Please understand first and foremost, that there's been quite a bit of negative talk about our units recently on forums which is a real bummer. I'm sure you are aware of this. To a certain extent, I see it as natural. When a new product comes out, people rave about it if it's good. But if there are even just a few complaints, it spreads pretty quickly like wildfireo. It seems to be the natural course of forum talk and behavior. The pros and cons I guess

Somehow, people with "noise issues" and complaints about the inverted monotube coilovers for the GDB platform automatically began to attribute any and all problems with a particular "inferior grease" issue we had. I also mentioned this to you as well when we sat in your vehicle for a test drive so I can understand people automatically thinking they have the same problem (Feel free to post this by the way)

The fact of the matter is, however, that the grease issue was not as serious as we and others may have thought. It was a rare case of a small handful of individuals that we realized experienced a lack or premature wearing away of grease. We've nonetheless changed what we were currently using. It was actually the U.S. side that helped make the change for the Japan side. More importantly, of all the issues we've dealt with so far, the majority of the "noise issues" were solved with simple maintenance and/or tightening the lower lock for the lower adjustable cup/brackets.

It seems that the majority of users are not tightening this enough and they are not realizing that it's becoming loose. Although not everyone can measure the torque, we really recommend tightening this by using a rubber mallet or something similar as to not damage anything, but at the same time something that can create a good impact and lock it into place.

As for a torque rate, a safe and suggested torque rate would be 10 ~ 12 kgf-m (kilogram force meter) or 100 ~ 117 N-m (newton meter) or
85 ~ 87 pounds of torque. This is much tighter than simply hand tightening it.

Again, the majority of noise issues have gone away by simply tightening the locks to the lower adjustable brackets (and the lock for the spring seats). Also, we noticed through experience that the majority of users need to maintain the units much better. A few extra minutes of maintenance will increase the life of the units and save you money and time in the long run. Most of our customers fail to do so.

Although our regular monotube units have a dust boot to protect the shaft, the inverted monotube types are constructed differently. Thus, it's much easier for debris to get stuck inbetween the shell case and the cylinder. Especially in your case, there was quite a bit of debris almost to the point as if you were doing some kind of gravel/dirt driving. Although I know you did not drive in this type of environment, quite a bit of dust, dirt, and debris has gone in contact with the units.

However, I do know of some people who like how the ZEAL's feel and decide to take it out on those types of environments (their units looked much worse), but our units aren't made for gravel/dirt driving.

Anyhow, I digress. With your specific units, our engineer found nothing out of the ordinary at all. We've been taking extra precautionary measures with the inverted-monotube systems for the GDB platforms and did a complete re-overhauling.

Replaced dust seals. Regreased units. Gas pressure check and refill. Checked condition of rum cylinder and its movements. And especially, completed a thorough cleaning of the entire system.

Although we believed the noise may have been due mainly to a greasing issue, upon inspection, there was not a significant decrease in grease nor a change in the compound/texture whatsoever. Nonetheless, we went ahead and regreased the entire system with an almost unnecessarily thicker and higher temperature resistant grease.

Our engineer is that confident that the systems will not make any noise at all.

We would really like to emphasize to everyone now to clean the system periodically using a water spray. A hose with a sprayer will do. The more powerful, the better, but making sure to get any type of debris out of certain areas is key.

Cleaning debris from between the shell case and cylinder and cleaning debris (pebbles, rock, dirt, foreign debris, sand, tar, etc.) from inbetween the spring and spring seat, spring seat and spring seat lock, adjustable bracket lock and adjustable brackets. VERY IMPORTANT. Alot of noise issues can be rooted to these areas as well.

Also, if alot of height adjustments are made, it's necessary to regrease threads so as not to create any type of seizing. We've had cases (especially in colder environments) where customers would send in the units for an overhauling, but due to zero maintenance, they had to replace the entire shell case because the lower brackets were completely seized.

In your systems case, especially, we are very confident that they will be noiseless. Our engineer also feels that after inspecting the units and realizing the condition they were in, that type of noise, to some extent, is to be expected. Maintenance will prolong the life and decrease noise issues.

Even ONCE a month is enough, although we recommend doing so after runs and/or on a weekly or bi-weekly basis, depending on the extent/quantity/conditions of driving.

*Note: For some reason, the hex mechanism within one of your shafts in the rear seemed to have been tampered with. Although I'm aware that you are unaware of this tampering, this is just for future reference.

Luckily, in your case, there was no decrease in gas, but we've had a few guys in the past who've tampered with this thinking it was related to a noise issue and ended up releasing gas unknowingly and thus causing noise as well.

The only other suggestions/information I can give to noise issues to you and other customers or potential customers are the following:

Noises related to Pillow Ball Upper Mounts: This is of course, inevitable. There are no rubber bushings with strictly metal-on-metal. If this type of noises is bothersome, we suggest maybe some kind of rubber or cork material between the upper mounts and body. Of course, the downside is a decrease in direct feel with the road.

Noises related from Tension: Of course, the vehicle wasn't necessarily made to be lowered. When lowering, suspension components should be upgraded as well for a balance. The angles of the stabilizers change. Lateral links and stabilizers should be upgraded to pillow ball types. Simply upgrading to coilovers can cause unnecessary stress and tension.

We once had an individual who only adjusted camber via the pillow ball mounts. He caused so much tension that it created indentations in the plates.

Anyways, I wish your experiences with our coilovers were better. I'm definitely tending to GDB clients with much more care due to the negative image being portrayed especially by GDB customers.

Come think of it, posting this for us on NASIOC or iWSTi might even help?

I'd like to deal with each and every GDB customer in a specific manner. In some cases, the user's explanations are right on the money while with others, it's completely different from what we receive. Thus, it's difficult to guess a remedy just by hearsay. Of course, it's easier to deal with customers as yourself that are local. But, again, I welcome any GDB customers with noise complaints to contact me. We're that confident that we're able to help, explain and/or alleviate any noise issues we have and are now giving extra attention to this community.

Again, please understand that we feel that in your situation, we basically cleaned, tightened, and gave you a complete inspection and overhaul due to our concerns with noise. Consider your units as close to brand new as can get. We will from this point forth, judge each claim on a case-by-case basis instead of jumping to any conclusions.

Anyhow, thanks for your patience and understanding. Please feel free to call or email us anytime regarding any comments, questions, and/or suggestions.

Truly,

Kent Chen

Endless USA
7283 Murdy Circle
Huntington Beach, CA 92647
Truly

Kent Chen