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The rear strut bump stop 96494604 is the compression buffer fitted over the rear shock absorbers of the Chevrolet Aveo family, the small GM Korea hatchback and saloon sold worldwide under several badge names. Bonpora supplies the same component in micro-cellular polyurethane as number 4110128, direct from the factory in China for wholesale buyers. This guide explains what the part does, which vehicles the reference covers and what to check before ordering.
The Aveo rides on a torsion beam rear axle with separate coil springs and telescopic dampers, and each rear damper carries a polyurethane buffer over its rod.
Under normal load the buffer does nothing: the coil spring carries the body and the damper controls the wheel. When the car meets a sharp ridge or a deep pothole fully loaded, the rear suspension can reach the end of its stroke. The 96494604 compresses progressively at that point, turning the last part of the travel into a controlled deceleration instead of a hard knock through the floor. It also protects the damper, whose rod seals wear faster when the strut is repeatedly driven against its upper limit.
The part is a cylinder of micro-cellular polyurethane with moulded ribs along its length. The ribs fold in turn, so the buffer stiffens as it shortens. Bonpora records a bore of 10.6 mm, an outside diameter of 49.7 mm and a free length of 124.6 mm, and the narrow bore locates the buffer on the damper rod.
A worn rear buffer rarely announces itself on smooth roads. The usual symptoms are a hollow knock from the rear over sharp compressions, a harsher ride when the car is loaded, and a crumbled or crushed buffer found during damper or spring work. Because the buffer is inexpensive next to the dampers, workshops normally renew it whenever the rear suspension comes apart.
The reference belongs to the GM Korea small-car platform and follows the Aveo through its badge names and generations, as summarised below.
| Model | Platform | Body styles | Catalogue years | Position |
|---|---|---|---|---|
| Chevrolet Aveo / Aveo5 | T250 | Hatchback and sedan | 2006-2011, US records 2007-2011 | Rear, both sides |
| Pontiac G3 / G3 Wave | T250 | Hatchback | 2008-2010 | Rear, both sides |
| Daewoo Kalos | T200 / T250 | Hatchback and sedan | 2003-2008, regional | Rear, both sides |
| Chevrolet Aveo | T300 | Hatchback and saloon | 2011 onwards | Rear, both sides |
European catalogue lists for the family run from the 1.2 and 1.4 petrol engines, including LPG versions, through the 1.6 petrol to the 1.3 diesel of the T300 generation, covering outputs from roughly 69 to 140 hp. One buffer geometry serves the range, so stock can be planned against the platform rather than the engine.
The same car left the GM Korea plants as a Chevrolet Aveo, a Daewoo Kalos, a Pontiac G3 or G3 Wave in North America, and under further regional badge names. European aftermarket records file 96494604 as an original number of Chevrolet, Daewoo and Opel, because the group moved the car through several sales companies. For stock planning this means one reference answers enquiries written against any of the badge names.
Wholesale listings for this reference sometimes carry a wide multi-brand field that reaches beyond the GM family. Catalogue evidence points the other way: GM publishes the number for the Aveo and the G3, and the European equivalent kits are catalogued for the Chevrolet Aveo alone. Buyers working on other makes should treat the brand field as unconfirmed and match by OE number, dimensions and the removed part before ordering.
The drawing data below summarises the part as supplied from the factory.
| Item | Value |
|---|---|
| Bonpora number | 4110128 |
| OE reference | 96494604 |
| Catalogue companion | 96535162, quoted beside this number in T300 kits |
| Position | Rear axle, both sides, 1 per side |
| Nominal size, Bonpora data | Bore 10.6 x OD 49.7 x length 124.6 mm |
| Material | Micro-cellular polyurethane |
| Country of origin | China |
| Warranty | 1 year |
| Delivery | 15-30 days |
| Packaging | Neutral export packaging |
| Custom service | OEM and custom design support |
The bore slips over the damper rod, the outer diameter seats against the dust boot cap, and the free length sets the remaining travel. Aftermarket packaging for this reference is much larger than the part itself because most equivalents add two dust boots, so compare the buffer geometry rather than the box.
Enquiries often arrive quoting an aftermarket number instead of the OE. The main equivalents are KYB 910223, FEBEST CHSHB-T300R-KIT, Ashika 159-0W-W05, Japanparts KTP-W05, Japko 159W05, Maxgear 72-4300, GSP 5407320PK, Blue Print ADG084500, SKF VKDP 43502 T, Lynxauto PR-7303 and Oyodo 80A0014-OYO. Most of these are protection kits that add dust boots, so confirm whether the enquiry needs the buffer alone or the full kit.
The catalogue naming around this reference can confuse a first-time buyer, because most European equivalents are sold as kits.
KYB, FEBEST, Ashika and the other brands list the reference under dust cover kits: a pair of boots plus the bump stops, packed for one axle. The kit protects the damper rod from dust and moisture and renews the buffer in one job, which suits workshops replacing rear dampers. The trade names run from protection kit to dust cover kit, while the buffer inside keeps the same function and geometry.
Bonpora manufactures the polyurethane buffer as a separate line item, so distributors can buy the stop alone for their own kit assembly or for retail counters. Buyers who need the complete kit can request both items together, and the factory confirms the combination before quoting.
Bonpora moulds this buffer in micro-cellular polyurethane rather than filled rubber, a choice that changes how the part behaves on the vehicle.
| Property | Polyurethane (Bonpora) | Conventional rubber |
|---|---|---|
| Compression set | Low, recovers shape after repeated hits | Higher, takes a set over time |
| Ozone and heat ageing | Strong resistance | Cracks sooner in hot climates |
| Oil and fluid contact | Good resistance | Swells and softens |
| Load consistency | Uniform batch to batch | Varies with compound |
| Unit cost | Moderate | Lower |
City cars work their rear buffers hard: short wheelbases pitch the axle into compressions at kerbs and speed humps, and many of these cars run overloaded. A compound with a low compression set keeps its free length stable through repeated compressions, protecting the travel reserve of the damper. The full polyurethane bump stop range applies the same approach across other platforms.
A correctly sized buffer only works at the end of the stroke, so a polyurethane replacement does not change normal ride comfort. What decides the fit is the geometry: height, outside diameter and bore must match the removed part.
Buyers want a faithful replacement sourced directly from a manufacturer with OEM capability.
Bonpora moulds buffers against the published OE data and ships them from its own production line, without trading layers in between. Every enquiry is checked against the reference before dispatch, and buyers can request samples and measure them against the drawing figures above.
For distributors with their own brands, the factory offers OEM labelling, branded boxes and private moulding. Custom design covers changes of compound hardness, free length or outer profile: send the sample or the drawing, and the tooling, minimum order and lead time are confirmed before production. Details of the programme are on the custom parts page.
Standard supply ships in neutral export packaging on a 15-30 day schedule with a one-year warranty, and pricing is quoted against order volume so that distributors can plan their season.
Send the OE number, the model year, the quantity per vehicle and the destination port to the export desk. If the number has worn away, quote the height and the outside diameter and the factory will match the drawing. Buyers building a wider programme for GM Korea platforms can browse the shock absorber parts catalogue alongside this line, where buffers, mounts and related hardware are grouped for one-stop purchasing.
The two numbers appear together on European catalogue listings for the T300 generation, and the main equivalent kits quote both. They describe the rear buffer family of the platform, but generations can differ in length, so match the removed part against height, outside diameter and bore before ordering.
No. This reference covers the rear axle, one buffer per side, two per vehicle. The front struts of the Aveo use their own shorter stop with a different reference, and the two are not interchangeable. Confirm the axle and compare the removed part before ordering.
Catalogue records tie the number to the Chevrolet Aveo and Aveo5, the Pontiac G3 and G3 Wave and the Daewoo Kalos family, with European data filing it under Chevrolet, Daewoo and Opel sourcing. Listings that extend the field to unrelated brands are not supported by catalogue data, so verify by number and dimensions.
One per rear side, two per vehicle, and the part is not handed. Workshops normally renew the pair together whenever the rear dampers are dismantled, because mixing a new buffer with a worn one upsets the end-of-travel behaviour.
Bonpora manufactures and exports suspension buffers from China for wholesale buyers worldwide. Quote 96494604 or 4110128 with your quantity and destination, and the export desk will return unit pricing, packing details and the next available shipment. For the material background behind the range, the polyurethane bump stops overview is a good starting point.
