When the Geiser springs were in development it was stated that the test mule was on mid perch and that is where they were intended to be run. I bought a pair as soon as they were released and ran them on factory perch (low) for about three years and 50k+ miles with zero issues. The bottom line is either defective part, spring or top hat, or assembly error. I've never seen or heard of a defective top hat before but you may have discovered the answer to the front end clunck thread.
I kept them on bottom perch as well. I have up to this point only heard of people having issues on mid perch. I’m definitely not ruling out the possibility of a defective top hat either. But the passenger one looks to have some bushing issues starting but not anywhere near as bad as the driver one was. That last stud on the driver’s side was barely holding it all together lol.
I did the whole swap all 2.5 times, long story lol. But both shocks were never off the truck at the same time and I’m pretty good at taking pictures, marking , etc so I know the two wedge spacers were are-installed as they were removed. I’m also starting to get pretty good at aligning the spring hat with the lower bushing lol. Basically if there was an assembly error, I’m not sure what it would have been.
I knew I was in for a more complicated disassembly when the suspension kept drooping and more and more of the upper spring isolator was showing.
Either way got the springs swapped back to factory. Got my new control arm delivered today. So I should have it back up and running for my next event.