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Bilstein B8 8100, Mounting Instruction

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Bilstein B8 8100 Mounting Instruction Download Page 10

E4-WM5-Y630A00 

 

MOUNTING INSTRUCTION 

 

 

 

created: 04.16.19                                                   E4-WM5-Y630A00_2 Page 10 of 22                                                 latest revision: 09.29.20 

N. 

Remove the 5 screws holding the mud flaps and black plastic piece under the rear quarter panel. They are circled in 
red in the pictures below.  

    

 

Right side depicted. Left side is a mirror image. 

 

O. 

Once  you’ve moved the  panel out of the  way,  locate  the  holes on the vertical section of the frame rail. On  the right 
side, they are either 10mm holes or threaded M8x1.25 holes depending on the year of your vehicle. On the left side, 
they are always threaded M8x1.25 holes.  

     

 

Left side                                                                                                    Right side 

 

 

Note: On GX470 models the air 
compressor assembly will need to be 
removed in order to install the reservoirs.  

Summary of Contents for B8 8100

Page 1: ...ion 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 Never attempt to ope...

Page 2: ...er 1 6 Alignment Washer 10 1 7 Alignment Washer 03 09 1 8 Bushing Upper 1 9 Concave Washer 1 10 Flange Locknut M12X1 25 1 11 Reservoir Mount Plate Rear 1 12 Reservoir Clamp 1 13 Flat Head Screw M8x1 2...

Page 3: ...nents are in good condition save them for reuse later If damage or excessive wear is present on any of these components purchase the required replacement OE components B Place the Anti Rotation Pin BO...

Page 4: ...is D ring into place as shown below may cause your shock to rotate and contact the E Brake cable as well as other components on the vehicle E Slide the Lower Bushing BOM item 5 and the appropriate Ali...

Page 5: ...r the Alignment Washer BOM item 6 or 7 in the chassis mount hole as shown below Right side depicted Left side is a mirror image H Slide the Upper Bushing BOM item 8 over the threaded pin followed by t...

Page 6: ...pper and lower shock mounts secured and with the rear suspension drooped out make sure the Anti Rotation Pin is not contacting the Anti Rotation Plate or shock body If it is contacting loosen the Nylo...

Page 7: ...E4 WM5 Y630A00 MOUNTING INSTRUCTION created 04 16 19 E4 WM5 Y630A00_2 Page 7 of 22 latest revision 09 29 20 J You should now have both shocks installed as shown below Left Rear Right Rear...

Page 8: ...es need to be removed to gain access to 2 frame holes that will be used for the reservoir mounting Left side Right side L Remove the 5 screws holding the black plastic piece under the rear quarter pan...

Page 9: ...29 20 Right side depicted Left side is a mirror image For Lexus GX460 Steps M N can be skipped for 4Runner and GX470 M In order to install the reservoirs the following plastic pieces need to be remov...

Page 10: ...ow Right side depicted Left side is a mirror image O Once you ve moved the panel out of the way locate the holes on the vertical section of the frame rail On the right side they are either 10mm holes...

Page 11: ...Then place the Socket Head Cap Screw BOM item 14 through the hole in the Reservoir Clamp threading it into the Nylock Thread in a few turns for now with a 5mm hex but leave loose enough so the reserv...

Page 12: ...Cap Screw then place it through the other hole in the Reservoir Mount Plate and into the threaded hole in the frame Now slide the reservoir so that it s almost touching the rear body mount bracket as...

Page 13: ...oles in your frame are threaded skip to step AA for 4Runner GX470 or step FF for GX460 Process for installing Threaded Inserts into frame complete this procedure for all Threaded Inserts V If you have...

Page 14: ...While keeping the Threaded Insert flange firm and parallel against the frame rail tighten the screw using a 7 16 box end wrench or socket Turn it 2 5 rotations to set the Threaded Insert Tightening i...

Page 15: ...ft lb 22 Nm BB Place the Nylock BOM item 3 in the upper slot of the Reservoir Clamp as shown below Then place the Socket Head Cap Screw BOM item 14 through the hole in the Reservoir Clamp threading i...

Page 16: ...and use a 13mm wrench to mount the assembly to the frame If Threaded Inserts were installed apply non permanent thread locker to two of the Hex Head Cap Screws BOM item 16 and use two of the Washers B...

Page 17: ...n below Then place the Socket Head Cap Screw BOM item 14 through the hole in the Reservoir Clamp threading it into the Nylock Thread in a few turns for now with a 5mm hex but leave loose enough so the...

Page 18: ...serts were installed apply non permanent thread locker to two of the Hex Head Cap Screws BOM item 16 and use two of the Washers BOM item 2 and a 7 16 wrench to mount the assembly to the frame Now slid...

Page 19: ...BOM item 16 and use a 7 16 wrench to mount the hose to the frame Torque either Cap Screw to 14 ft lb 19 Nm Right side depicted Left side is a mirror image except for KDSS models Note On the left side...

Page 20: ...5 Y630A00_2 Page 20 of 22 latest revision 09 29 20 Final left rear driver 25 284584 B8 8100 shock installed on 4Runner and GX460 470 2016 4Runner KDSS model depicted Note On GX470 models some trimming...

Page 21: ...16 19 E4 WM5 Y630A00_2 Page 21 of 22 latest revision 09 29 20 Final right rear passenger 25 284591 B8 8100 shock installed on 4Runner and GX470 2016 4Runner KDSS model depicted Final right rear passen...

Page 22: ...ed adjustment TURN IN Clockwise the adjuster screw to INCREASE damping TURN OUT Counter Clockwise the adjuster screw to DECREASE damping 3 Tighten the jam nut against the bypass adjuster housing while...

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