Thanks everyone for posting your findings on the forum. Dynatrac always appreciates when users get involved in making our products better. I thought it would be good to add some more information to it, so everyone has the latest facts. Here goes.
Fox Factory conducted a series of more tests today on the new sleeves and they are confident they have resolved the problem for us. Here is why:
In order for the bolted compression test to be accurate, the 2 halves of the bushing sleeves must meet concentrically in the middle. Obviously if they do not, then the steel will deform since it is point loaded (all force applied to a very tiny area). When loaded into the urethane bushing, and then tightened, the sleeves will be held concentrically, spreading the load into the whole bushing.
The new sleeves Fox is providing for our shocks are superior to the prior embodiment we are replacing. Here is why we think so:
- The newly added flange on the sleeves contributes to holding the sleeves aligned as they are tightened, and prevents the point load pitfall which was the root cause of the original sleeve failing for some users. The new sleeves are also slightly longer so the factory bracket will “close” on it with less misalignment.
- The holes in the OEM JL shock mounts are large for easy assembly line install. They are also “V’d open” for the same reason. Depending on the exact position of the shock when tightened, our original sleeve would push through the OEM bracket holes, misalign and deform from point loading. As was mentioned earlier in this thread by drhcobra and Nicorumiz. The flange and length improvements resolve this.
- Fox Factory confirms they have deployed the same sleeve design in millions of shock applications without any issues. They tested the compression of the new EnduroSport sleeves to full bolt torque multiple times, and as long as they are installed in the eyelet bushing, they showed negligible deformation.
- The flange on the new sleeve will also provide more support for the sleeves where they meet in the center when the shock cycles up and down.
- As an extra precaution, when installing the shocks and tightening the eyelet bolts, it is best to have the shocks fully extended and relaxed to prevent unexpected sleeve misalignment. Our instructions shall call this out more emphatically in the future.
Dynatrac thinks Fox has done a great job of responding to this issue in just a matter of a few days. Dynatrac will have all new sleeves loaded in all EnduroSport kits shipping from now on. We are standing by to help anyone that needs replacement sleeves or bolts for the kits they have already received. Thanks again for your input. If anyone has any further recommendations on ways we can improve, or needs assistance, please call us at 714-596-4461 x-204.