2024 F-150 Bilstein 6112 & 5160 Suspension Upgrade: Complete Review & Installation Guide

Looking to upgrade the suspension on your 2024 Ford F-150? We recently installed and tested a complete Bilstein suspension package on a new F-150 PowerBoost with the Max Tow Package, and the results were impressive. Here's our comprehensive review of the Bilstein 6112 front struts and 5160 rear shocks upgrade.

Stock Suspension Analysis

Before diving into the upgrade, we thoroughly tested the stock suspension to establish a baseline. The factory setup showed several notable characteristics:

• Underdamped front suspension, particularly noticeable on repetitive bumps
• Rear suspension prone to engaging the overload springs too easily
• Soft initial compression followed by harsh bottom-out feelings
• Excessive body roll during cornering
• Bouncy rebound characteristics

The stock twin-tube shocks, while functional, left much room for improvement in both comfort and performance.

The Bilstein Upgrade Package

Our upgrade consisted of:

• Front: Bilstein 6112 struts and springs - Shop 6112
• Rear: Bilstein 5160 reservoir shocks - Shop 5160

The 6112 front setup was configured for approximately 2 inches of lift on our PowerBoost model (note: EcoBoost and Coyote engines may see closer to 2.5 inches due to their lighter front end).

Installation Notes

A key consideration when installing 6112s is the assembly process. While Bilstein ships the struts and springs separately, we offer professional assembly service to save you time and ensure safety. Our comparison test showed:

Installation Steps

Remove Front Coilover

1. Jack Up the Vehicle, Support with Jack Stands
2. Remove Wheels
3. Support Lower Control Arm with Jack
4. Remove Sway Bar End Link - 21mm
5. Remove Brake Line Bracket - 10mm
6. Remove ABS Wire Bracket with Panel Popper
7. Remove Upper Mount Nuts - 18mm
8. Remove Lower Shock Mount Nuts - 18mm
9. Remove Outer Tie Rod - 21mm
10. Remove Level Sensor for Control Arm - 11mm
11. Remove UCA Nut - 18mm and 8mm
    Note: If you need more droop to remove the coilover - loosen the LCA bolts and make sure to remove the axle nut to prevent damaging the axle.
12. Pry Lower Shock Bar Pin Mount Up to Remove Coilover

Install New Front Coilover

1. Position New Coilover Assembly into Place
2. Loosely Install Upper Nuts - 15mm
3. Loosely Install Lower Shock Mount Bolts
4. Use Jack to Lift Lower Control Arm
5. Reinstall Upper Control Arm Nut - 18mm and 8mm
6. Reinstall Outer Tie Rod - 21mm
7. Fully Tighten Upper Mount Nuts - 18mm
8. Fully Tighten Lower Mount Nuts - 18mm
9. Reinstall Sway Bar End Link - 18mm
10. Reinstall Brake Line Bracket - 10mm
11. Reinstall ABS Line Clip
12. Reinstall Level Sensor for Control Arm - 11mm
13. Reinstall Wheels

Remove Rear Suspension

1. Jack Up Rear of Vehicle, Support with Jack Stands
2. Remove Wheels
3. Loosen Upper Bolt - 15mm
4. Loosen and Remove Lower Shock Bolt (15mm) to Nut (18mm)
5. Remove Upper Bolt and the Shock

Install New Rear Shocks

1. Install Upper Mount, Place Bolt to Secure the Shock
2. Install Lower Eyelet Mount, Place Bolt to Secure Shock
3. Tighten Lower Shock Bolt (15mm) to Nut (18mm)
4. Tighten Upper Shock Bolt (15mm) to Nut (18mm)
5. Position Reservoir and Install Bracket (5mm Allen)
6. Reinstall Wheels
7. Remove Jack Stands and Lower Vehicle

Performance Improvements

The transformation after installation was immediately noticeable:

Ride Quality

• Eliminated secondary bounce in the front suspension
• Significantly reduced overload-spring engagement in rear
• Improved small bump compliance despite the progressive damping
• Better stability over uneven terrain

Handling

• Dramatically reduced body roll
• More precise steering response
• Improved stability during cornering
• Better overall vehicle control

Technical Gains

• Approximately 2 to 2.25 inches more wheel travel
• Maintained factory droop travel even with the lift
• Better damping characteristics throughout the suspension stroke

Value Proposition

The Bilstein 6112 and 5160 package offers excellent value considering:

• Premium 2.6-inch diameter shock bodies
• Competitive pricing compared to other premium options
• Long-term durability
• Low maintenance requirements
• Significant performance improvements

Final Verdict

The Bilstein 6112 and 5160 combination transformed our 2024 F-150's ride quality and handling characteristics. Despite being a progressive damping design, the setup actually improved small bump sensitivity while better controlling larger impacts. For F-150 owners concerned about the setup being too firm - don't be. The balance between comfort and performance is excellent, making this upgrade a compelling option for daily drivers and work trucks alike.

Whether you're looking to level your truck, improve ride quality, or enhance overall performance, this Bilstein package delivers impressive results across the board. The professional installation and assembly services we offer ensure you get the most out of this significant upgrade.

Stay tuned for our upcoming off-road performance review where we'll put this setup to the test in more demanding conditions.