Ford E-450 RV Shock Absorber Upgrade Guide: Bilstein 4600 vs Koni FSD

The Rundown

For your 2023 Ford E-450 chassis 28' RV, I'd recommend going with Bilstein 4600 series shocks as your best all-around upgrade from stock. Given that you occasionally tow a 12' flatbed with dirt bikes but mostly travel solo, the Bilstein 4600s will give you excellent ride quality improvement without being too stiff for daily driving. Koni shocks are also excellent, but the Bilstein 4600s work well on commercial chassis applications like your E-450 and offer better value. Check with Bilstein or your parts supplier for the correct part numbers for your specific 2023 E-450 configuration. Skip the "Heavy Duty" versions unless you're constantly towing heavy loads - the standard 4600s will handle your occasional trailer perfectly while providing much better comfort than stock.

For sourcing, I recommend either Summit Racing or RockAuto for the best prices on Bilstein shocks. Summit typically runs around $85-95 per shock with frequent sales, while RockAuto can be $75-85 each but shipping costs vary. Amazon has them too but prices fluctuate wildly. Avoid the cheap "Comfort Ride" knockoffs - they'll ride soft initially but won't last half as long as the Bilsteins.

Why It Happens

Your rough ride issue on that last trip is completely normal for stock E-450 shocks after a year of use. Ford equips these chassis with basic Monroe or Gabriel shocks that are designed to be cost-effective rather than performance-oriented. These stock shocks use a very basic valving system that doesn't handle varying road conditions well, especially when you add the weight and leverage of a 28' RV body.

The stock shocks also tend to fade quickly under continuous use - like during a long road trip. When they get hot from repeated compression and extension cycles, the hydraulic fluid thins out and you lose damping control. This creates that bouncy, unsettled feeling you experienced. Add in the occasional trailer towing, and those stock shocks are working overtime trying to control both the RV's movement and the trailer's influence on handling.

Bilstein and Koni shocks use monotube designs with better heat dissipation and more sophisticated valving. The Bilstein 4600 series specifically uses a velocity-sensitive valve system that automatically adjusts damping based on how fast the shock is moving, giving you comfort on smooth roads and control when things get rough.

Gather These Items

• Bilstein 4600 front shocks - Quantity 2 (verify part number for your specific E-450 configuration)
• Bilstein 4600 rear shocks - Quantity 2 (verify part number for your specific E-450 configuration)
• Floor jack rated for at least 3 tons
• Jack stands rated for your RV's weight (check door jamb sticker)
• Socket set (common sizes include 15mm, 18mm, 21mm - verify for your specific configuration)
• Torque wrench capable of 85-100 ft-lbs
• Penetrating oil (PB Blaster or similar)
• Safety glasses and work gloves

The Fix

Start by parking on level ground and chocking the wheels you won't be working on. For the front shocks, you'll need to remove the upper mounting bolt (typically 18mm) that connects to the frame rail, and the lower bolt (21mm) that attaches to the lower control arm. The Bilstein 4600s are a direct replacement, so they'll bolt right into the existing mounting points. Apply penetrating oil to the bolts 15-20 minutes before removal - E-450 chassis bolts love to seize up.

The rear installation is similar but requires accessing the upper mount from inside the frame rail. You may need to remove the spare tire for better access depending on your RV's configuration. The rear shocks on your E-450 are typically held with 15mm bolts top and bottom. Take photos before removal so you remember the exact positioning and orientation of any bushings or washers.

When installing the new Bilsteins, don't fully tighten the mounting bolts until the RV is back on the ground and at normal ride height. This prevents binding in the bushings. Torque shock mounting bolts to manufacturer specifications (typically 85-100 ft-lbs for E-450 chassis, but verify with your service manual). The entire job should take 3-4 hours for someone with moderate mechanical skills.

After installation, take a short test drive to make sure everything feels right before your next long trip. The improvement in ride quality will be immediately noticeable - less bouncing over bumps, better control in crosswinds, and much more composed handling when towing your dirt bike trailer.

Know Your Limits

This is a straightforward bolt-on replacement that most DIY mechanics can handle, but there are some important safety considerations for your E-450 chassis. Note that on some E-450 configurations, you may need to disconnect sway bar links for shock access - check your specific setup before beginning. The RV's height and weight make proper jack placement critical - always use jack stands and never trust a jack alone to support the vehicle. If you're not comfortable working under a vehicle of this size, many tire shops or RV service centers can install shocks for $200-300 in labor.

The main challenge you might encounter is seized bolts, especially on the rear shocks where road salt and debris accumulate. If you run into a bolt that won't budge after applying penetrating oil, don't force it - you could damage the mounting threads in the frame. A professional shop has the proper tools like impact guns and torch heating equipment to deal with stubborn fasteners safely.

Also be aware that shock replacement won't fix other suspension issues if they exist. If you're still getting excessive bouncing or handling problems after the Bilstein upgrade, you may need to inspect other components like sway bar bushings, leaf spring bushings, or even tire pressure and balance. The E-450 chassis is generally robust, but at 28 feet with occasional towing, all the suspension components work together to provide good ride quality.