KONI FSD Possible FAILURE - CORROSION

spike

Well-Known Member
If not already noted, this info on warranty is from the Koni web site -

A: The KONI warranty is to the original purchaser against defects in materials or workmanship for as long as you own that car (registered for street use) during the applicable warranty period in your country. The warranty does not cover damage to the parts caused by misuse, misapplication, installation, motorsports, etc. and does also not include mounting bushings.
The warranty involves replacement. When replacement is no longer possible the warranty involves repair. When repair is no longer possible the warranty involves a refund.
Always get in touch with the point of purchase (with a copy of the purchase and vehicle registration) or, when point of purchase is no longer existent, the KONI distributor in your country


Cheers Spike
 
Last edited:

sojah

Banned
Whether you want a Koni replacement is another story...might be better to get them then sell the new FSD's on assuming anyone actually wants them now.
That's exactly what I did with my replacements after the front dampers failed in less than a year of ownership. I got onto Larkspeed who forwarded them onto Koni who then asked for a receipt for who fitted them, 4-5 weeks later new ones were delivered to my home. They also had rust on all the legs and signs of flaking paint. The rears were fine and did work well, but I lost faith in them and sold them on to a forum member and now so far so good with Bilstein B6's and Spidan springs.

:cool:
 

the grim reeper

A2OC Donor
Wonder how i would stand with the fitting receipt as it was me and a tech from work that fitted them, not had a look yet

Phil
 

humps

A2OC Donor
And so it was dry for a change! I took a look at my front FSDs. They are no worse than when I put the winter wheels on, meaning lots of paint flaked and corrosion started to become very visible. See for yourself in the photo. Mine was bought and installed at Stealth on 6th Feb 2007, so almost 6 years old. Very vaguely, I seem the remember them started to become visibly bad about 2 years ago.

IMG_0630.jpg
 

spike

Well-Known Member
Does anyone know the outcome of the warranty claim against Koni for the rusted FSDs

Cheers Spike
 

chb

Well-Known Member
Koni FSD corrosion.

I know from other threads that many have has corrosion on their FSD's
This is what mine look like after just 4 years!



Has anyone claimed on the Koni warranty with success?

Am I being unfair by expecting a premium product like Koni to rust less in 4 years than the struts on my old volvo V40 did in 13 years?
 

murdo

Admin Team
Blimey. I think you are entirely justified in being miffed at this. They aren't as bad as the pictures posted by DarrenC - I think himself and Sojah have claimed on the Koni warranty so its worth a message to them.

Hope you get it sorted and thanks for sharing this, when my suspension starts to get really worn out ( not far away now) I am definitely going down the Spidan and Monroe route as recommended on other threads. The Koni's don't give me any confidence with this corrosion issue.
 

sojah

Banned
The issue I had with my FSD's was the front dampers leaking but I only noticed as because it sounded like the top mount had gone, it was basically the spring holding it up. I sent them back to my retailer Awesome GTI and they sent them back to Koni, it took around 4 week to sort out. They were just under a year old and weren't corroded but did have rust spots in places. They supplied a new set and I sold the complete set with Weitec springs onto a forum member.

All sorted now with Bilstein B6's & Spidan springs. Hope this helps!!

:cool:
 
Last edited:

d4v1d sm4rt

A2OC Donor
Just found your thread so apologise for the late response.
My koni front shocks rusted right through and caused the suspension to collapse. The spring pan collapsed onto the wheel which locked up the wheel.
VERY DANGEROUS!
I complained to the place I got them from who send me some more FOC. Very good service as they were a main importer. And they sent me some new springs too as one broke.
THEY WILL COMPLETELY FAIL IF YOU LEAVE THEM SO BE WARNED.
I would be interested if anyone else has had this problem and would ask the administrators if this thread is worth elevating to a sticky on safety grounds as many A2 owners have these shocks fitted.
When I get a chance I will post some pics...
My back ones are quite rusted as well so I really should do them as well.
UPDATE 16.12.13
have sent mine back to Koni in Holland who are inspecting them for the cause of corrosion. Changed the backs as well as a precaution. Koni been quite supportive so far and issued replacement parts free.
 
Last edited:

d4v1d sm4rt

A2OC Donor
The importers changed mine without question. But didn't refund any labour unfortunately.
My daughter was using the car at the time and I am so grateful it didn't result in a major accident and a major compo claim.
Bearing that in mind Koni should be more pro active in organising some sort of recall.
Thinking of contacting VOSA, when a friends wheel fell of their car in a contra flow the accident investigations branch were all over it like a rash.
 

murdo

Admin Team
The information on the forum relating to Koni FSD corrosion has been merged and stickied as requested. I've also renamed the thread so its easier to find on a forum or other search engine.

It would appear that this is an 'issue' both on the UK and German forum with a number of members experiencing excessive corrosion.

If you have FSD's - please keep a close eye on their condition during cleaning and routine maintenance, and if you are in any doubt please contact a qualified technician if applicable to verify any corrosion is cosmetic - and consider contacting KONI or the fitting supplier of your suspension to discuss the terms of the lifetime guarantee.
 
Last edited:

d4v1d sm4rt

A2OC Donor
Don't be fobbed off by your supplier

A very big thanks to Murdo for making tHis topic a stickie particularly at 5.45am! I hope it will save someone who is unaware of this problem.
May I suggest that the title of the thread be "Koni" FSD... So that it is searchable from outside the forum because I am sure that we are not alone in this problem and that other car marques fitted with Koni FSD shocks also have the same problem.

For anyone who is fobbed off by their supplier under the guarantee, the route I adopted was under the terms of what is a "reasonable" time for a product to last under the Supply of Goods and Services Act 1982 which is an implied term of this act that all traders are bound by. Whilst I would not expect the damping action to remain as it was when it was new, it is unreasonable for the actual shock body to corrode away completely. As it happens I still had the original shock absorbers which showed no signs of corrosion and had been fitted for a similar amount of time before they were removed and had been stored outside in all weathers. I actually think that the problem is from the steel rusting from the inside out. In the 1970's the Lancia betas all rusted because they were made of Russian steel which was made of recycled metal which still had rust particles in it.
 
Last edited:

humps

A2OC Donor
I have one of the oldest FSD installed on any A2 in Britain and last week I had to take the wheels off working on the bumper. Upon another inspection, there is heavy flaking and breaking off of the paint around the spring seats. Where the metal is exposed because of the missing paint, it is quite badly corroded. They don't look good at all but don't look imminently breaking (fingers crossed). However, I also driver very little in comparison. The car covers about 4000 miles a year and it must have been a good 5 years since I had the FSDs. So I think the corrosion is likely related to the exposure of winter road salt. I think a lot of you have much younger FSDs but covered much more miles over road salt than me in London.
 

d4v1d sm4rt

A2OC Donor
I have one of the oldest FSD installed on any A2 in Britain and last week I had to take the wheels off working on the bumper. Upon another inspection, there is heavy flaking and breaking off of the paint around the spring seats. Where the metal is exposed because of the missing paint, it is quite badly corroded. They don't look good at all but don't look imminently breaking (fingers crossed). However, I also driver very little in comparison. The car covers about 4000 miles a year and it must have been a good 5 years since I had the FSDs. So I think the corrosion is likely related to the exposure of winter road salt. I think a lot of you have much younger FSDs but covered much more miles over road salt than me in London.
Mine were fitted in 2007 and have done mainly London and the home counties driving. They looked ok from the outside but were thin as paper underneath particularly where the pan met the body where the moisture must have collected despite there being drain holes built in. I would give them a firm poke with a screwdriver in that area just to check if I we're you.


My other theory is that they were stored outside at the factory for a while before being sprayed and got rusty and they simply sprayed over the rust. My rear ones are also rusty and I will be changing them soon.
 

ndavid

A2OC Donor
Hi,

My FSDs were also fitted in 2007 but they were sold with 3-year warranty only by the Hungarian importer... And they also have some corrosion in all corners.
Was it a bad series in 2007 or is it a permanent issue for Koni? Should I buy a new set or should I swap them with some other brand?

Norbert
 

d4v1d sm4rt

A2OC Donor
As we have seen the amount of corrosion varies so you will need to make a determination based on your own individual circumstances. Given the experiences of other members it may be wise to conduct a thorough investigation of the structure of the spring pan. Even though the material may not have any actual holes in it, the actual thickness may be significantly reduced due to corrosion which may not be evident on initial inspection. Consider attempting to puncture the spring pan ( with a screwdriver or similar impliment) to test its strength.
 

murdo

Admin Team
Title edited as per suggestion in my lunch break! Thanks David, but it was 0645 before work - I was still in the land of nod at 0545.
 

nee777.a2

Member
Unfortunatly like most brand names they are cost cutting with materials,i work in the automotive world and this is a common issue including my area in developement.Sadly and for most of use we are still paying top prices for branded components.....To add i stick to OE components but again these are being made else where with an OE sticker on them,not all of them but cetrtainly being used,just look at some older high spec Audi/VW vehicles and the quality is just not here anymore.
 
Last edited:
Top