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Old 04-15-2014, 08:50 PM   #1
nikkatnight
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Default Bolt fell out of rear shock?

My dad replaced the rear shocks for me on my 2006 Saturn Ion. He replaced the passenger side shock first and tightened it up based with a torque wrench based on the video we found on how to replace Ion shocks. Next day I hear a banging and find the shock is hanging there and the bottom bolt is gone.

Any ideas why this might have happened?

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Old 04-15-2014, 09:09 PM   #2
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2001 SL2
Default Re: Bolt fell out of rear shock?

yes they were 1 time use only bolts read the instalation sequence below instalation#2

xTooltipElement
Service Information


2006 Saturn ION | ION VIN A Service Manual | Suspension | Rear Suspension | Repair Instructions | Document ID: 870568
--------------------------------------------------------------------------------

Shock Absorber Replacement
Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
 2. Remove the wheel. Refer to Tire and Wheel Removal and Installation.



 3. Support the rear axle with a tall jack stand near the shock absorber.


 4. Remove the upper and lower shock bolts.
 5. Remove the shock from the vehicle.
Installation Procedure 1. Position the shock absorber to the vehicle.
Notice: Refer to Fastener Notice.




 2. Install NEW upper and lower shock bolts.
Tighten

◦Tighten the upper bolt to 90 Y (66 lb ft).
◦Tighten the lower bolt to 110 Y (81 lb ft).
 3. Remove the jack stand.
 4. Install the wheel. Refer to Tire and Wheel Removal and Installation.
 5. Lower the vehicle.
2014 General Motors. All rights reserved.

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Old 04-16-2014, 02:48 PM   #3
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Default Re: Bolt fell out of rear shock?

I also read in the service manual that the shock mounting bolts should be replaced whenever the shocks are replaced. This is because the bolts can sometimes stretch if reinstalled multiple times or if they are overtorqued. FWIW I reused them anyways when I replaced my shocks last weekend. They looked fine and felt secure when I torqued them with a torque wrench. Regardless, I have a very hard time believing that one of the bolts fell out after just one day as a direct result of not using new bolts.

I suspect that the bolt wasn't installed at all or the nut welded to the trailing arm is missing. I'd bet a friendly wager that most shops do not replace those bolts anyways unless they are stripped or otherwise physically compromised.

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Old 04-17-2014, 04:05 AM   #4
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Default Re: Bolt fell out of rear shock?

Quote:
Originally Posted by ruley73 View Post
I also read in the service manual that the shock mounting bolts should be replaced whenever the shocks are replaced. This is because the bolts can sometimes stretch if reinstalled multiple times or if they are overtorqued. FWIW I reused them anyways when I replaced my shocks last weekend. They looked fine and felt secure when I torqued them with a torque wrench. Regardless, I have a very hard time believing that one of the bolts fell out after just one day as a direct result of not using new bolts.

I suspect that the bolt wasn't installed at all or the nut welded to the trailing arm is missing. I'd bet a friendly wager that most shops do not replace those bolts anyways unless they are stripped or otherwise physically compromised.
Interesting! I haven't heard of this. I didn't replace mine either and I've reused them twice now.

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Old 04-18-2014, 08:06 AM   #5
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Default Re: Bolt fell out of rear shock?

Quote:
Originally Posted by ruley73 View Post
I also read in the service manual that the shock mounting bolts should be replaced whenever the shocks are replaced. This is because the bolts can sometimes stretch if reinstalled multiple times or if they are overtorqued. FWIW I reused them anyways when I replaced my shocks last weekend. They looked fine and felt secure when I torqued them with a torque wrench. Regardless, I have a very hard time believing that one of the bolts fell out after just one day as a direct result of not using new bolts.

I suspect that the bolt wasn't installed at all or the nut welded to the trailing arm is missing. I'd bet a friendly wager that most shops do not replace those bolts anyways unless they are stripped or otherwise physically compromised.

The bolt was installed. I can tell it was a slow process as the bolt fell out because it started with just a little bit of noise, then when it fell out completely there was a louder clanking. Got a new bolt from the dealer. They said they don't replace the bolt after one time. Another shop suggested using Loctite.

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Old 04-21-2014, 11:19 AM   #6
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Default Re: Bolt fell out of rear shock?

I just ordered a set of rear shocks for my Dad's 2005 Ion, the right one on his is leaking. I'm going to install KYB instead of the Delco units. I had no idea I had to also order new bolts. These are the original shocks so the bolts have never been removed. I'd like to replace the bolts as well now. Does anyone have the part numbers for the bolts?

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Old 04-21-2014, 07:10 PM   #7
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Default Re: Bolt fell out of rear shock?

upper bolt: 11609755
lower bolt: 11518185

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Old 04-21-2014, 08:22 PM   #8
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Default Re: Bolt fell out of rear shock?

Thanks for the info and part nbs . This is really interesting . I have an 05 ion and back in 07 changed to Monroe rear shocks then in.2008 I went with. 05 cobalt FE5 rear shocks and just recently replaced those with the. 08+ fe5 cobalt SS/TC rear shocks. I have kept the stock original bolts and never changed them out. I'm going to look them over this weekend .

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Old 04-29-2014, 02:57 PM   #9
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Default Re: Bolt fell out of rear shock?

Well I can understand why they say replace the bolts along with the shocks. I did the job over the weekend and the lower bolts were corroded and the threads dirty. Removing them was easy tho, putting them back was another story. I had to clean the bolts well along with the threads in the mounting hole. The upper bolt was not a problem, just the bottom. It took a little effort to reinstall the bottom bolts, even after cleaning. If I do this job again, I'm getting new bolts.

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Old 04-29-2014, 06:07 PM   #10
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Default Re: Bolt fell out of rear shock?

You cannot torque a bolt correctly unless the threads are 100 clean. Period. Not to mention each time you torque a bolt it stretches, and if it isn't meant to be reused, it will never hold torque.

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Old 04-29-2014, 08:02 PM   #11
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2003 ION-2 Sedan
Default Re: Bolt fell out of rear shock?

iv reused the bolts on my shocks. one side came loose slightly, causing the shock to rattle over bumps. tightened it up a little bit, using a standard ratchet, and never loosened again.

i never realized these were one time use bolts

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Old 06-15-2016, 12:20 PM   #12
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Default Re: Bolt fell out of rear shock?

In having a similar problem here. I replace my struts and rear shock with Monroe. The bottoms bolt to my left rear shock won't screw in all the way. It eventually stops 3/4 way in then it gets harder and I don't want to snap the bolt. Any suggestions on what I can do? I have a 2007 saturn ion level 3. I'm thinking maybe the thread is dirty so I'm gonna work on it again today. Please any reply is appreciated. I really don't want to get a new bolt being as gm won't have it available for over a week and I need the car this weekend.

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Old 06-15-2016, 01:12 PM   #13
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Default Re: Bolt fell out of rear shock?

Examine the threaded hole where the bolt goes into. With the shock out of the way, try wire brushing the bolt threads of corrosion using some oil and try threading the bolt into the hole without the shock. This may be enough to clean the threads. Use oil or penetrant as a lube and don't tighten the bolt. Turn the bolt in until it gets tight and back out some while penetrant is used to help lube and clean threads. Scraping the threads of loose rust may help to prevent these bits from becoming artificial loctite. A pick tool may help here or simply blowing out the hole to move debris. Blue loctite may be used here to prevent future corrosion when the bolt is tightened. Loctite cures and seals threads from oxidation while acting as a glue against loosening.

When working on corroded, rusted nuts and bolts, recommendations to use Liquid Wrench, WD40 or PB Blaster helps loosen corrosion that becomes a glue or artificial loctite to prevent removal. Experience to approach these problems carefully when loosening for the first time by spraying your choice of penetrant then either applying heat to accelerate penetration or loosening then tightening - this breaks the bonds while allowing penetrant to seep in to help. Loosening some more and using more penetrant then tightening exercises the threads while clearing them of corrosion. This loosening and tightening with backing out the nut or bolt allows removal. These methods aren't printed in any manual and learned the hard way from experience or from others passing this info to anyone. Once fasteners are removed, cleaning may require wire brushing or in a worse case scenario, thread chaser. Thread chaser is a hardened threaded nut or die with slits to allow rethreading nuts or bolts to clean out threads while renewing them. Without thread chasers, a home made thread chaser can be made using a disposable nut or bolt by using a dremel with a cutting blade to cut slits perpendicular to the threads. The slits allows dirt, corrosion or rust a place to gather while running the nut or bolt in a little at a time. Penetrant or oil is used to lube this rethreading operation. If not familiar with rethreading tools, Google for images. There's always a solution to a problem.

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Old 06-15-2016, 02:46 PM   #14
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Default Re: Bolt fell out of rear shock?

Thank you so much!!! I figured it would be dirty and was thinking of getting a wire brush for cleaning. What kind of oil do I use when tightening? I'm going to get everything after work. I just hope I don't have to get bread or anything like that because I have no knowledge or experience with that. Plus gm says it'll take a week for new bolts so I don't want to snap it

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Old 06-15-2016, 03:19 PM   #15
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Default Re: Bolt fell out of rear shock?

Any oil will work. Whether its liquid wrench/pb blaster/cutting oil or motor oil, they're all made to lubricate and makes things slide. Rusted threads from road salts and normal weathering allows moisture to seep into things that create corrosion if not protected with loctite or antiseize compound. The lower shock bolt is probably made using normal coarse threaded bolts to allow removal with less chances of seizing but there are exceptions depending on where and how long corrosion sets it. If you're lucky these threads are just dirty from corrosion and cleaning them with or without using the bolt can allow reusing it. Try wire brushing the bolt to remove as much rust as possible and coat in some motor oil. Clean out the threaded hole with whatever fits to remove loose rust and debris. The more time spent removing corrosion by wire brush, picks with whatever's laying around, the better the chances of the bolt going in with less resistance as oil helps loosen up any more rust to allow threading the bolt all the way. Examine the bolt for squashed threads as this may be from overtightening and causing more problems with the threaded hole. As long as the bolt can clean up to reveal clean straight threads, the hole is the other half of the problem.

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Old 06-15-2016, 08:24 PM   #16
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Default Re: Bolt fell out of rear shock?

Thank you so much...I feel so stupid. Turns out it wasn't even the bottom bolt. The top bolt was tighten all the way. I tightened it until I couldn't anymore with a lug nut wrench and now no noise with a much smoother ride. Engine oil worked with ease btw

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