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]

I've forwarded your information to CSS the engineers who created my lowering springs. As this could be an alternative.

 

[BrianPetersen]

here's the culbrite:

View attachment 8393
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.

It isn't a "bad design from Ford". It isn't a problem until you created it!

Every front-drive vehicle that I've ever owned that has twist-beam rear suspension, and there's been a few, relies upon spring preload to hold the rear springs (and spring seats) in place, via the dampers running out of travel in extension before the spring runs out of preload. There is no need for anything to be locked in place.

This is why Bilstein B8 dampers (intended for use with lowering springs) are shorter and have shorter travel than B6 dampers (intended for use with stock springs).

 

[LostInTransit]

Thanks to all those knowledgeable engineers for helping islocate this issue. Although I'm not able to locate the specs for the FoMoCo/Motorcraft shocks ( ASH-85936 & KV6Z-18125-A ) that were designed for our van, I'm under the impression that the shocks were designed for the cargo van which has longer/taller rear springs. If this is the case, they survived road travel for 6 months before failing or hyper extending beyond the norm causing the rear springs to pop out. We've ordered a set of the KYB Excel-G shocks which have a spic of 11.08 inch down travel and a 17.99 up travel which seems to be the ideal number for the rear springs. I checked this the other day with the shock limiter straps which measured 16'' but can stretch to 17.35 inches. Come Wed, we'll know for sure if the FoMoCo shocks was a bad choice for our 2'' lowered rear coil springs.

We'll find out and learn more this Wed.

 

[LostInTransit]

We installed the new KYB shocks wed and the coil springs still fell out but only while on the lift. The tech at the shop seem to think we need a shock that's 3/4'' inch to 1'' shorter that will offer more retention to the rear suspton as not to allow the springs to fall out. I'm turning the van into a custom hotrod. Not that I wanted to but I've just located a spec sheet that has all the manufactures shocks and struts specs on extended up travel. I'm focusing on something around 16.50 - 16.60 limited up travel.

In steps fleet pride and they have ample supply of truck shocks that I have access to. I found a set of the Monroe 66608 shocks that have an up travel limit of 16.88. However I'll have to modify the shock loops from the current 3/4 sleeve down to a 5/8 sleeve and I was able to find these sleeves and well as thinker washers to use as spaced on the Monroe shocks.



Random or stock image, but these sleeve will arrive at 4.5'' lengths and we'll need to straight cut them in half to work with the Monroes. because the monroe shock loop is x2 larger than the OE shocks, these will fill the void between the "U" bracket. But washer will be need and we ordered these from mcmaster-carr.com these 1/4 inch thick washers will arrive today.. fast shipping too. The sleeves will arrive Sun, but will need to be cut in half.



In other words, the KYB shocks failed and we're getting ready to install the Monroe magnum shocks which are shorter. Although at one point I had the limiter straps, I was looking at attaching these to the shock bolts.. but now I'm having other ideas about using the strap to like the dead axle completely. this could mean some welding and custom fabrication.

I'll know more if these Monroe 66608's offer a better retention to my shock up travel troubles next week.

Interesting news this morning from Greg at CSS, he informs me that their shop doesn't do custom shocks, but their shock engineer is out on Vac and will return soon who can. Greg never told me that CSS not only designed springs, but shocks too and prob other things.. So till then we'll check the Monroe shocks with the current set up and see what our next move should be.



Although Greg suggested that they have a shocks engineer in house, they don't actually make the shocks.. along with this. No one has told me anything about what leingh I may need. so I'm having to buy test, discard, buy test discard till I find one.. I only have one option left after the monroe 16.88 However, Byron from GAZ tells me that they designed shocks for a 2014 Connect and he sent the schematic for the design.. This is the only thing I got to work off of as it says 16.25 or 16.50 inches. we'll find out shortly.

 

[LostInTransit]

This morning wrapping the lower portion of the new Monroe 66608 shocks. These have been rated for the class 3-6 trucks and they are extremely heavy and heavy duty. Som fear that these would not offer the van the 'track feel" I'm searching for. I'm actually using these shocks more for keeping the dead axle in check if lifted off the ground. Currently the van resting on level ground the shocks measure from bolt to bolt 15.00''. These monroe shocks measure 16.88'' extended which the current KYB shocks which allow the springs to pop out once on the lift measure 17.99''. if by chance these new Monroe do not support the dead axle, we have one more set to check and these are not as heavy duty, but measure 16.5'' extended and the shock loops will need to be drilled from 1/2 to 5/8. This would make the 8th set of shocks we've tried on the van since the springs started popping out.

not liking the amount of air bubbles within the wrap, so I'm opting for paint and will get some later this weekend. This way I can mask off the area I don;t want painted prep and lightly sand the lower half of the shock. Seems a bit much just for a shock, But I've always considered my cars/trucks as 1:1 scale models. Oh byw, I've sent an email to monroe lettings them know we're installing the 66608's on the Transit Connect, just to see what they say. After all, Ford does list the van as a "truck".

 

[LostInTransit]

Yesterday, Located a local fabshop who's willing to cut the 4.50'' sleeves in half and drill out the 1/2 shock eyelets to 5/8. However they did not or could not locate their 5/8 bit so I told them I'll buy the bit and take that off the $100.00 I'll pay them to do the jobs. They agreed.

Next, went to the paint shop and got a can of the bright yellow paint, primer and glossy clear paint. So I'll be working on the lower portion of the shocks this morning while it's raining. But first have to drive to the hardware store to pick up the carbide tipped 5/8 bit.

Looking to the future.. if by chance these monroe 16.88 shocks do not have enough rigidity to retain the springs , I have two different shocks in route to our locations.. One measure 16.53 while the other measure 16.48. However both would need to be drilled out from the 1/2 to 5/8 and spacers would need to be calculated within the "U" bracket distance.

We're pushing to get this done because 2 weeks from now we have to drive about 2 hours to a shop to pick up our wheels and if the van isn't ready to make this haul.. we're looking at mounting storage fees for the shop to hold the wheels. I hate it, but may end up renting a truck to get the wheels.

 

[LostInTransit]

The 2nd and 3rd pair of shocks arrived today. I ordered these just in case the 16.88's don't work. The shocks that arrived have a measurement of 16.43 and 16.54. However I was unsure if the 1/2 could be drilled out to allow for a 5/8s sleeve.. and if we drilled thes eout, there wouldn't be enough meat left on the swage sleeve already installed on the shocks.. I'll have to send these back. Fortunately, we ordered them through Amazon and they have some easy returns.

We're left with 2 options as the wife and I agree that we're not able to order a custom set of shocks which could cost us more than what we're willing to spend.. so we're hoping that these Monroe 66608's will fill that void, or I hate it but it's back to the factory springs.. On a positive note, if we send these springs back.. we'll be looking at getting our money back.

The issue i'm faced with and simply can not understand what has changed between dec and now, (6 months) this setup worked just fine. Now all of a sudden if we hit a big bump or place the vna on a lift, the springs fall out. again which they've never done before. Several time I've crawled under the van inspecting if anything is missing.. Only thing that comes to mind is maybe the dead axle front bushings need to be tightened if that's some that can be done.

As for repainting the lower portion of the shocks today.. I had to paint them twice.. because the clear coat was gloppy and didn't over a smooth finish.. have to strip the paint sand and start all over again. Current;y its just been primed again and I'm beat. will pick it back up tomorrow.

The last piece of the puzzle will arrive tomorrow.. we've order those 3/4 to 5/8 sleeves which are 4.5 inches long.. and will need to be cut in half. Then it's off to the shop again and get these 66608's installed.

 

[LostInTransit]

Feeling tired and dejected I was about ready to go to bed when I told myself to look for shocks again.. but select a new extended range number.. and BAM.. I found a shock that have the 5/8 eyelets at both ends and has a extended travel of 16.50.. I can't move on these just yet, as we get paid this week.. We're still going to proceed with the installation of the Monroe 66608's but at least I have a reserve lined up when I thought there wasn't any left. reason I wasn't able to locate these is because the manufacture updated them to a new part number. So now we're back to having 3 options instead of just 2 options..