, where's the top washer? I want to see what's left of it. Did the top washer just shear? I'd be amazed if it did.

Eta - From your pics it appears the lower washer was forgotten... are you sure the top wasn't also forgotten??

[TBYODA]

Thanks for expiation I have been trying my best to follow along. Have not torn into SUV yet, and sometimes hard to get everything straight in my head on these threads. I figure if i read enough come next spring (bonus time ) I will have good plan.

[v7guy]

Jason, where's the top washer? I want to see what's left of it. Did the top washer just shear? I'd be amazed if it did.

Eta - From your pics it appears the lower washer was forgotten... are you sure the top wasn't also forgotten??

The washers were gone, I have no idea where they went. I suppose it's possible they were forgotten. That would explain the failure. The washer on the drivers side is pounded pretty good but is still there. Now that you mention it I just put it back together without a washer. I'm pretty irritated right now.

[Trail X]

I bet that was the root. Don't feel bad, I've seen a couple others do that through the years. It generally lasts less than a week when they do.

[boog2006]

Yep...I did that



Boog2006