1990 XJ40..... I replaced the air suspension with the manual set up. I got Bilsteins, which was a bit risky as I thought they may be too hard, but to my amazement they were fantastic...... great handling yet still smooth.

The issue is one of them broke last week (It showed itself as a loud clunking noise over bumps). My man replaced it free of charge..... and I broke another one 2 days later.

So.... the general question was has anyone else had this issue with Bilsteins? My current thinking is to change them both out to another brand, but that would be a real shame because the ride is so good.

 

I find it hard to believe that you broke the shocks. More than likely it is just the top bushings (13, 14, 15) that have worn out and need replacing. That would produce the "clunking" noise over bumps.

 

@StuG

I was surprised also, but my man showed me the broken shock........ instead of only being able to push and pull the rod in one direction, you could move it in many directions, kind of like stirring a pot of soup........ we haven't taken the second one off yet, but I am getting the same sound, and the cars handling has deteriorated same as before, so I am heavily suspecting we find the same thing.

I also thought is was the bushes as we had bush issues on the front of the car, but it seems there is something strange going on at the rear..... to be continued.

 

Hi Sarc,

That is really strange! In all my years I can't recall anyone having a problem with a broken Bilstein, Boge or Sachs on a Jaguar saloon. On the other hand, everyone has had the rubber and foam bushings go bad.

The only questions I can think of are:

1. Are you certain the correct model Bilsteins were installed?

2. Are you certain the mechanic installed all the components and in the correct order?


All the foam and rubber bushes should be renewed whenever the shocks are replaced. The yellow foam cylindrical isolators that are Parts 13 and 15 in the diagram in StuG's post usually come with the new shocks. You also need the large foam spring isolator "donut," Part 5, and the small hard rubber "Top Hat" bushing, Part 14, and those parts usually have to be ordered separately. Part 14, the Top Hat bush, usually deteriorates and disintegrates to the point that you may not find any remaining crumbs of it on disassembly. Without it, the shock shaft can bang against the rim of the hole in the steel upper mounting plate, Part 7. Part 5, the foam donut, hardens and compresses over time, and when you install the new ones you'll typically gain 1/4 - 3/8 inch of ride height.


Cheers,

Don

 

@DonB

We will check everything today when the car is up on the ramp......After we broke the first one, we were incredibly careful in how we put the second one on, including all the bushes you mentioned.

 

Hi Everyone,

I'm getting ready to do this work and noticed there are two different materials for the "Top Hat" component. One rubber, the other a composite material, any feedback on which is best?

 

I have run Bilsteins on Land Rovers, Jaguars, MINIs with no problems whatsoever. I don't understand the breakage as these shocks are usually 25% stronger than other shocks. Very good warranty. I had these on the heavy Discovery for 10 yrs. and on my track MINI for 5.

 

Hi Rob,

By "Top Hat", are you are referring to #14 in the diagram? If so, then I used the polyurethane replacement.


Cheers,

Stu

 

Hi Rob,

If the composite material is supposed to last a lot longer then that is what I would use. The Top Hat bushings are under considerable stress, and the OE style rubber ones tend to fail before the other components in the rear shock/spring assemblies.

Polyurethane would be better - I don't know what other options exist. Can you tell us more about the composite versions you've found?

Cheers,

Don

 

HI All,

I used the term composite as a generic term, mainly because I couldn't think of another word at the moment.

I'm sure what I saw was the Polyurethane that I saw on eBay. Thanks for the input.