Wow I am starting to agree with you guys: Bilstein probably should include a warning and a washer with their kit regarding this issue.

Thanks for the very interesting and helpful thread.

 

So before dropping off my stocks back to the installer I took a couple of pictures so others can see what you shouldn't get back after the install

If someone can chime in and tell me which #'s SHOULD NOT be there that would be great.

Thanks again!

 

This post will explain it all. Please read carefully and look at the diagrams.

https://www.6speedonline.com/forums/...0-post114.html

 

thanks for the reply Mike. From that diagram it looks like the spacer that should have been taken out is #3, BUT it also seems #1 should have also been taken and transferred over to the bilsteins... Does that seem correct?

 

Yes, I believe you need all three.

 

Mike/AWE, C4SxM5, Chris, et al,

It's not that simple. Comparing the 2 diagrams. I assume Washer #1 is A, washer #2 is D, and cone washer #3 is E.

From Bilstein's diagram, washer #2 or D is ***NOT*** OEM. So you are not using both #1 and #2 from the OEM shock, isn't that correct? And if so, which one should you use?

Yikes, why do I think everyone of us should have ours inspected? And this could be the source of the long mysterious click on parking speed turning that people have been reported and thought to be "normal"? Thank you, drkbrent!

 

#3 is improperly labeled. It should read "Continuum Transfunctioner"

 

Just took a look at the instructions that came with my Bilstein and item (A) is not listed as an OE part on my instruction. Everything else looks the same comparing the instructions that came with my coilovers and the one posted. Either way, the only thing missing from my install was indeed the spacer (E) on the diagram or (3) in my picture.
I can also see how an installer would miss this item now. The spacer is acutally hidden with the rubber boot on the stock shock and the boot needs to be pull down to be visible.

 

Heck, if Can (our resident suspension guru) is confused then we're all in trouble. Why don't they just supply all the parts and make it a true bolt on mod? I guess that would be too simple. I wonder how many other vehicles are on the road with a missing washer? Yikes is right.

 

The Bilstein's come with washer "A" & "D" (see attached pic). I believe we need to use the OEM "C" & "E". I just dropped off my car with Luis at Autodynamica to install the Bilstein's that I bought from AWE a couple of weeks ago & he was aware of this issue. The attached pic shows the hardware that comes with the coilovers. I agree with everyone; dont know why Bilstein dosent include "E" in their kit.

 

Yikes, why do I think everyone of us should have ours inspected? And this could be the source of the long mysterious click on parking speed turning that people have been reported and thought to be "normal"?

Very interesting thread. I've always had the mysterious click occur when backing out of my driveway with the first application of the brakes and again on the first application of the brakes in the other direction (all at very low speed). When I asked my tuner about this he said it was the brake pads and it was normal. Since I have more than 10K miles on the car, I feel safe in assuming the Bilsteins were installed correctly.

BTW I believe this washer/spacer problem came up way back on a thread either on this forum or on the Renn Speed forum. It was at that time that I questioned my installer if he was certain he had used the OEM washer. He just rolled his eyes and made me feel stupid for questioning his capabilities.

Up here in the rust belt I know of two other cars with the same mods by the same installer and none of us have had a problem in this regard. We all have experienced strange suspension noises which we chased for several months that seems to have been resolved with an application of waterproof silicone grease to the sway bar bushings.

I'm with everyone else, in that I wouldn't have that Porsche dealer tech ever touch my car again even if it was for putting air in the tires.



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I have no clicking, popping. or anything like this. I also have them on both cars .
I have never looked but when I bounced the idea off my installer informally of Dereks car he did mention this clear set of instructions Bilstein provides and how important it was to follow it to the letter.

In order to Tune my car , convert the cluch , upgrade the brakes , install the aerokit .. there's so much to know that it really takes a person who clearly has a passion for perfectionism with working on Porsches .

I feel the lesson I am getting from the thread is not so much about Bilstein but rather what it takes to find a professional installer. A lot of shops might offer a great price or insist that they are the right guy for the job . As an owner who never worked on the car myself I can understand that its hard to differentiate talent from a great sales pitch .

But with 500+ Hp there's just too much riding on who you choose as well as what you chose for the car.

 

I had my Bilstein's installed about 30 months and 18K miles ago by an company that is well known in the Southern California area for this type of installations and projects that are much more envolved than a coilover installation.

I did not hear any sounds from my supension in the first 20 -30 miles but I did notice that everytime I drove the car and parked it inside my industrial building with a good flat floor I would notice the car would not be at the same ride hieght on the front passenger side. I measured the hieght and then took the car out in the parking lot for a 1/10th of a mile and parked it inside and measured again an the change was almost 3/8" different only on the front passenger side.

I next removed the passenger side coilover myself and found the "E" washer was missing. I found one of the "E" washers with my stock parts and installed it per the Bilstein instructions (included in the coilover box). I next checked the front drivers side and found the "E" washer installed properly. I next checked the rear installation and all was good.

I drove the car about 50 miles over the next week and the ride hieght was no longer changing and so I took my car to have it aligned and conner balanced.

As much as I am disapointed in the company that did a bad installation I will not name this company because I did not call them and give them a chance to fix or make good on their mistake. I was very sure before I removed the passenger front coilover that someting was wrong and I just needed to put an end to the disapointment and fixed it myself. So right or wrong I wiil never do bussiness with them again.

On a good note I was advised to take my car to RSS Stuttgart in Costa Mesa CA and they did an awesome job setting my final ride hieght, alignment and conner balance.

BTW my car is a Cayman S and I was reading this thread because I am thinking the 997TT might be my next Porsche and stock 997TT ride hieght is just to high.

 

Bilstein provide the lower large disc as the damper rod is a different diameter. The spacer properly locates the top mount. It is intuitive. Any engineer who misses it is either rushing or not experienced.

 

the key word being "engineer". Most owners and techs are not engineers!