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Both front Koni struts failed in 20k/2 years


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Hey all, wondering if anybody else has had experience with their Koni yellow struts failing prematurely. Just came back from Surgeline and can confirm now that my fronts both need replacement. The left front insert twists around in the housing causing an irritating squeak. The right front is leaking fluid and is bouncy now. I'm just barely out of the warranty by a few months and am hesitating to put another pair in the car to replace them after that experience. Roads where I live are pretty smooth, too. 

 

Anybody had similar issues or gone with something else? Part of me is wishing I just ponied up for KWs.

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I'm thinking, install error. I think the Koni's can be rebuilt, call them.

 

Mine are still working great many years later, even after the right front hitting a huge rock years back. I had to replace the strut, but reused the Koni.

 

BTW, I still have that rock...

DSCN7888.JPG

 

Bottom of right strut.

DSCN7902.JPG

DSCN7900.JPG

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305,000miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. CHECK your oil, these cars use it.

 

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It's entirely possible that it was installed erroneously, however Surgeline is pretty top-notch. No clue who there installed them, but given that they have techs that can do custom fabrication and they work on crazy stuff day in and out, I can't imagine this would be super difficult for them. And then both failing? 

They gave me a quote to rebuild them but it's not cheap to have a shop do it and I don't have a vice, so not sure if I wanna attempt it myself. 

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Why would your Koni's not have a lifetime warranty? That's what they advertise on their website. 

https://www.koni-na.com/en-US/NorthAmerica/Products/CARS/Sport-(Yellow)/

Either way I'd reach out to Koni to see what they say. I've seen a handful of people report over and beyond customer service from then on other forums. I could potentially see them saying the left is due to install error but can't imagine the same would apply for the leaking one. 

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13 hours ago, DoctorDaveLGT said:

Why would your Koni's not have a lifetime warranty? That's what they advertise on their website. 

https://www.koni-na.com/en-US/NorthAmerica/Products/CARS/Sport-(Yellow)/

Either way I'd reach out to Koni to see what they say. I've seen a handful of people report over and beyond customer service from then on other forums. I could potentially see them saying the left is due to install error but can't imagine the same would apply for the leaking one. 

From what Surgeline told me, their warranty basically covers stuff that doesn't really break unless there's a major manufacturing defect. However, you inspired me to call them and talk to a rep. Seems like it might actually work out in my favor. Here's what the rep told me.

1. I need a copy of the registration for my car to prove I was the owner of the car who purchased the struts and still am.

2. They can either have me leave the car on jack stands and send the defective strut back and give me a replacement free of charge, OR they can charge me for a new strut, send it to me, have it set up and on, then, upon them receiving my defective shock, they'll take a look over to determine it actually has failed and then refund me. It doesn't appear that they will refund the labor, which is the lion's share of the cost for me in alignment and installation costs.

3. The squeaky strut that twists inside the housing is likely from the bolt on the bottom of the strut that holds the insert in place needing to be tightened. It's apparently a fairly common issue. It also could be from the strut housing being cut too short.

I should have asked if they need the whole shock body or if just sending them the old failed insert is sufficient. I don't have another KYB housing lying around and cutting it up is just more labor in the end.

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Yea that sounds like even in a worst case scenario of working with Koni you'll still be better off than just having them rebuilt. That's awesome they even gave options for how to handle everything. Seems to be in-line with what I've seen from others about their customer support. Hope it goes well and works out in your favor.

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Called and got the same rep again. Their phone system actually kinda sucks but whatever.

So they can actually warranty just the insert without the entire shock tower, which is nice. The only problem I have now is that Surgeline needs to do the warranty stuff since their supplier (I believe it's Turn 14) only warranties the Konis for two years. I think Koni won't care regardless, but I'm gonna leave it in their hands as they purchased the shocks and then installed them. Would be nice to save a few bucks. 

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I had the konis fail on me. The screw on the bottom of one came loose and tore apart the casing from the extra movement, and the other the bottom of the casing just rusted away basically and was leaking.... since then I've given up on konis, it happened to me twice in the front, the rears were fine. Rather than trying to save money with this bs insert nonsense, they should just make a normal strut like everyone else imo. At that price point, 200 or so each, I would rather get some simple coilovers, which I ultimately ended up doing. My ride comfort is already shot from all the poly so konis don't really do much for me, with the coilovers you can adjust the corner loading/balancing and ride height. I figured 1k for some coilovers or 800 bucks for inserts only to have a limited option if any for springs and having to butcher 2 struts which is like another 50 bucks or so... its just to much bs for my liking, way to many places to fail with this sleeve garbage.  But thats just my 2 cents, if your looking for stock ride quality and comfort, then yea we really don't have many options....

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8 hours ago, Tehnation said:

I had the konis fail on me. The screw on the bottom of one came loose and tore apart the casing from the extra movement, and the other the bottom of the casing just rusted away basically and was leaking.... since then I've given up on konis, it happened to me twice in the front, the rears were fine. Rather than trying to save money with this bs insert nonsense, they should just make a normal strut like everyone else imo. At that price point, 200 or so each, I would rather get some simple coilovers, which I ultimately ended up doing. My ride comfort is already shot from all the poly so konis don't really do much for me, with the coilovers you can adjust the corner loading/balancing and ride height. I figured 1k for some coilovers or 800 bucks for inserts only to have a limited option if any for springs and having to butcher 2 struts which is like another 50 bucks or so... its just to much bs for my liking, way to many places to fail with this sleeve garbage.  But thats just my 2 cents, if your looking for stock ride quality and comfort, then yea we really don't have many options....

We don't salt the roads here in the PNW so I'm not too worried about rust, but yeah, I'm sort of leaning towards putting KWs on the car. We'll see how warranty replacement goes if Surgeline can make it happen. If not, I'm just gonna drive around with shot struts for a bit till I've got the cash for KWs.

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Is that what the spec b's have? I hear those are pretty good, comparable to the konis, just not adjustable. I think you also need to buy new top hats for front as well to use them. 

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22 hours ago, Tehnation said:

Is that what the spec b's have? I hear those are pretty good, comparable to the konis, just not adjustable. I think you also need to buy new top hats for front as well to use them. 

I believe the Bilstein B8s are more aggressively valved for a lowering spring while the B6 are a Spec B drop in. Yeah, the top hats would set me back a bit.

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