problem with Bilstein's
 

Car is an 02 TransAm convertible. Original suspension was pretty worn out so I decided to install a new setup. I went with the Bilstein BTS-7501 kit (new springs and shocks/struts). I used a pair of new Moog strut mounts on the front, had a local shop mount the front springs to the struts. Install went well, no issues. First thing I noticed is that the ride is a bit harsh for my taste, I dont do any type of racing. I could live with the hard ride. Have about 400 miles on the install and I noticed a very heavy banging noise from the front area of the car. I found that the metal sleeve ( inside the upper rubber mount) had pulled out of the mount, passenger side, front. There is one washer and a nylok nut holding the strut to the mount. The washer is just about the size of the nut (O.D.). I checked the left side and with the car up in the air, there is about 3/4" of the mount sleeve exposed, but it hasnt separated from the mount. Normal or is the left side mount on the way out? Is it a good idea to install a large washer ( maybe a fender washer) under the nut to spread the load on the mount? Is there a better mount than the Moog or is it just that my old friend Murphy is back visiting?

Most likely your missing the Insulator, without it the center of the upper mount will eventually get pulled through.

http://www.rockauto.com/catalog/rafr...&parttype=7520

http://img.photobucket.com/albums/v3...shock2copy.jpg

FYI, you're going to need new upper mount now.

http://www.rockauto.com/catalog/rafr...&parttype=7600

Yes, those parts are not there. Guess I should have disassembled and reassembled them by myself, that way I would have noticed the "extra" parts. I have one new mount, best order those insulators and a new mount for the left side as well. Thanks for the help.

Just to be sure, I checked the shop manual and it doesnt mention the insulator. Looks like it assumes you are reusing the old mount, etc. Anyway, is the correct assembly procedure to install the mount on the spring, install the insulator on the mount and then compress the spring and install the nut and washer?

Short answer; Yes

The shock body caps(metal) and boots assembles (with bump-stops inside)were also transferred over; correct?

The lower metal rings/mounts , on the shock body, were installed. The old assemblies were just trashed, he assembled the new parts that were in the kit. No boots. I just ordered a pair of boots and bump stops ( KYB SB103). Looks like a fun weekend if everything shows up on time.

IMO, coat the upper shock shaft that goes through the upper mount with a light coat of anti-seize, then coat the center metal of the isolator(top an bottom) with a medium to heavy coat of anti-seize. This will help prevent that area from becoming heavily rusted over time; wear disposable gloves while doing this since it can get quite messy as far as transferring from your hands to anything you touch.

Good tips. I see many references to how rusted these things are. Thanks, now I sit and wait for parts. Question, the boots go on first and then the bump stops?

Should be bump stop, then boot.

OK, thanks. Bump stop, boot, spring, upper mount, insulator and then washer/nut. Anti-seize and some locktite. It's been a while, last time I did this was on my 3rd gen, less parts.

No Loctite, and use a locknut.

Understand. I purchased new locknuts from GM. Thanks for the help.