I’m with you on that one, even when lightly loose it shouldn’t snap like this,

 

I hope the installer will step up to the plate and help you out, clearly his error.

 

Heck of a detailed, easy-to-read report from Bilstein! I think the evidence is now irrefutable...looks like installer error! Thanks to Mike for continuing to be with me on this issue every step of the way! AWE is truly a professional operation!

The ONE complaint I have on this whole issue (not related to AWE at all) is that Bilstein did NOT include this washer with the original shock. Does that surprise anyone other than myself? I mean, when I go and buy oil filters for my BMW's, even they have little, replacement washers that come with them...even though you could easily use the one already on the car. Seems to me that this tiny piece would simply come with the damn shocks! This would solve all problems in my humble opinion! Then, the instructions wouldn't have to include "making sure the OEM washer is used..." etc, etc. Does anyone else agree with me here?

 

Bilstein should include a new washer. But regardless its clearly installer error.

Its little things like this that makes it so important that you bring your car to a shop that is used to modifying your type of car. They will know all these little things.

 

I am glad that we found a problem; it would be extremely disturbing otherwise.

While I thought initially that there should be a warning, mainly because of the potential disastrous result; I am now only 60/40 because I am thinking the package would then come with 200 warnings: make sure you put this screw on, make sure you put that screw on, make sure you don't over tighten here, etc., etc.

Whether to include washer? Very good question; I am 50/50 here. What it comes down to is how OBVIOUS this washer is to a professional installer? And that -- we don't know and the pros are not "talking." That said... your installer did have it on the other side. That would imply it is obvious and he made a mistake. Making a mistake is maybe not preventable, but NOT having a procedure to catch a mistake (Test drive? Why he didn't hear the noise?) might be the major failing here.

Have you decided to flat bed the car to another installer or have this tech put back original suspension so you could drive to the other installer? Or have you decided this tech is not to touch the car anymore? Is he giving you a full refund? I actually would vote for a total take-down and inspection of front and back Bilstein coilovers before re-installation. By another person.

I feel your pain & sincerely hope this terrible incident doesn't detract you from enjoying your amazing car!! It might seem like it's not worth it anymore but I think so as it WILL transform the car. (A Bilstein 997.1 Turbo feels more sporty and has better feedback than even the improved 997.2 Turbo.) Best of luck and drive safely.

 

I'm with you on this one drkbrent. It's pretty lame imo not to include ALL the parts especially a $2 washer with the new kit. The OEM one could be worn, etc...It certainly would be a prudent thing to do since it might have prevented catastrophies like this one.

 

due to this thread i am taking my car back to my installer to verify the washer is there. i've heard a pop every once in awhile while going up driveways at a slow pace and don't want to run into this issue. hopefully my installer won't think im being picky...

 

UPDATE!!! Just got a call from the owner of the shop and the pieces are not there!!! I am so glad I went with my instincts on this one. So he asked me to bring my stock coilovers back up so they can fix the problem.

Mike, do you think adding them on now is too late? Its been about a month and less than 1KMI but I'm kind of worried that the metal may be weaker now if that makes any sense...

 

Wow, I guess the pros really don't know how to install these. I assume these have instructions, no?

 

C4SxM5, I am SOglad you went with your instincts on this one! I guarantee the steel shaft has wear; mine didn't have 50 miles on them and mine snapped! I know you have to order that piece from Porsch...Bilstein does NOT provide it! Good luck!

 

its to late to just fix they problem(by putting int he washer on the damaged system). I think they will need to R&R them. I wouldn't feel safe personally just putting in the washer now after ANY stress has been put on them.

 

I think the majority of installers assume its a straight forward install like any other coilovers and really don't read the manual. My installer said he was trying to locate the pieces and when I told him it was on my stock coilovers and that they were suppose to remove them he was a bit shock that Bilstein wouldn't include them.

Just to make everything clear, I am suppose to remove these 2 washers from my stock coilovers correct? I do not need to order these pieces new or get them from the dealer?

Also, can someone tell me what page in the install instructions it states that this piece needs to be removed from the oem coilovers?

 

Great intuition and follow through! Check out post #121 and user guide. There are three labeled "OE" parts in the diagram. It seems odd that an installer would install only two of the three labeled OEM parts but it obviously happens.

 

I've seen the diagram but when reading the written instructions I really don't see anything in writing stating what needs to be removed from oe. Wish bilstein made it clearer or maybe the mods can sticky this thread.

Thanks again op and mike for bringing this subject up. Bet it will help out a lot members in the future.

 

Just checked mine out, all is well OE in place!