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Unread 04-01-2012, 06:26 PM   #1
KCJeep
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1996 ZJ 
 
Join Date: Nov 2009
Location: Kansas City
Posts: 58
KYB rear shocks won't fit!

So I bought a matching set of both front and rear KYB Excel-G/GR-2 for my 1996 ZJ. Fronts went on with little drama except they were a little shorter. Shorter than the stock that came out of the truck, but I made them fit.

So the rears are giving me more trouble. The lower portion of the new shock has what looks to be a permanent metal sleeve that you place the bolt through. The old shock does not have this piece. Well, that rod is too wide for the shackel. Its not like it's real close either, it's off by a good amount.

I got them from RockAuto and confirmed that they are the one spec'd for my GC. They are part number 344396.

Has anyone run into this before? What did you do?

I really don't want to have to send them back to Rock(if they will even take them back) if I can make them work.

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Unread 04-01-2012, 07:02 PM   #2
Mark05059
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1989 YJ Wrangler 
 
Join Date: Mar 2009
Location: quechee Vermont
Posts: 4,353
will the bolt fit through the sleeve? if it does then just grind the sleeve to fit
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Unread 04-01-2012, 07:37 PM   #3
TheHalfWit
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1995 ZJ 
 
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How close is the bolt to the bushings through size? I'm betting they preinstalled a sleeve for a smaller bolt that is normally supposed to come in a plastic bag with the shock.

I just got a set of bilstiens and there wasn't a sleeve inside the bushing, but one was in the bag and the instructions stated to use it if I used some bolt size that I can't remember.
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Unread 04-01-2012, 09:17 PM   #4
Dyn0mitemat
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1998 ZJ 
 
Join Date: Dec 2010
Location: BC, Oh
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My 4.5" Bilsteins I got off kolak were the same way, only one end fit the top stud in the rear, and the end that went down (body down) was like 1/16-1/8" too wide, I just took a huge crescent wrench and tightened it on each side of the brackets and bent them out just a bit. Did that enough to get the loop of the shock in it, and used a pointed punch to get it centered to get the bolt through. Tightened up the bolts and its been fine
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Unread 02-05-2013, 05:21 PM   #5
ddb
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Join Date: Feb 2013
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I have the same issue on my 1997 ZJ. Same KYB shocks from RockAuto.com with the same fitment issue on the rear. The sleeve in the bottom of the shock is just a tad too wide to fit in the shackle.

Before I attempt to modify the sleeve or the shackle I would like to know how the OP resolved his issue (I sent him a PM but haven't yet heard back). I'm willing to send the rear shocks back but from all of the online resources that I have checked they appear to be the correct shocks.

Has anyone else experienced this? How did you resolve it? I just want to know all of my options before making a decision.

Thanks,

ddb
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