Owners manual

ManualsBrandsBilstein Shocks ManualsAutomotive24-131582 4600 Series Shock Absorber Fits 03-06 Expedition

E4-WM5-Y294A01

MOUNTING INSTRUCTION

created: 09.05.09 E4-WM5-Y294A01 Page 1 of 5 latest revision:

IMPORTANT!

PLEASE READ ALL INSTRUCTIONS FIRST!

In case of doubt, please contact your local BILSTEIN dealer or our sales department before

installation.

When replacing other brands, BILSTEIN shock absorbers should always be installed as a set.

Installation of shock absorbers, struts and cartridges requires special tools and expert knowledge.

Accordingly, installation of all BILSTEIN products must be performed by a qualified suspension

specialist.

Always use a chassis hoist for the installation of BILSTEIN products, and make certain that the

raised vehicle is securely attached to the hoist to prevent the vehicle from slipping, falling, or

moving during the installation process.

If you choose to install any BILSTEIN product without the necessary special tools,

expertise or

chassis hoist, you may subject yourself to the risk of serious bodily injury or

death. If you elect not to use a chassis hoist, at least make sure the vehicle is on level ground,

that all tires on the ground during installation are blocked to prevent movement, that at least two

tires are on the ground at all times, and that adequately secured safety stands (jack stands) are

used to support the chassis. NEVER

get under the vehicle until you have checked to make sure

all of these things are done.

All BILSTEIN products must only be used for the specific, intended application as indicated in the

application guide. Any use of any BILSTEIN product other than for its intended use may

result in serious bodily injury or death.

BILSTEIN suspension products are gas-filled and are highly pressurized. Never place any

BILSTEIN product in a vise or use a clamp on any BILSTEIN product; never apply heat near any

BILSTEIN product, and never attempt to open or repair any BILSTEIN product, in order to prevent

serious bodily injury or death. Any attempt to misuse, misapply, modify, or tamper with any

BILSTEIN suspension product voids any warranty and may result in serious bodily injury or

death.

All mounting fasteners for struts must be securely tightened before tension is placed on the

suspension system. Make sure that the bump stop and dust cover are correctly and properly

fastened.

Do not use impact tools for loosening or tightening fasteners, because this may destroy the screw

threads. Self- locking nuts must only be used once

Suspension springs are PRELOADED

! The suspension spring must be compressed with the

assistance of an appropriate strut vise and spring compressor. The top mount must not be

removed until the preload pressure is no longer present and the spring can be moved by hand, or

serious bodily injury or death may result.

Reuse original equipment components only if they are in good condition, otherwise replace them

with new components. Never remove the slight film of oil on the piston rod and seal.

After installing any BILSTEIN product, the suspension caster and camber must be checked

and/or adjusted to comply with the vehicle manufacturer’s specifications. Also, the (load

dependent) brake compensator and the anti-lock brake system must be checked and/or reset to

comply with the vehicle manufacturer’s specifications. Also the headlight aim must be checked

and adjusted.

Be sure to properly dispose of all old parts.

Summary of content (5 pages)

PAGE 1
E4-WM5-Y294A01 MOUNTING INSTRUCTION IMPORTANT! PLEASE READ ALL INSTRUCTIONS FIRST! In case of doubt, please contact your local BILSTEIN dealer or our sales department before installation. When replacing other brands, BILSTEIN shock absorbers should always be installed as a set. Installation of shock absorbers, struts and cartridges requires special tools and expert knowledge. Accordingly, installation of all BILSTEIN products must be performed by a qualified suspension specialist.
PAGE 2
E4-WM5-Y294A01 MOUNTING INSTRUCTION A. Remove the shock and spring unit from the vehicle following all procedures in the vehicle manufacturer’s service manual. Note the position of the studs in the upper mount relative to the lower mount bearing (important for reassembly). B. Using an appropriate spring compressor, compress the coil spring until it can be rotated freely by hand. Then disassemble the shock and spring unit. C. Refer to Figure 1 to identify which original parts must be re-used.
PAGE 3
E4-WM5-Y294A01 MOUNTING INSTRUCTION If installing 5100 Series Bilstein shock absorbers, proceed with step D. If installing HD Series Bilstein shock absorbers (yellow in color), skip to step E. D. 5100 Series only: Install the circlip in the desired ride height location**. Refer to Figure 2. Use appropriate tools to move the circlip. Ensure that the circlip is fully seated in the groove after moving it. You should be able to rotate it manually in the groove.
PAGE 4
E4-WM5-Y294A01 MOUNTING INSTRUCTION Refer to Figure 3 for steps E through I. E. Install the spring seat support (4) on to the shock body (with the tapered end up) such that the groove inside the spring seat support fits over the circlip on the shock body. Install the spring seat support in the direction shown only. The circlip must fit completely in the groove inside spring seat support (see detail). Improper installation will cause permanent damage to the shock! F.
PAGE 5
E4-WM5-Y294A01 MOUNTING INSTRUCTION Refer to Figure 4 for steps J through N. J. Fit the bump stop (6) over the rubber sleeve (3) as shown (see detail). K. Using an appropriate spring compressor, compress the coil spring (7) and install it on the shock absorber. Align the lower coil end with end of the ramp on the spring seat (8). L. Install the upper mount (5) over the piston rod end and on to the top of the coil spring.