Possible broken top mount on new lift? Please help

[02projectkj]

I just upgraded my full suspension to OME. I haven’t even hit any trails and my left front started making a lot of noise. I got the vehicle towed to my house and it appears as though my top strut mount may have broken. I’ve loosened up everything but because the strut is no longer compressed I can’t seem to get it out. Any help/tips would be appreciated. Thanks

 

[KJowner]

Looks like the top nut has come off in the first picture.

 

[02projectkj]

The second pic shows it better. The nut is still there. The top mount sheared off around the strut post. Crazy! It’s a KYB mount so it’s under warranty but what is going on with quality assurance with all these parts manufacturers these days? It’s obviously a poor casting that caused this failure. Frustrating now that it’s gonna cost me money to have the strut reassembled again plus another alignment and obviously the time involved in a tear down and rebuild…not looking forward to it.

 

[KJowner]

The second pic shows it better. The nut is still there. The top mount sheared off around the strut post. Crazy! It’s a KYB mount so it’s under warranty but what is going on with quality assurance with all these parts manufacturers these days? It’s obviously a poor casting that caused this failure. Frustrating now that it’s gonna cost me money to have the strut reassembled again plus another alignment and obviously the time involved in a tear down and rebuild…not looking forward to it.

That's terrible, KYB are allegedly decent parts, I have 2 new KYB front shocks sitting on the shelf to go on mine! I'll get them out of the box and have a look at them.

 

[02projectkj]

That's terrible, KYB are allegedly decent parts, I have 2 new KYB front shocks sitting on the shelf to go on mine! I'll get them out of the box and have a look at them.

KYB used to be a solid company and maybe they still are. Every company has faulty parts occasionally I suppose. Mine is actaully the top mount and it appears as though the part that the strut shaft goes through just sheared off the mount leaving a metal “ring” around the the strut shaft…poor casting for sure.

 

[Luke]

I’ll be sure to let you know the results… I have a set going in shortly. We’ll get a cross sampling as it’s not for a KJ.

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[Luke]

When the crisis is over… post some pics of the failure if you can.

 

[02projectkj]

Will do!

 

[duderz7]

Should be a large washer on top of mount which would prevent shock pulling through

 

[02projectkj]

I used all the hardware that came with the replacement parts….and if I remember correctly the stock struts didn’t have any such washer either.

 

[duderz7]

https://images.app.goo.gl/VjC79bRV652CyMNZA big washer is here

 

[02projectkj]

Interesting. But if the strut pulled through a cast iron/steel top mount I really don’t think a washer would’ve prevented it from happening.

 

[duderz7]

Interesting. But if the strut pulled through a cast iron/steel top mount I really don’t think a washer would’ve prevented it from happening.

That a bushing with steel sleeve through the center where the shaft passes through. I can see in you pictures where it looks like the sleeve pulled out taking some rubber with it. A thick wide washer would not have pulled through the bushing.

 

[ikuo78]

I looked carefully at the KK mounting plate and the holes are 30mm.
KK's mount bush can be disassembled.

Anything less than 30mm will pass through.

KJ's is probably the same.

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[duderz7]

Me thinks the kj bush is molded into the mount, (see picture I linked above) at least it sure seemed to be every time I had mine apart. And yes, the washer is pretty big so it doesn't pull through.

 

[02projectkj]

That a bushing with steel sleeve through the center where the shaft passes through. I can see in you pictures where it looks like the sleeve pulled out taking some rubber with it. A thick wide washer would not have pulled through the bushing.

I installed everything that came with the OME strut/coil spring as well as everything that came with the KYB upper/lower mounts. If there was supposed to be a washer I think it would’ve been included…but who knows.

 

[duderz7]

I installed everything that came with the OME strut/coil spring as well as everything that came with the KYB upper/lower mounts. If there was supposed to be a washer I think it would’ve been included…but who knows.

Mine is bilstein and ome and I honestly can't remember if the washer came with shock ir was carried over from the stock assembly, I reused original top mount.

 

[02projectkj]

I figured with 132k on the vehicle the suspension was about done so I just changed out everything to prevent future issues.

 

[Rokk]

I have seen 2 different types, the type above that can be disassembled and one that can’t. The latter is often on cheap quick-struts. I believe they are interchangeable. Either way it looks like you forgot an important washer. This pic shows a version with a large washer on top, I think this is what you’re missing

 

[02projectkj]

I have seen 2 different types, the type above that can be disassembled and one that can’t. The latter is often on cheap quick-struts. I believe they are interchangeable. Either way it looks like you forgot an important washer. This pic shows a version with a large washer on top, I think this is what you’re missing

It’s just crazy to think that I bought all new components for my whole suspension and washers didn

Me thinks the kj bush is molded into the mount, (see picture I linked above) at least it sure seemed to be every time I had mine apart. And yes, the washer is pretty big so it doesn't pull through.

this is what mine look like…