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Shock top hat failure on our stock 2024 Tacoma Off-Road while offroading

TacoFreak

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Those are picts I posted of the OEM top hats on the Pro.

Do a search on torque specs - it was posted here earlier in another thread.
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TrashPanda

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I guess this is another thing to put on the watch list. I donā€™t think Iā€™ll ever buy first year new gen anything again. Was the Tacoma a better choice than the Colorado? Stuck with it now.
 

TacoFreak

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@TrashPanda Yeah - that is hard to say, but I think the Tacoma will have fewer problems than a Colorado. A Chevy tech posted a list of Colorado failure points on another thread.

I had a first year production 2nd gen Taco and I never had a single problem, so I thought wtf, I'm going for it. Now I have the most expensive truck I have ever bought and it is on the transmission TSB list. I have no idea what I would get if I bail on my current truck.
 

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@TrashPanda Yeah - that is hard to say, but I think the Tacoma will have fewer problems than a Colorado. A Chevy tech posted a list of Colorado failure points on another thread.

I had a first year production 2nd gen Taco and I never had a single problem, so I thought wtf, I'm going for it. Now I have the most expensive truck I have ever bought and it is on the transmission TSB list. I have no idea what I would get if I bail on my current truck.
Exact same situation. At this point, Iā€™m along for the ride. I had 3 midsize trucks to choose and the Tacoma won. The Colorado had waaay too many complaints, the Ranger Raptor was fugly, so Tacoma won.
I think what pisses me off more right now is I feel like I need to avoid the Wescott Designs kit at the moment to prevent any warranty dispute if/when something happens.
 
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TacoFreak

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Yep - dealers have always jumped on mods as the cause of any suspension failure, even when it has nothing to do with it.

That was the same decision process for me. Tacomas obviously have issues but Colorados have more and I really hate the look of the Ranger. Plus Ford has a lot of quality issues too.

I am also along for the ride on the transmission. I am just over 500 miles now and starting to see some bad shifts, which will probably only get worse.

I think I am starting to miss my 14 year old Tundra!
 

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kingrosk

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We went out with the new taco to try and see what it was capable of in stock configuration and I have to say, for the most part, it was great! We didnā€™t do anything crazy but we did test traction, comfort and clearance pretty well (although we didnā€™t record it all)

We tried not to beat up the truck too much but the truck did end up breakingā€¦

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On our way back we picked up some speed on a flat area of the desert, and without hitting any jumps, rocks, or washboard one of the top hats of out right shock managed to come apart.

These new tacos have no frame mounted bump stops like the 2nd and 3rd Gens. Instead, the shock has an ā€œintegratedā€ bump stop that is simply a piece of foam that bumps the shock body to the shock mount or ā€œtop hatā€ when at full compression.

Our only conclusion is that fatigue or a hard enough hit was able to crack the top hat, a cap holding the bushing for the shock shaft came out and the shaft was able to completely go through the hat. We were unable to locate the cap so we are unsure if the cap broke or simply slipped out after the hat cracked.

In any case the cap was being held in place only by a groove on the hat that might have about 3/32ā€ engagement with the cap, both aluminum parts. The hat seems to be formed over what seems to be a cast cap.

A7B26E27-1E3D-4CF1-B66E-C9920FE48838.jpeg
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Needless to say, I believe the cap is not enough to take the force a bump stop normally would. I am not exaggerating when I say we DIDNā€™T HIT anything that would have caused a hard bottoming of the truck.

THIS IS THE 10TH TACOMA Iā€™ve owned and weā€™ve hit significantly worse things on old stock shocks, without a break. Pot holes on a regular street would have been much worse than anything we did on this run. Weā€™ve worked on hundreds if not thousands of tacos at this point and weā€™ve yet to see a shock mount break. Mostly because all other tacos did have a frame mounted bump stop I would assume, but thatā€™s exactly the point, if youā€™re going to make ā€œoff roadā€ shocks and integrate the bump stop, the hats better be able to take an impact. These donā€™t seem to be able to do that. I could be wrong and this could be a fluke but the way it is designed seems to me like a weak point that will hardly be able to take a good impact without a redesign.

We have a clip on this video of where this happened, you can see we picked up some speed but thereā€™s no obvious exact point where this would have happened, like I said, we didnā€™t hit any crazy terrain while taking that shot.

Do you know if this happens to the trailhunter as well?
 

TacoFreak

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The top hat design of the Trailhunter and Pro are different than the rest of the trims, and as far as I know there have been no failures in either of the halo models.
 

Gfenza89

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The top hat design of the Trailhunter and Pro are different than the rest of the trims, and as far as I know there have been no failures in either of the halo models.
Seems to only have effected the off-road model. All other trims are fine as far as I know. Makes me think it was a bad batch of top hats from bilstein
 

Gfenza89

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The top hat design of the Trailhunter and Pro are different than the rest of the trims, and as far as I know there have been no failures in either of the halo models.
I have to drive through some rough road and about 6 speed bumps every day and my truck takes it like a champ
 

TacoFreak

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Yeah - most 4th gens seem to be fine.

I bet your idea about some bad top hats from Bilstein might be the cause of those failures. I have not seen any reports on here far a good while.
 

Gfenza89

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Yeah - most 4th gens seem to be fine.

I bet your idea about some bad top hats from Bilstein might be the cause of those failures. I have not seen any reports on here far a good while.
Yup just like the cracked hvac boxes early on, lot of talk over the summer about that.
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