Shocks started bouncing on mine and I replaced with the same bilsteins about 6 years ago. Back are easy DIY. Front need spring compressor. I have 137k on mine and not a single problem in 16 years. These trucks are amazing.
For this project I used Bilstein HDs and the freshly powder coated H&R lowering springs.
The KYBs that I put in 12 years ago are ugly, but equal to each other and a bit stiffer than the new Bilsteins. The fitment of the new shocks looks nearly identical and the eyelets fit my hardware.
Love my Koni STR.T's (Orange) with VW Driver's Gear Spings (similar to stock GLI springs, only lower), they're perfect. Particularly since I don't have to wonder if they're on the right setting, as they're not adjustable lol. Inexpensive too. Simple, solid, can't go wrong.
I've always liked Bilsteins so I decided to go with a set that were made for 2" lifts. Installing the fronts was a bit of a pain as the lower bolt on these trucks likes to seize. The rears were about 10 minutes each side.
Bilstein B6 is for stock springs. The B8's were noticeably firmer than the B4 (sport, which was available for my Passat, due to the available sport package on the car).
Koni yellows, simply for adjustability. This can give you a option of making it a weekend cruiser.. Koni orange is basicly koni yellows set on soft settings, IMO best for daily because of price point and comfort.
KYB shocks front and rear, usual stuff like alternator, brakes, wheel bearings, coolant hoses, front end rebuild and fixing all kinds of electrical switches, lights and gauges that weren’t working. Just keeping up with systems that were failing.
I responded to a few Bilstein HD threads when I had my EVC, recommending against them. They were just too damn firm. Now I have an EV Weekender with Bilstein HDs (installed by PO) and they are almost just right (could be a tad firmer). I can't explain it. Did Bilstein change their valving at some point in time?
Now I have discovered something interesting. I have twice had to remove one of the Sachs shocks because the stop clip came out of the groove in the piston. I figured I must have overtightened the nut on top and pushed it off, so I only finger tightened it the second time. It slipped again. I looked at the clip groove on the Sachs piston and was shocked to see that instead of being square cut like the Bilstein, it was taper cut which obviously stupid. There is no way this clip is going to stay put unless I am able to modify the groove to give it a ledge for the clip to rest on.
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