Help! W250 front suspension rebuild!

[earthdad]

Hey group!

Purchased 1992 W250 club cab. Problems:
a) Dana 60 drivers side front spring hanger sheared off and was booger welded on
b) Same side leaf spring center bolt sheared off and axle pushed back 3/4" bending u-bolts.
c) Sam side knuckle wobble(shattered king pin bushing)
d) Steering shaft worn
Remediation:
a) Demo'd existing front hangers and frame bushing(shackles).
b) Installed "Jungles" 2" lifted front spring hanger and HD frame bushing and shackles.
c) Installed new stock replacement leaf pack from SD Suspension(not the seven leaf HD).
d) Rebuild knuckle with new pin, bearings and seals.
e) Borgeson shaft to be installed
f) Bilsteins on their way.

Hang Ups:
a) Distance (outside to outside) of front leaves on hanger about 33.5" (should be the same as stock as the new hanger assembly bolted where the existing rivets were. Distance across rear of front leaves(on shackles is 36")

**Is this a problem?**

b) New leaf packs at negative arch. Called SD and they confirmed I had the correct springs. (I should have gotten the HD's )
c) Passenger side shock mount bump stop edge looks like it will hit the sway bar weldment on spring plate if bottomed out. Only by about 1/8".

**How would I know if frame was bent? Or maybe the axle tube on the drivers side(long one) got bent back when the front damage occurred causing the short side to move back when that side(drivers) was centered on the spring. I think I just answered my question. ****

I think I am going to loosen all bolts on front hanger and spring u-bolts and re-position.


Any advice or experience would be appreciated.

[bmoeller]

Not a suspension guy, but get a buddy and a tape measure the frame to see much it might be tweaked. Corner to corner and do the same with the axles. Something isn't right.

[BILTIT]

Some pics would help too.

[earthdad]

Im not seeing that attachments are allowed. How do I post pics?

[earthdad]

Here is a link to some pics. All I could capture was the arc of the springs which look like the top leaf is bending at edge of second and shock tower to spring plate. As far as the difference in overall length of the left and right spring, the front should be right on cause it is a one piece front hanger. Can the front springs be "toed in" like that? Should I attempt to return and exchange the springs(if they will) or have them reworked with an add a leaf?


http://s1256.photobucket.com/albums/ii4 ... ont%20end/

[BILTIT]

I don't think i would use those springs, they wont last long. The springs might be toed in from the factory, i would have to measure mine and see where it is at.

[earthdad]

Hey, I am in a big debate weather or not the front springs toe in toward the front on extended cab 92 w250 cummins. If anyone could post some measurements across the front springs at the front hangers I would be grateful. I know the Dana 60 is 32.5" on center which should make it around 35" overall at axle.

Thanks

[BILTIT]

Yes they are, i measured mine and found ~35'' outside dimensions on the front mount and ~37"outside shackle measurement on rear.

[earthdad]

Biltit, were those measurements across the spring flats or the edge of hanger/shackle?

[BILTIT]

Edge of hanger/shackle.

[GoldenRule]

Please report on the results of this upgrade. I'm looking to do something similar on a 91.5 W250. Any links or suggestions on a cost-effective front spring upgrade would be appreciated. Not looking for a lot of lift, just a more comfortable ride off the pavement. Thanks!

[earthdad]

I went with a 2" front hanger and shackles and larger frame bushings AND! what was supposed to be stock OEM front springs for Cummins from SD suspension. I have read many posts and off the top of my head I cant seem to remember anyone particularly gloating over the ride quality of their 1st gens. Except maybe for guys/gals running air ride. Check out parabolic springs. Some seem happy with, some don't. One thing to note on these(that i have gathered from others posts) is advertised lift and actual lift may vary. My truck is not a daily driver. I actually love the rough ride. When I bought the truck I brought my dog with me. I hit a bump and looked over to see him airborn. The expression on his face was priceless. I wouldnt have it any other way so far. I still have to get my truck on the road. Im stuck with the springs I have now for a season anyways, I did add Bilstiens, so, well see how it rides.


Here is a link to a site that was referred to me for the parabolics.

http://www.customsuspension.com/store/p ... ts_id=1742

[earthdad]

Oh, if you decide to go with conventional leaves, I would suggest making sure to have the poly slides installed on the leaf ends, as I have heard it minimizes the edges of the leaves jamming into eachother and maximizes spring travel.

[BILTIT]

Please report on the results of this upgrade. I'm looking to do something similar on a 91.5 W250. Any links or suggestions on a cost-effective front spring upgrade would be appreciated. Not looking for a lot of lift, just a more comfortable ride off the pavement. Thanks!

I used Alcan springs in mine, quality spring but at a price.

I think it is ~$250 per spring.

[GoldenRule]

BILTIT, Was it worth the $500? Would you do the same thing again? Thanks