Bilstein shock securing roll pin question
 

Anyone ever come across a Bilstein shock that had such a small diameter bottom shaft that the strut/shock securing roll pin could "jump out" of the shock's groove under greater than normal impact such as driving over speed bumps or small pot holes?

EP Slick - Tucson

Is it possible that someone put the wrong size pin in or that the pin is broken (split) and not holding?

Something's not right. A smaller hole would make the rollpin tighter, no? You must have the wrong parts.

Pin size
 

I removed pins and they look fine. Proper fit into strut housing hole with proper compression. Clunking problem emits from both sides of front of car. All poly bronze bushings are lubed and free. Monoballs and bushings in fine shape. Sway bar drop links have been removed to eliminate possibility of contributing. Steering box properly tight etc.

Eyeballing through expansion pin hole in strut housing it appears as if the slot/shaft of the shock securing rod is just not meaty enough to do the job under more than normal stress

Holy hole batman!
 

Holes in strut housings are proper for the pins used which compress well and fit as expected. My question is about the shock shaft diameter and its groove. Seems as if there is not enough material to secure shock rod to bottom of strut under harsh driving conditions i.e. potholes, speed bumps.

Just measured several Bilstein strut inserts and all have a 10 mm diameter on the part of the shaft below the groove.
We have seen some struts that were bent, and the shaft does not seat into the hole at the bottom of the housing.
Do you have a center punch or awl ? Get the strut insert in the housing and use the tool to check that the groove is aligned with the roll pin hole. Pull up hard on the insert to see if it will pop out. If it does, and its 10 mm diameter, you have a problem with the housing.
If it does not pop out, then press the roll pin into place.. We like to use safety wire thru the hole after wards to keep the roll pin from moving out- 99% of the time you don't need to do this, but this sounds like cheap insurance in this case

Fit
 

Have done the center punch test but cannot pull shock out of pin seat as I am old and weak. Don't have the oomph of pothole or speed bump impact. Am considering building up shock shaft with TIG and re-grooving in AM. The hunt goes on. Thanks for your input.

EPS