I recently had to replace my front shocks in my d 250, when I pulled them out both sides had pulled the stud through the washers and hole and were not connected at the top. so I replaced them and 2 weeks and 10 pot holes later the new ones have done the exact same thing. is there some kind of limiter on the front suspension that wont let it drop out put so much on the shocks? or could the front springs be wore enough that it putting to much load on the shocks? it does sag in the front but it has 135,000 miles. just looking for ideas before I throw another 100 bucks at new shocks

 

There is a bumper on the upper A that limits the downward stroke of the suspension. If that is in place and in good shape, you are installing the wrong shocks or are stacking the bushings wrong. The shocks are not supposed to limit the suspension travel. It is item 11 in the diagram.

 

Here is some pictures of the bumpstop. It looks intact and too on both sides. Also the brand new shock and the top of the hole that the threaded end of the shock goes through. Anything not look right?

 

It doesn't look like you have the large washer between the nut and the rubber bushings on the shock. From main shock body up it should go- Large washer, bushing, frame, bushing, large washer, nut. Also that is the bumpstop for uptravel the one for downtravel is bolted to the upper control arm facing down and hits the upper shock mount area when the suspension is fully extended.

 

The washer was there. On the original shock that I pulled out it had pulled the stud through the washer and it did the exact same thing on the brand new shock. The new shocks are rancho 9000 shocks. Also the top bump stop is in place and in good shape. Im wondering if I might possibly need to put a bigger diameter washer on top so it can't pull through so easy. I'm wondering if the hole in the a arm might be too big?

 

Its hard to see whats going on in the pics. But yes, the bushing and washer should be too large to pull through the shock mount hole. Either you've got the wrong bushings/washers or the hole has been enlarged.

 

You also need to make sure the shocks are for the 4000 pound axle. The lighter duty shocks are too short internally.

 

Looking at your pic again something seems wrong. I don't have any 2wd 1stgens here to look at, but if I recall the shock should have the stud attached at shock end. Said stud should have one bushing on it then slide through mount hole then another bushing with washer and nut should capture the shock. The pic showing bolt at 90° angle to shock body leads me to believe the shock is wrong style or been damaged. But I cannot see whats going on as coil spring is blocking view.

 

The shock was right at first and it was installed correct with washer,bushing, through control arm, then bushing,washer,but. Ranchos website says there for a 4000 pound axle. Is why its at a 90 angle is because it pulled through the hole and then bent over the next time the spring compressed. Something does not look right with the hole to me. I think I'm gonna go buy a cheap shock and put a bigger washer on top and see if it does it again before a I buy nice shocks again. I might just try the billsteins after I figure out the problem. I'm kinda wondering if my saggy coils are not helping any thing out

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Be sure you verify the length. I bought KYB shocks online and they were too short. I got them mounted, but the shocks were destroyed on the first test drive.

 

That very well could be my problem. What is supposed to be the correct factory length?

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The tension on the springs will not affect the suspension travel. You're trying to put Dakota shocks on a real truck. Even the mounting parts are wrong.

Or something is seriously wrong with the suspension geometry or stops.

Compare the mounting and length to the shocks you took off.

 

The model number of rancho shock I used is rs5199. Rock auto and ranchos website shows that is the right shock but after doing some more research it does not show its a diesel specific shock. I already chucked my old shocks or I would measure them. I did lay tyhgem side by side though when I put them on and they appeared to be the same length. But I dont now if the travel is the same on them.

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"RANCHO Part # RS5199: Front; w/ 0" - 2" Front Raised Height; Slight Grinding Of Lower Control Arm Is Req'd; w/o 4000lb Front Axle"

As in, without the 4000lb axle.

Compressed Length 9
Extended Length 13.375
Travel 4.375


For the 4000lb suspension:
MONROE 34868 Front; w/ 4,000lb Front Axle

Compressed Length 10
Extended Length 15.5
Travel 5.5


Sorry for being a busy body, but it looks as though you got the wrong shocks. I hope the mounts on the truck are okay.

 

I think you may be right. I'm pretty sure I read that wrong. I took is as though grinding would be needed if you did not have the 4000 pound axle. I think the ( grinding would be required) and ( w/o 4000 pound front axle) are 2 different parts.

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