Bilstein 5100 rear install issue! Super confused!

Ok, I have silenced the mystery. You guys were all really close, but it turns out that There were two factors…
1: I did not check the diameters of the holes in the washers quite close enough…

2: Bilstein Screwed up and sent me one alignment washer with 3- 24.3mm diameter washers. Thus allowing the barrel spacer to pass through everywhere that it shouldn’t.

I think this can all be fixed my using the original mounting hardware from my old shocks.

Thank you all for helping my mental gears spin to figure this out! Y’all Rock!

 

So I just installed rear 5100’s on my 2021 last night. Similar concerns with the included bushings install order so I tried to mimic how the stock ones were set up. Did I do this wrong, ie bad enough to have to redo? Haven’t driven it yet. The first two pictures show the stock setup with no washer under the mount, and the last is how I set it up before tightening with no washer between the lower bushing and bottom of the mount. Bilstein should be ashamed of their instructions.

 

I just did an install and afterwards realized I didn’t include the alignment washer either. Have you had any issues with yours? I put it together the same way that it was stock which didn’t include the alignment washer. It looked like it would have way too much play if you put it in which was why I didn’t and the original didn’t include it. But wondering if you’ve had any issues?

 

No issues and seems solid. I had similar concerns washer underneath and figured if it was OK for stock, it would be OK with the 5100’s. I’ve even pulled my pontoon a couple times. The only issue I can think would be if the Bilstein bushing was too narrow and possible slide through, or if the under washer was needed to get enough thread grip. Again, no issues so far.

I did keep all stock and extra hardware just in case. I also called Toytec and the tech told me to use the washer, but I’m not sure if it’s just because the (crappy) instructions also say to. Just keep an eye on it but I don’t lose any sleep.

 

awesome sounds good! The videos I watched were kind of split between them. I figured it’d be alright but wanted to see your experience before I just sent it.