How the HELL do I fix this???...Broken KW V3 Coil

[JumboBlack1.8]

First of all, I'd like to start off by saying....ajdflksjdflkasjdflkajdflkjdf!!! F@CKKK!!!!

Now....onto the problem....

So, I came home from college yesterday because I had a dentist appointment, and before I even pick up the keys, my dad tells me that "The rear suspension sounds loose." Of course, I tell him thats impossible, cuz I tightened EVERYthing to factory specs when I installed my KW Variant 3 coilovers last year, but I told him it could've been a blow shock, which I also doubted.....So I took the car out for a drive, and everything was as smooth as usual....BUT, on small bumps, i'd hear a loud banging sound coming from the rear passenger side wheel well...

So, after a lil test drive, I got out my torque wrench, re-tightened everything....drove around....still the banging sound, which really does sound like a TON of parts are loose and literally bouncing around....WTF

So this morning, I take off the rear strut assembly, undo the bottom bolt on the bottom control arm....and the WHOLE DAMN COILOVER falls out!!!

[O_O]

After taking the whole thing out, found this....The weld on the top of the strut just broke.....check it out...





Heres what the weld SHOULD look like


Now the obvious question is...how the HELL do i get this fixed? The strut itself is still in perfect condition...no leaking oil or anything.....but that weld just needs to be fixed. Can I just go to a regular welder to get it fixed, or do I have to send it directly to KW?.....I'm hoping this won't cost a lot of money, cuz i'm workin on some other things for my car right now, so someone PLEASEe give me some good news....

[Poopie]

take it to a local fab shop to have it welded. Not a huge issue. Should only cost like 30 bucks to tig weld.

[Yaktizzle417]

Yeah just take it and get it welded.

[pfa65]

make sure who ever welds that is good. any heat distortion could warp the strut shape. If that were my car and suspension, KW would be notified to say the least. I would call them up and ask for a new strut... send them the pictures because that is effed up! I have always worried about that joint...

[JaVa]

there was no penentration on that original weld, or very little at least. get it rewelded, take the bushing out before you have it weled or it will melt. like said above make sure they stich weld it so it doesnt get too hot.

[This Is Epic]

Jb Weld Ftw!

[Stampy]

I would send them an email/call before you get it welded. They might be willing to send you out a replacement and you send that back to them. I mean, I would at least try to replace an important piece like that correctly first. Like mentioned before, you have to be really sure about who is welding that for you. I have seen many people that can "weld" that mess up bad. I had a $300 GHL DP ruined a few years back by someone that said " no problem, just give me $20"

[tdn]

clearly the manufacturers fault. if you have time, a spare car or something, definitely let the company know before you let anyone touch/weld it. i've been welding (and certified.. doesn't mean much) for a very long time and thats clearly not a simple mistake. the welder either didn't give a shit, is way overworked or came in hung over. and on top of that there's no quality control/supervision.

on a mistake like that, the company would be stupid to not send you a replacement. it's completely obvious they screwed up.

good luck.

[JumboBlack1.8]

Thanks for all the responses.....I just sent KW an email with a few pictures attached...Unfortunately, I'm not the original owner, so I'm not sure how this will work out for me....I can't believe it broke off so easily. I literally NEVER drive over potholes, and, altho I live in Boston, I stay away from the bad roads. It's just so weird to me, especially considering how expensive and high quality KW V3's are

I don't have another car, so I'm just gonna be without one for a while until I can get this fixed....I'll let you guys know when I get a response

For now, the car will just sit on jackstands

[JumboBlack1.8]

Heres the response I got. According to them its "not repairable".....looks like I might be screwed without the original receipt....

I have reviewed your pictures, from what I see that is not something
that can be repaired. You are probably looking at replacing the actual
housings. I would also need to see some pictures of your vehicle.

I have included in this email our warranty claim sheet. Please fill this
out completely and get it back to us. Once we receive the completed form
we can issue an RGA number for you to send your units back to us.

If the unit is leaking, and this is due to a manufactures defect we
will fix the unit and return it to you shipping COD. If the unit shows
signs of misuse, damage, or improper installation, the warranty will not
cover the issue and you will be contacted with a cost to fix the unit.

On the claim form, please include both who installed the kit, and if
any other aftermarket parts are being used with it i.e. sway bars, upper
mounts, ect.

I strongly suggest sending in the entire kit minus the springs if
possible. If we find a problem with one unit, we can check the rest of
the units to be sure you will not encounter this problem again.

When returning the kit, please be sure to include both a copy of the
warranty claim sheet, and a copy of your original receipt from the time
of purchase. Both of these items are needed to process any warranty
claim.

Please complete the attached warranty claim form, and let us know if
you have any questions!

[tdn]

That guy doesn't know what he's talking about. You may be screwed without the receipt. I'm sure if this got to the warranty department (assuming you have the receipt) they would take care of you. Picture number four says it all. You may just be better off having it welded correctly somewhere local, since you haven't got the receipt, they probably won't reimburse you shipping anyway and it'll take much less time.

It would be nice to see them stand behind their product.

[SilverB5A4]

JB weld will fix that no problem...

[AudiA4_20T]

wow that sux, it could go both ways. Either you get a free new shock or your forced to pay for repair. To be honest, if it happened from just normal driving then it was not misused and you should be fine

[Militant-Grunt]

I wouldn't try re welding that, weld brakes again and you may sustain major damage to your car. Just replace it, its your best bet.

[JumboBlack1.8]

After exchanging a few emails with a guy, he told me that he would need to SEE the shock in order to make a judgment about it.....I told him that I am the original owner, but I threw out the receipt a while ago.....unfortunately, that didn't work.....I'm guessing that if I send it to them, they'll give me some speech about how it can't be fixed, and that I need to spend $400 or so on a new strut.....I think at this point I could just try to fix it locally, and see what happens with that.....

Anyone know of a REALLY good welder I can send this thing to?....I really don't wanna have to buy new shocks.....I've already been spending way too much money on my BT

[Poopie]

Anything metal can be fixed. Take it to a local fabricator and they can give you their professional oppinion. If it broke around the weld there would be an issue. since its the weld itself, it is a manufacturing defect in the weld. it can just be ground off and welded.

[Poopie]

Also, if you look at the weld, the two metals from the shaft and the shaft end were never bonded. When you weld, you want to melt the two metals together to form one piece. This weld looks like they just used filler to close the gap. Kinda like a using glue or sealant. When something is welded, the joint should be stronger then the metal around it.

[SilverB5A4]

Also, if you look at the weld, the two metals from the shaft and the shaft end were never bonded. When you weld, you want to melt the two metals together to form one piece. This weld looks like they just used filler to close the gap. Kinda like a using glue or sealant. When something is welded, the joint should be stronger then the metal around it.

Exactly, that must of been welded on a friday afternoon, somebody did take there time with that one.

[JumboBlack1.8]

yea, it really does look like a shit welding job.....I'm gonna try to get it fixed locally....but I"m just worried that some of the other welds are that bad too.....

[JaVa]

itll be fine to have it welded. just make sure they tig it. and take the bushing out! you can see in pic 4 there is zero penetration in the weld.