Bilstein 25-187632 User guide

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created: 04.20.10 E4-WM5-Y377A00_1 page 1 of 3 revised on: 01.26.12
IMPORTANT!
PLEASE READ ALL INSTRUCTIONS FIRST!
If in doubt, please contact your local BILSTEIN dealer or our sales department before installation.
When replacing other brands, BILSTEIN shock absorbers should always be installed as a set.
Installation of shock absorbers, struts and cartridges requires special tools and expert knowledge.
Accordingly, installation of all BILSTEIN products must be performed by a qualified suspension
specialist.
Always use a chassis hoist for the installation of BILSTEIN products, and make certain that the
raised vehicle is securely attached to the hoist to prevent the vehicle from slipping, falling, or
moving during the installation process.
If you choose to install any BILSTEIN product without the necessary special tools,
expertise or chassis hoist, you may subject yourself to the risk of serious bodily injury or
death. If you elect not to use a chassis hoist, at least make sure the vehicle is on level ground,
that all tires on the ground during installation are blocked to prevent movement, that at least two
tires are on the ground at all times, and that adequately secured safety stands (jack stands) are
used to support the chassis. NEVER get under the vehicle until you have checked to make sure
all of these things are done.
All BILSTEIN products must only be used for the specific, intended application as indicated in the
application guide. Any use of any BILSTEIN product other than for its intended use may
result in serious bodily injury or death.
BILSTEIN suspension 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, and never attempt to open or repair any BILSTEIN product, in order to prevent
serious bodily injury or death. Any attempt to misuse, misapply, modify, or tamper with any
BILSTEIN suspension product voids any warranty and may result in serious bodily injury or
death.
Do not use impact tools for loosening or tightening fasteners, because this may destroy the screw
threads. Self- locking nuts must only be used once!
Reuse original equipment components only if they are in good condition, otherwise replace them
with new components. Never remove the slight film of oil on the piston rod and seal.
All mounting fasteners for shocks and struts must be securely tightened before tension is placed
on the suspension system.
After installing any BILSTEIN product, the suspension caster and camber must be checked
and/or adjusted to comply with the vehicle manufacturer’s specifications. Also, the (load
dependent) brake compensator and the anti-lock brake system must be checked and/or reset to
comply with the vehicle manufacturer’s specifications. Also the headlight aim must be checked
and adjusted.
Be sure to properly dispose of all old parts.

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created: 04.20.10 E4-WM5-Y377A00_1 page 2 of 3 revised on: 01.26.12
BILSTEIN 5160 Series Reservoir Shock Absorbers are designed to fit your vehicle’s original
shock mounts with no modifications. With the exception of reservoir placement, the 5160 Series
shocks are installed in the same manner as a standard replacement shock.
A. Remove the existing rear shocks from the vehicle following all procedures in the vehicle
manufacturer’s service manual.
B. Before installing the shock/reservoir assemblies on the vehicle, use the supplied “piggyback”
hardware to mount each reservoir to its shock body. Each reservoir is mounted using two
polyurethane isolator blocks and two steel hose clamps. Please note that the position of each
reservoir relative to its shock body is different for each side of the vehicle. These positions
are depicted in Figures 1 and 2. The hose fittings are designed to swivel and will allow the
reservoir and hose to be easily moved.
C. The isolator blocks should be spaced approximately 6”-8” apart. The hose clamps should be
positioned in line with the isolator blocks.
D. Tighten the hose clamps sufficiently to prevent the reservoir from slipping, but loose enough
to allow for small subsequent adjustments of position. The hose clamps will be tightened
further once the shock/reservoir assembly is installed on the vehicle and the proper reservoir
position has been confirmed.
Figure
1. rear driver side

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created: 04.20.10 E4-WM5-Y377A00_1 page 3 of 3 revised on: 01.26.12
E. Install the complete shock/reservoir assemblies on the vehicle. All original fasteners can
be reused.
F. If a chassis hoist has been used, be sure to lower the vehicle such that its full weight is
on the suspension prior to fully tightening the fasteners.
G. Tighten all fasteners to the vehicle manufacturer’s service manual torque specifications.
H. Carefully check for any possible interference between the reservoirs and any other
components on the vehicle, then make any necessary adjustments to the reservoir
positions. The reservoir mounting locations depicted herein are appropriate for most Jeep
vehicles for which this product is intended, however, some aftermarket components and
or lift kit combinations may create interference problems. It is the responsibility of the
installer to determine if the reservoir is mounted appropriately and if there is any potential
for interference.
I. If no potential interference is found, tighten the hose clamps until the reservoirs cannot be
manually moved independent of the shock body. This completes the installation.
Figure
2. rear passenger side