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COMMON FAILURE REASONS

Shock absorber failure can be grouped into 3 areas:
Oil leakage, physical defect or noise.

OIL LEAKAGE

Normally oil leakage occurs as a result of damaged oil seal or bushing. Any damage to the piston rod can affect the oil seal.

Chrome peeled off on a piston rod   Damage on surface of piston rod as in photo   Damage on one side of a surface of piston rod as in photo
 
CAUSE AND ACTION
Damage due to worn out parts (Dust cover, bump rubber). Replace those parts, with new parts, and replace new KYB shock absorber    Damage by tools (plier etc) during installation of Shock Absorber). Do not hold piston rod by any tools. Replace new KYB shock absorber    Unsatisfactory installation of shock absorber causes irregularity. Correct installation with the right instruction or suitable tools.

NOISE

Noise can be present as either a rattle or a swish. Any damage to the piston rod can affect the oil seal.

Circlip on a piston rod broken Defect of a shock absorber of parts Noise (dismantled parts) from inside of Shock Absorber

CAUSE AND ACTION
Not using KYB supplied parts during installation, or use of other brand parts. Replace shock absorber using parts provided.   Damage by tools (plier etc) during installation of Shock Absorber). Do not hold piston rod by any tools. Replace new KYB shock absorber.   Incorrect bump or rubber used. Piston rod or internal components may be damaged by using wrong rubber. Replace shock absorber by using correct components.

PHYSICAL DEFECT

Physical defects are bent or broken shock absorbers.

Defects on cartridge outer shell Thread broken off at the top of piston rod

CAUSE AND ACTION    
Pressure by frozen liquid put in the strut. Do not put any liquid in the strut housing.   Tightened with impact wrench. Do not use any power tools.

Thread of eye-Ring broken. - Bent piston rod

CAUSE AND ACTION
Wrong Installation of shock absorbers and equivalent parts. Confirm KYB Insruction Sheet and Car Manufacturer Manual, and Replace Wrong parts or procedure.

Coil spring failure is mainly caused by corrosion. If the epoxy power coating on the spring is damaged during installation, by stone chipping or friction caused by metal to metal contact with spring seats, exposed metal will start to rust (this can be very rapid in cold / wet climates).

Because of the high stress levels involved during compression and recoil, any rust will be a weak point that will cause the spring to break. The break often occurs at the top or bottom of the spring because of the higher levels of stress.

Coil spring failure

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