3G TL (2004-2008)
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Koni yellow sport shock fork collar

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Old 08-18-2018, 10:03 AM
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Koni yellow sport shock fork collar



Is this normal with koni yellow ?
I hit a pot hole and this happened.
Old 08-18-2018, 10:49 AM
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There should either be a groove that the pinch bolt sits in or a welded collar that prevents that from happening.

Did you line everything up during install?
Old 08-18-2018, 03:15 PM
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I'd say that's *NOT* normal...
Old 08-18-2018, 09:08 PM
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The plate where the damp fork lines up fell off. I guess welding from koni was not to spec during manufacturing.
Old 08-18-2018, 10:51 PM
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OP,
Did the bottom of the shock hit the axel? In your picture, it seems there are a few inches of clearance, but it occurred to me that the axel may be hanging low because you lifted the car.
Old 08-18-2018, 11:50 PM
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Originally Posted by redbeard1
OP,
Did the bottom of the shock hit the axel? In your picture, it seems there are a few inches of clearance, but it occurred to me that the axel may be hanging low because you lifted the car.
Yes it did hit the axle during the impact when the plate from the shock fell of. This is what the plate looks like.
Old 08-19-2018, 12:07 AM
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Originally Posted by BROlando
There should either be a groove that the pinch bolt sits in or a welded collar that prevents that from happening.

Did you line everything up during install?
Yes, I believe it was manufacture defect or maybe koni Drop the ball on their research on our car make. The stock shock you can see for yourself has ring and a buldg to prevent the shock from sliding through like that.
Old 08-19-2018, 03:00 AM
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Definitely not normal. Depending on how old they are, but probably regardless, I’d try to get in touch with them and get a replacement
Old 08-20-2018, 03:55 PM
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From my best recollection, there isn’t an oem ring, but there is a metal nub (like your recent pic) (if you will that prevents the shock from going beyond the fork). Again this was years ago during install, but am pretty sure the nub is there, and difficult to remove (if wanting to lower the shock to get more travel, as some have done).PM moderator Justnspace......he may have more accurate info...
Old 08-20-2018, 04:35 PM
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Originally Posted by RocxOne-TL
The stock shock you can see for yourself has ring and a buldg to prevent the shock from sliding through like that.
Here is a picture from the stock forward shock I replaced on my 2005 TL base. There is a ring, instead of the rectangular plate on the koni, that is welded so maybe less likely to fail as there is more area to weld. That said, the koni yellows have a very good reputation. Maybe a manufacturing defect like OP wrote.

Old 08-20-2018, 05:28 PM
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The stock rings aren't welded on. You can remove them via hammer pretty easily.

They butt up against a thicker portion of the shock, however...which prevents them from sliding upward.

OP's shock likely had a manufacturing defect...or the pinch bolt was under-torqued...or the parts were assembled in an incorrect orientation.

I don't think the design is very good. But...Koni yellows are meant to be massively inexpensive.
Old 08-20-2018, 05:39 PM
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Koni Yellows have been pretty popular here on this site and this is the first I've seen of this failure..


@justnspace Have you seen this happen before?

Old 08-20-2018, 05:53 PM
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I've seen that failure on a cheap set of shocks that had a similar spot welded tab.

The tab probably isn't doing a majority of holding the car up. It seems to me that its just there to locate the shock.

The pinch bolt (when properly installed) should be doing most of the heavy lifting. Don't take that as direction to over-torque the pinch bolt though.

You're definitely putting a crushing amount of weight into that point. They really should design the shock with a thicker section to prevent upward travel....similar to stock...or similar to Tein, etc.
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