Follow Up

[LostInTransit]

As part of our continuing experiment of upgrading the suspension of a 2020 Transit Connect, for the last 2 years we've been testing the Cobra Suspension rear lowering springs on the van. When first installed, these springs were listed as being 40mm lowering springs which was actually the distance between the tire edge and the fender edge. But over these last 2 years, the springs have started to sagging, and the tires have been hitting the fender edge on a regular bases. They went from the 40mm down to 34mm. At one point we've attempt to have a tool made that would curve or bend the fender edge inward. But never got around to having this tool made.



Our most recent project include a custom set of rear springs that are 2'' shorter and 20% stiffer than factory, which were installed on the cargo version of the van. we had a spring company design a set of rear springs for the van based on the desired specs and they completed this task in less than 4 weeks. We got the springs 3 weeks ago and test fitted them just to make sure the specs were spot on. All doubts where pushed aside when the springs went right in.



With the springs now verified, we had the springs sent to our powder coaters where they laid down a thick bright red color.. got the springs back last week and installed them for the last time.



These new springs are very tight and stiff so much so that the front factory springs seem to bouncy more often now. which means these will also be upgraded to a stiffer shorter set from the same spring manufacture.

 

[LostInTransit]

According to the coil spring manufacture, they just started designing a new set of front springs for the van. The height of these springs will not differ from the factory version, the the coil diameter and spring rate will be increased to 20%-25% stiffer than factory. This process will take 4 weeks to complete and we're somewhat confident that these springs will fit even without testing. Thus we'll drive 1 hour to our powder coater and again allow them to coat the semi-gloss black springs a bright red color as they did before on the rear springs.

Once those springs have been successful fitted after powder coating, we can officially list thes springs as "Flord Performance" springs designed for the 2019-2023 Ford Transit Connect. Transit Connect owners can then contact the coil spring manufacturer and request a set of the "Flord Performance" springs for their vans. The springs have a dual purpose. While installed on the passenger wagon, these springs will lift the rear of the van 56mm. While installed on the cargo van, The springs will lower the factory ride height to 56mm. The best way to describe these new springs, is that they are like coilovers, but without the sturt/shock integrated into the coil over design. A set of stock or aftermarket shocks/struts can be used with these springs.

This has been a major accomplishments for us and even though we don't see a "rush" from other Connect owners to buy these springs, The design would be saved within the coil spring company system for future references. These springs will set the Connect owner back 1K and would be shipped to buyers shop or door with a semi-gloss black powder coating. We paid an extra $180.00 to have our set of springs powder coated by another company.

 

[LostInTransit]

According to the the tracking, the new coil springs have shipped and should be arriving at our location today. Originally I wanted to have the springs drop shipped to the powder coaters. but assuming the springs arrive today, we'll drive up that way next week taking a day off just to go talk to our powder coaters. These new front coil springs made for the 2020 Connect are the same ride height, but 20% stiffer.. Once powder coated and installed we can finally say that we've created a full custom set of leveling springs for the 2019[2023 transit connect.

As posted above, I don't see a "rush" of transit connect owners looking to buy our set. But if they did, here's how to go about doing it.

Contact Coil Spring Specialist and ask for the "Flord Performance" level springs for the 2019-2023 transit connect.

Here's what you'll get when ordering direct from CSS:

• A pair of standard ride height but 20% stiffer front coil springs
• A pair of 2'' shorter but 20% rear coil springs.
• The springs would be powder coated black
• Suggest price of $1,000 USD
• Allow 5-7 Weeks for delivery

If purchased through me:

• A pair of standard ride height but 20% stiffer front coil springs
• A pair of 2'' shorter but 20% rear coil springs.
• Custom powder coated Colors available at additional charge. $1,600 USD (price based on the desired color change and time given to coat the springs)
• Allow 6-8 Weeks for delivery

Note: These springs have only been tested on the 2019-2023 Transit Connect. But should work on the UK version within the same year/time frame.

We're very excited to have a custom set of ride height coil springs designed to retain the towing and hauling capacities of the van but at a lower rear ride height.

 

[LostInTransit]

Look what just arrived:


Our newly designed front coil springs for the 2019-2023 transit connect. These have been designed to retain the same ride height, But are 20% stiffer than stock. Same with the rear springs, Expect the rear springs are 2'' shorter and 20% stiffer.. this is a new leveling kit" for your 2019-2023 Transit Connect. CSS did a great job this time powder coating these springs.. shame we're wanting to color change them to match the already installed red rear springs. The gunmetal grey isn't a bad color, but we've already opting for the signal red. Once coated and installed, this will be a new "Leveling Kit" designed just for the Transit Connect. The main draw, is to retain the same towing and hauling capacities of the van but at a stiffer and lower ride height.

 

[LostInTransit]

BREAKING

One week ahead of seclude the new front springs have been powder coated and ready for pick up Monday morning.. then off to the performance shop to schedule a date to get these on the van.. this is a major accomp[lishemnet for me as I've worked nearly 4 years to get a set of spring just for the van. Once on the van and we check the ride height, we can finally list these springs as for sale to any 2019-2023 Connect owner you wants a stiffer/fermer ride and still have the towing and hauling capsatiests as with the Connect cargo version van.

Once in a while, I'll catch myself looking back at the van and wonder should have shave off another inch from the rear springs.. One thing is for sure these springs do not allow the tires to rub the inner fenders like the failed set of Cobra springs of last year. these were so bad, I just threw them away and for just 100.00 a set.. they aren't worth it.. Our new springs will run you 1K for the full set of front and rear springs, but you're limited as to what color of powder coating. All indications point to a grey smooth finish, unlike the first set which was a gloss back.

I would highly recommend that if you need springs for your car/truck.. contact Coil Springs Specialiets out of KS, USA

Stay tunes, we pick up the springs and get them installed with the Bilstein B6 struts very soon and we'll report back afterward.

 

[LostInTransit]

Picked up yesterday.. but we're not able to get these on the van just yet. seem our performance shop has become swamped with work orders. Best date they can get to us is April 12th Bummed.. Yesterday after picking up the springs, we drove over to our performance shop and showd the techs a single springs the first thing they said is it's too large diameter and won't fit into the inner strut tower socket, all without actually testing which will come in 1 week. So I contacted CSS and ask what was the best way to check the speck of these custom springs as compared to the OIE springs.. simple.. measure the middle of the springs which in this case came to 6 1/4. messayured the OE springs and BAm same thing.. 6 1/4.. I did have my doubts but everything seems to want to line up.. now I'm sure these will fit, but will they at the correct ride height we need.

 

[gruntguru]

Surely there's a Transit fanboy forum somewhere on the net?

 

[LostInTransit]

Nope, I've attempt to post this several types of TC forums only to have my topics removed and my account banned claiming this is spam.. I've even attempted to post this topic of hotrod & sportscar forums and so on.. with the same result. Reddit (r/fordtransitconnect) was the latest to suspend my account for posting this.. Even Grassroots racing banned my account..

Although this topic is not technically oriented.. it does or should show others with half a brain can get coil springs made for their car/truck like we did. What draws me to doing this is because "they" said it couldn't be done. I think they meant they didn't want to hear that it could be done. A 10K upgraded suspension on a transit connect? hogwash they said.. Most would rather you installed coil overs.. we opted for something different.

Besides, doesn't matter now, Cause once the front coil springs are installed along with the rear camber plates.. the build is over.. there's nothing more to upgrade.

 

[GregLocock]

Although this topic is not technically oriented

Oh, I thought that the detail of what color you selected was pretty technical. Compared with the rest.

 

[LostInTransit]

Very pleased to announce that the front coil springs have been installed earlier this morning and we drove about 2 hours around two just testing them out. The springs are 20% stiffer and you can tell it. So it's official.. we now offer a set of these springs for those who have the 2019-2023 Transit Connect which will lower the ride height but retain the towing and hauling capabilities.

To order these springs or have CSS design a set of springs for you.. contact them today via email or phone call.

However, not all news is good news. Seems over the last few months since installing the rear springs, the driver side upper seat at the dead axle have torn and we'll need to replace the full set of upper seats as well as the isolators which will happen new weekend. Then it's on to installing the rear camber plates.

 

[LostInTransit]

First of all thanks for all the views.. this is one of the most viewed topics I've ever had. Now the bad news.. Last fri while driving to the airport on MD 195 which was one a concrete road with section that have been pushed up over time, we drove the van at the speed limit 60 mph and hit one of these concrete hums in the road, this cause the drivers side upper seat to dislodge allowing the rear spring to dislodge from the lower perch and was resting sideways between the lower perch and chasses.

Although the spring did not complete fall out because weeks before I had feared that something like this was going to happen. I had placed a single heavy duty zip tie on both springs to keep them from completely falling out and doing more damage. We limped home and I set up shop to attempt to reseat the spring back into it's perch and reinsert the upper seat. Oddly even with all the noise while driving home, Once home and I was able to jack the van up and the springs completely fell out, and the powder coating was still intact and without any merring.



I thought best to clean the rubber flap located on top of the upper seat and clean the spring while I was at it. Using brake clean I clean the spring, upper seat and lower perch.. checked the chassis frame and using my foot, I pushed the entire spring system back into place. I was under the impression that the upper seat and lower seat was damaged so I ordered new ones.. They arrived yesterday and while the shop reinstalled all of this.. the springs still fell out.

What is soo odd about this, if one was to scroll back to the top of my topics, it will show the date or round about when these springs were installed.. several month without any issues till now..



I called CSS and emailed eaton Springs asking what can be done to correct this.. first reply was that the shocks have too much up travel which is not compressing the springs and holding them in place.. They gave me a few options..

• New softer springs
• Reinstall the old longer springs
• Custom set of shocks
• or what is called "shock limiters"

Oddly soon after the springs dislodged Fri on the road.. I had already placed an order for a shock limiter but I wasn't sure what length. Fortunately, both eaton and CSS agreed on a limiter length and just so happen I selected the correct one.



Days of research learning about shock or suspension limiters has taught me that this have been used in a variety of applications, Semi trucks, off roading, ATV's and drag cars.. but I've never heard of an average street car using this trick to limit their shock travel. granted the limiters I ordered are not meant for extreme duty use or are longer than normal. According to both springs experts, the limited should allow for 1.50'' - 1.75'' worth of added distance or stretch. However the limiters I ordered, did not come with an exact measurement.. but are close enough to limit shock travel. Just in case, these shock limiter straps can withstand up to 10,000 lbs ea.

This Wed and I used my free trial of prime, I was able to order a set of the RAStp shock limiters and once I get these, I'll run over tot he shop and have these limiters installed on the shock bolts, right between the mounting locations and shock bolt. ideally this was not the best location and time is ticking as we've not been driving the van since the spring fell out.

Now I've seen the limiter straps used in the past while I was a member of the SCCA.. but I never thought I'd end up using a set of these myself. This is all things that crop up with newly developed products.. so Now if someone orders this lower springs kit, they will have to order a set of the shock limiters, or research custom shocks etc.

Stay tuned as this story continues to develop.

 

[BrianPetersen]

I do not think you want to be using limiting straps long term.

I spy yellow dampers. Are they Bilstein? The B6 series are standard length. The B8 series are meant to be used with lowering springs to avoid this specific problem. If they are not Bilstein, perhaps your damper manufacturer can address this.

Aftermarket lowering springs are frequently dual-rate springs, which is another way to address this. The initial rate is very soft, so that the free length of the spring is long enough that it doesn't escape the spring seats the way you've described, but the tightly-wound section coil-binds somewhere in the vicinity of whatever static load is on the spring, so that the higher spring rate takes effect in compression.

Latest Transit Connect is supposedly same vehicle platform as Ford Focus, but google search suggests twist-beam rear axle as opposed to traditional Focus multilink independent, so it would be quite coincidental if springs and dampers crossed over due to the very different suspension layouts. (Disclaimer, I don't know if the latest Focus that we never got in North America, cheaped out and went backwards in its rear suspension layout. If it did, maybe you're in luck.)

 

[GregLocock]

Professionals design springs for road use such that they have a minimum preload of X with the wheels at full droop, ie on a 2 post hoist. Amateurs don't, they worry about powder coating.

 

[gruntguru]

I have always wondered whether sudden droop-limiting by the shock or external droop limiter causes undesirable handling anomalies during (eg) at-the-limit cornering plus bumps. One solution would be to secure the spring to its seats so it goes into tension during large droop excursions.

 

[GregLocock]

In theory it seems a good idea, sometimes in practice it is the other way round. It can be useful to force a sudden change in weight transfer across the axle in limit handling events.

 

[LostInTransit]

Thanks for the support and comments, the yellow springs are NOT bilstein because we've already tried a set of the bilstein previously, those B6 shocks kept bottoming out.. so we reverted back to the stock factory shocks.. which I now feel are failing or can not support the up travel to kepe the springs in place. I simply wrapped the shock yellow till I located a better more colorful solution.

As for the "temp use" again, I've spoken with the coil spring developers as well as eaton springs and both agree that the limiters would be the easiest thing to do at this point. Also, they suggested many of the same things you did, either new custom shocks or revert the system back to the OE rear springs. We're just trying to limit the up travel of the van. The strap limiter we've selected shows that it's long enough yet can stretch slightly more if needed which is within a desired range. Now the objective is to attach these to the shocks either on the inner side or outer side of the shocks. I'm leaning towards having them mounted on the inner side as this is the most direct route from top to bottom without any obstructions, but is close to the springs. The other option is on the outside of the shocks but the shock metal top cover may interfere with the strap. Only way to know is when the shop gets the van on the lift, supports the axle and completely removed the shocks just to verify the mounting positions.

 

[lucky-guesser]

So, I will go the opposite direction as Brian. In the street racing/light duty scene he may be correct so I'm not calling him wrong per say, but in the offroad world you want limiting straps to do all of the work, not the shocks. Of course in off road set ups, you are often talking about a solid axle with heavy tires with a combined weight of several hundred lbs, sometime close to 1K, and that is obviously a much different circumstance than your set up. A standard pickup truck that will rarely if ever reach full droop, relying on the shock to hold everything together is fine. On a dedicated off-roader though, where reaching full droop is common (rock crawling/uneven terrain) and may often include shock loading (jumps, whoops sections) putting that load on the shocks over and over again will destroy them.

All of that to say, your car is light duty enough and should be rarely if ever reaching full droop, so I think that relying on your shocks would actually be fine if they are the right length to keep everything together. Since they are too long though, I would have not problem sticking with your straps.

As mentioned, this is all from an off road perspective.

 

[LostInTransit]

This morning was a big fail.. these straps (mainly the bracket/plates) would not clear the "U" brackets which retain the shocks. So after talking with the wife, we've concluded that we have to revert back to the factory springs.. which in this case are 2'' taller and about the same stiffness. however I also spoke with CSS about what's going on and both of use aren't sure why after installing these spring back in Dec they are just now wanting to fall out. Although CSS doesn't list a return policy, they did say they are going to gather everything up and talk to their engineers about what our options would be. But till then I have to put the old factory springs back on. Oddly, a few days ago I spoke with Byron from GAZ shocks as they are willing to design a custom shock/damper for our set up. However, because of the tariffs.. these would be out of reach for us at this moment. it's clear that if you see a lowered transit connect, they are either on bags or running the eibach springs.. which we've already tested before and the bags lose air or the lines get tangled while the eibach springs sag causing the tire to make contact with the fender edge. it was a good run while it lasted, but I've grown tired of the snowball effect.

 

[LostInTransit]

here's the culbrite:


This is what's referred to as the upper spring seat. it's a metal tube with a top flat surface and a rubber gasket at the top. In the middle of this gasket is a nub and under the nub is part of the metal tube. This is placed on top of the spring then inserted into a hole located in the chassis frame and that's it.. there's nothing retaining this upper seat flush with the chassis other than the compressed spring. I'm on a mission to see if someone can redesign this so that it could lock in place, yet when unlocked can be extracted for maintenance. what's to say that when the factory springs are installed that this upper seat doesn't fall out again. I fear this is a bad design from ford and this part needs to be redesigned or reworked by someone who can create a means of attaching this to the frame.

 

[GregLocock]

That's why they have a preload in the springs. Adding a check strap to the rear axle will increase the tendency to spin if the inside wheel lifts, as it suddenly overloads the outer wheel which can then break away.

So the proper solution is to design a 2 stage coil spring with a soft initial rate to hold the spring assy together followed by the hard rate you want, or engage in a tuning exercise with the rebound stop in the shocks.

So the main vertical part of that is designed to (a) contact the lower bump stop and (b) keep the sprig cap located on the coilspring. The nub presumably locates on a hole in the chassis. WAG the nub is 10mm high, if you can have 10mm of free play at full droop then it can mislocate. I'm used to coil overs, hence this is a non problem for 'my' coil spring suspensions. Not too sure why Ford would change a part to cure a problem of your own making.