I think that you've been unfair to the Bilsteins. Had you put the replacements on and in short order failed them too then I'd understand going back to twin-tubes. Condemning them because of the failure of one set that could have easily been a QA/QC problem with the pair is not a valid test result. I replaced Rancho 5000's with Bilsteins and both ride quality and damper service life have improved. Your experience is far outside the norm for Bilstein dampers. There is an unaccounted for factor present that hasn't been determined and rendered inert. I suspect that there was a QC/QA issue with that pair (which have a high likelihood of having been made at nearly the same time) since it would appear that your truck and driving style are well within the norm, but that will be left unknown now.
I'm OK with your not wanting to experiment further and going back to what you're familiar/comfortable with, but I'm not OK with condemning a whole design based on a single, flawed "test" when there are too many positive results from their application to similar trucks.
Hi Thom,
I think you aren't reading my posts, even my last post: "After 40 years of thousand of miles with no problems with twin tubes and then going through two sets of 5100's in just a few hundred miles, I'd say I've done the acid test".
I had considered trying Bilsteins for a third time because I do prefer the on-road feel of the 5100's. It was my conversation with Bilstein that made me give up on the mono-tubes. I asked the tech about the 5160 but the tech told me they would only be slightly more likely not to overheat, "if you have blown out the 5100 that fast, you'll probably blow out the 5160's". He started talking much more expensive Bilsteins, special valving and even changing to a different oil than what they usually use. I just couldn't see going through all the expense and experimentation when what I had before worked great for 40 years. The people at Bilstein were very friendly, very accommodating and very honest. Where I take issue is that their website shows 5100's as on/off road shocks. Somewhere (I could not find it on their site) the Bilstein warranty lady read to me over the phone "for on road and light off road only". Finally, under the warranty details on Bilstein's own site the 5100's warranty does "not cover off-road use".
None of my comments have ever been a rant about Bilstein, I've only had nice things to say. I only brought this issue up to share with other members of this site hoping to save them the same aggravation. IMO, For the proper application of on-road and light off-road the Bilsteins are great. If you are doing long washboard like Saline Valley Road or certain roads in Baja, twin tubes are likely your better choice.