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Top hat rubber gasket bulging, Bilstein 6112

Discussion in '2nd Gen. Tacomas (2005-2015)' started by Hook78, Mar 24, 2022.

  1. Mar 24, 2022 at 12:29 PM
    #1
    Hook78

    Hook78 [OP] Well-Known Member

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    I installed Bilstein 6112s a couple weeks ago, 4th setting, assembled them myself with new top hats.

    Today I was measuring the ride height and noticed that the driver’s side rubber gasket between the coil and the top hat is bulging out from under the top hat. The other side doesn’t have this issue and looks perfect.

    Do I need to get this fixed/reseated/reinstalled? What would cause this?

    17E9CF9E-3939-441E-9AF8-6EE2FF5C40B8.jpg 55A5F16C-344C-4362-8E19-FC181EF3A6B6.jpg
     
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  2. Mar 24, 2022 at 12:37 PM
    #2
    Superdave1.0

    Superdave1.0 Grandma Dave

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    It is likely from assembly. The center of the top hat bushing has a lip that rides inside the inner diameter of the coil spring. Often times upon assembly it gets caught and isn't fully seated inside the coil spring.

    fde2e1d1e061226b51b7fba4d3f2322e.jpg
     
    blu92in99, tacotoe and Hook78[OP] like this.
  3. Mar 24, 2022 at 12:40 PM
    #3
    Hook78

    Hook78 [OP] Well-Known Member

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    This makes sense. I had a hell of a time getting one of them to seat in the center of the coil due to the spring curving an awful lot during compression.

    Can this be remedied by compressing the spring while installed and reseating it against the top hat? Or does the coilover need to be removed to adjust? I’m also wondering if I need to replace the top hat if the gasket is this mashed. I assume I need to fix this.
     
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  4. Mar 24, 2022 at 12:49 PM
    #4
    Superdave1.0

    Superdave1.0 Grandma Dave

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    I would remove from truck and start over to be safe. Maybe pay a shop to compress the coil spring so it goes in smooth.

    My wall mounted spring compressor makes the job easy. I have tried doing 6112 with hand spring compressors, it's a PIA that way.

    20220224_114000.jpg
     
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  5. Mar 24, 2022 at 12:55 PM
    #5
    Hook78

    Hook78 [OP] Well-Known Member

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    I assembled using this spring compressor stand at the hobby shop onboard my local base. Maybe I chose the wrong spots for the arms to sit, or otherwise did a poor job. It’s a nice stand though.

    Definitely going to have a shop do the work. Thanks for the advice!

    966C9554-E92D-4F8D-A720-192BB95A0490.jpg
     
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  6. Mar 24, 2022 at 12:58 PM
    #6
    fourfourone

    fourfourone Well-Known Member

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    Both mine did that after I drove on the new suspension for a bit. Used brand new KYB top hats. No issues in 25k miles and I lightly wheel the truck too. The rubber seemed a bit softer on the KYB top hats. Boths coils were seated properly.
     
  7. Mar 24, 2022 at 1:10 PM
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    fourfourone

    fourfourone Well-Known Member

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  8. Mar 24, 2022 at 3:06 PM
    #8
    Hook78

    Hook78 [OP] Well-Known Member

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    I don’t know, there are tons of photos there of the KYB’s looking “normal” with no gasket pouring out. But yeah could be that it’s in the backside. I’m having a shop take a look at it. Wish I could tell whether or not the inside of the gasket is pinched as Super Dave said.
     
  9. Mar 25, 2022 at 6:26 AM
    #9
    fourfourone

    fourfourone Well-Known Member

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    The tons of photos are either of the shock not installed yet or freshly put on the truck. The bulging doesn't happen until you drive on them for a bit. I promise you they are seated right.
     
  10. Mar 30, 2022 at 1:30 PM
    #10
    Hook78

    Hook78 [OP] Well-Known Member

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    So three weeks after install only the one bushing/gasket is bulging. Definitely an install error.

    I’m buying a new top hat and having a local shop reseat with new tophat. Just in case the bushing/gasket has become permanently deformed from pinching. Quoted an hour of labor, not bad.
     
    Last edited: Mar 30, 2022
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  11. Dec 3, 2022 at 4:27 PM
    #11
    bees

    bees New Member

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    Did this end up getting fixed after you brought it into the shop? Or did the shop confirm it was not installed correctly? I just installed a KYB top hat today and it looks exactly the same as your photo.

    Thanks
     
  12. Dec 3, 2022 at 4:40 PM
    #12
    Hook78

    Hook78 [OP] Well-Known Member

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    What shocks and coils did you install? Some do have a clocked position, some don’t.

    What I found out is that my coils were not seated against the top hats quite properly. It’s hard to describe verbally but there’s a potion of the top hat that has to fit inside the coil, like an insert. The machine I used to compress the springs did not compress them totally vertically and so the top hat did not seat properly inside the top of the coil. A shop reseated with a better compressor machine and they were perfect.
     
  13. Dec 3, 2022 at 4:53 PM
    #13
    bees

    bees New Member

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    I installed Bilstein 4600 shocks with the stock spring. The truck is a 2015 prerunner TRD sport. I didn't notice any clocking features, but the inside of the KYB top hat had a lip that perhaps the spring didn't seat on correctly.
     
  14. Dec 3, 2022 at 5:19 PM
    #14
    Hook78

    Hook78 [OP] Well-Known Member

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    I believe the 5100’s have a clocking position not sure. My 6112’s did not, confirmed with Bilstein. The top hats definitely have a lip. If the coil doesn’t seat against the top hat correctly it looks like crap and is obvious. I can send a pic of my coilovers against the top hat if that helps you. There’s a little bit of conformity to the top of the coilover but it’s minor.
     
  15. Dec 3, 2022 at 5:22 PM
    #15
    bees

    bees New Member

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    Yeah a picture would be helpful, thank you. I’ll probably just disassemble it tomorrow and reinstall it. I haven’t driven it yet so I’m thinking the top hat is probably still fine.
     
  16. Dec 3, 2022 at 5:28 PM
    #16
    Hook78

    Hook78 [OP] Well-Known Member

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    Consider taking to a shop that has proper compression equipment, floor mounted or even wall mounted. An independent shop shouldn’t charge much to reseat.

    I’ll post some pics of mine tomorrow. A shop reseated them and they’re perfect now.
     
  17. Dec 4, 2022 at 12:18 PM
    #17
    bees

    bees New Member

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    Well today I took it all apart and the top hat still looked good. I really wasn't able to tell if anything was clocked incorrectly. When I reinstalled it I had a helper compress the spring very slowly as I guided the inside diameter of it over the lip of the top hat, and that seemed to have done the trick. I took the truck out for a drive and the top hat still looks good. Yesterday when the hat looked messed up it happened as soon as I lowered the truck back on the ground and drove it back and forth a few feet. Today I also used an inspection mirror to check around the back side of the top hat to see if the pad was bulged in the back, but I didn't see anything abnormal.
     

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