Dobinsons HBS59-019K Hydraulic Bump Stops Instruction Manual
- June 12, 2024
- Dobinsons
Table of Contents
Dobinsons HBS59-019K Hydraulic Bump Stops
Product Information
Dobinsons Hydraulic Bump Stops
The Dobinsons Hydraulic Bump Stops (model HBS59-019K) are aftermarket replacement parts designed to enhance the suspension system of your vehicle. These bump stops are engineered to improve vehicle handling and behavior, providing a more controlled and comfortable ride.
Product Features:
- Hydraulic design for superior performance and damping capabilities
- High-quality construction for durability and longevity
- Compatible with various vehicle models
Safety Warning:
When installing aftermarket replacement parts like the Dobinsons Hydraulic Bump Stops, it is important to be aware that your vehicle may handle and behave differently. Always adhere to relevant road rules and practice safe driving and vehicle operating practices.
Product Usage Instructions
Step 1: Before starting the installation, ensure that the rest of the suspension components are fitted, adjusted, and aligned correctly. This ensures that the vehicle is sitting at its finished ride height with the Panhard rod and castor adjustment products installed correctly.
Step 2: Apply a small amount of lubricant, such as light oil or WD40, to the thread of the bump stops. Thread the bump stops into the mounts to ensure they screw in correctly. Install one locking ring below the mount with the grub screw tip pointing towards the mount. The upper locking ring is not required. Thread the bump stop fully but leave it loose for now.
Step 3: Safely raise the vehicle and support it with chassis stands. Remove the coil springs, rubber coil seats, and shocks. Use a 12mm socket and extension to remove the inner coil rubber bump stop.
Step 4: Use a hole saw between 58mm and 63mm to drill a hole into the bump stop mount, using the center threaded hole as a guide.
Step 5: After drilling the hole, deburr it to remove any rough edges and prevent rust. Apply black spray paint or zinc-rich spray paint to protect the mount from corrosion.
Step 6: Install the half circle plates with nuts through the hole, aligning them with the existing bump stop holes. Bolt the bump stop and mount into the vehicle using the supplied M8 x 35mm bolts, spring washers, and flat washers. Apply red high-strength Loctite to ensure a secure connection. Start by bolting one side first to hold the half circle plate and then rotate into place to secure the second nut.
Step 7: Bolt the striker pad into the bottom inner coil bump stop mount using the provided countersunk bolt and handle nut. Apply red Loctite for added security.
Step 8: Adjust the bump stop height by cycling the suspension and adjusting both the hydraulic bump stop and the under chassis rubber bump stop. The desired height is achieved when there is 5-10mm of the shaft showing and the outer bump stop is sitting on the chassis.
Step 9: Once the desired height is achieved, tighten the lock nut on the hydraulic bump stop. Then, tighten the locking grub screw to secure it in place.
Step 10: Reinstall the coils, shocks, wheels, and any other items that were previously removed during the installation process.
Following these instructions will ensure the proper installation and usage of the Dobinsons Hydraulic Bump Stops, enhancing your vehicle’s suspension performance and ride quality.
Install Time – 2-3 hours
Tools Required
- Floor Jacks and chassis stands
- Spanners, socket sets, hammer
- Drill and hole saw 58-63mm hole saw
- Black Spray Paint / Zinc Rich spray paint
Thankyou for purchasing Dobinsons hydraulic bump stops. Dobinsons hydraulic bump stops utilize a 30mm rod in conjunction with a 50mm diameter piston. This high quality hydraulic bump stop provides smooth bottom out control without excessive rebound associated with regular rubber and polyurethane bump stops. Dobinsons hydraulic bump stops have a M56 x 1.5 threaded high strength steel body for easy adjustment. It is important to ensure that the bump stops are installed and adjusted correctly and safely to provide optimum performance. Always check your local federal, state or territory laws before installation to ensure compliance for road registered vehicles – if engineering approval is required an engineer should be consulted before install.
Safety Warning
When fitting aftermarket replacement parts, it is important to note that your
vehicle may behave and handle differently. Always follow relevant road rules
and always use safe driving and vehicle operating practices. These bump stops
are pressurized with high pressure nitrogen gas and should never be heated or
opened whilst pressurized. These bump stops should only be opened by a
qualified technician. Take extreme care when de-gassing these bump stops and
ensure that the bump stop is in the upright position for 10 minutes to allow
the oil to settle to the bottom as there is no physical barrier between the
oil and gas which may cause oil to escape from the shrader valve. Always cover
the shrader valve with a cloth when de-gassing.
Installation Warning
These bump stops should be installed only by a qualified technician. Attempts to install these products without knowledge or experience may jeopardize the safety of the vehicle. As bump stops are a universal product that can be installed in many applications it is the installer and engineers responsibility to ensure correct and safe installation. These instructions provide only a basic guideline for installation and do not cover vehicle disassembly or re-assembly. The installer is responsible to insure a safe and controllable vehicle after performing modifications. Do not perform test drives on public roads with partially completed installations. Always double and triple check your work before use.
Selection of Bump stops
For the rear of Landcruiser 80/105 with 0 – 4 inch lift kits the HBS56-009 bump stop is recommended, for 4-6” lifts HBS56-006 is recommended – this may require additional outer spacers
Setup and Installation
IMPORTANT NOTE: Before commencing installation the vehicle must have the rest of the suspension components fitted, adjusted and aligned correctly. This is so that the vehicle is sitting at its finished ride height with the Panhard rod and castor adjustment products fitted and aligned correctly and will ensure that the bump stops contact the striking pad correctly at full compression. Always take extreme care not to damage the bump stop thread.
- Firstly apply a small amount of lubricant to the thread such as light oil or wd40 and thread the bump stops into the mounts to ensure they screw in correctly. Install one locking ring below the mount with the grub screw tip point towards the mount. The upper locking ring is not required. Thread the bumpstop fully in but Leave loose for now.
- Using safe and proper workshop practices raise the vehicle and support with chassis stands. Remove the, coil springs, rubber coil seats and shocks. Use a 12mm socket and extension to remove the inner coil rubber bump stop.
- Using a hole saw between 58 and 63mm, drill a hole into the bumpstop mount using the centre threaded hole as a guide.
- Deburr the hole and paint to prevent rust.
- Install the half circle plates with nuts through the hole and align with the existing bump stop holes.
- Bolt the bump stop and mount into the vehicle using the bolts supplied and red high strength Loctite using the M8 x 35mm bolts, spring washers and flat washers combined, bolting to he half circle plates. Bolt one side in first to hold the half circle plate and then rotate into place to get the second nut.
- Bolt the striker pad into the bottom inner coil bump stop mount using the countersunk bolt and handle nut supplied along with red Loctite.
- Setting the bump stop height: The Dobinsons hydraulic bump stop kit are designed to work in conjunction with the original under chassis rubber bump stop. The under chassis rubber bump stop must be contact when the hydraulic bump stop has 5 – 10mm of shaft remaining / travel remaining. Use the spacers provided on the outer bump stop and adjust the hydraulic bump stop to achieve this whilst also ensuring clearances on all contact areas such as diff housing, shock absorber full compression (must have 5 – 10mm shaft showing at bull bump), coil bind and all other areas that may cause issues. Cycle the suspension and adjust both the hydraulic bumpstop and under chassis rubber bump stop until this is achieved.
- Tighten the lock nut on the hydraulic bump stop and then tighten the locking grub screw.
- Re-install coils, shocks, wheel and other removed items.
Maintenance
Dobinsons hydraulic bump stops are completely rebuildable and tunable. The bump stops should be kept clean and the locking rings inspected regularly to ensure they are tight. For non-race applications the bump stops can be inspected periodically and at regular service intervals for signs of oil leaks, damage to the shaft and gas pressure. For race applications the bump stops should be inspected before and after each meet for signs of damage or oil leaks. Gas pressure should be checked before each race meet. For severe race applications it is recommended to rebuild and service the bump stops periodically.
Warranty
Dobinsons hydraulic bumpstops have a limited 2 year warranty for non-race vehicle applications from date of original sale against faulty manufacture. For full warranty terms and conditions for hydraulic bump stops please visit www.dobinsonsprings.com.
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