2nd Gen Non-Engine/Transmission How to soften the rear suspension

[JBodenhamer]

Got a question/need some help. Here is just a little background for clarity. I have an 01 2500 4x4 auto, quad cab. Got it in Jan 05 with 80K, have about 140K now. The heaviest thing I have towed is a jet ski with any regularity, and when we move(every 2-3 years at least since I am active duty Army), I normally rent a U-Haul that ends up about 5K pounds. I have towed a car on a trailer once and a few other such things, but like I said, not often. I only have a rear hitch too, no gooseneck or 5th wheel. It is a daily driver toy really.



So, here is the deal. I got the truck because I wanted a Cummins engine after my first Iraq tour, principally because I like diesels, and think I owe my life to the durability of Cummins engines. I know this sounds strange, but the short of it is that one night in late mid 2003 near the Baghdad Airport, on a road then known as Ambush alley, leading to our base, I was in my Bradley Fighting Vehicle leading my 1SG back to base to get some re-supply, when my gunner and I were suddenly covered with coolant and my driver told me all caution lights and the master alarm were on--radiator blew. Not wanting to stop in this hell-hole of a place, we decided to try and make it the last few miles to base, and my track got me there. Just inside the perimeter, it died, and when I raised the front cover, the engine(Cummins 8VT) was so hot that the oil residue on the valve covers was on fire. We stayed the night there, and in the AM, called the mechanics to check it out. Since we needed to get it to the motor pool for work, and figuring the engine was done anyway, they told me to try and start it up to see if we could limp it to their maintenance area, and believe it or not, it started. Topping this off, they fixed the radiator, and it continued to run for another couple months. Amazing. So, I am a Cummins fan for life.



Now, to the question. I have since been back to Baghdad for another year, ridden a few more IEDs/bombs, and have a pretty screwed up back. The truck is getting a little painful for me to drive, and my wife hates the rough ride too. At the orthopedic surgeon yesterday, as he was looking at the latest set of X-Rays I had, he recommended I find a smoother ride when he asked what vehicle I have. I am 31, have another 12 years of Active Duty at least ahead of me, so back pain will just be a fact of life. Not a big deal really, but I very much do not want to have to get rid of my truck, and it seems I could do something to take care of this.



So, is there any way I can make this truck ride like a 1500 but not destroy its usefulness? Air bags or something similar? I have heard changing ride height can mess up the brakes, so removing leaves seems like a bad idea without some other modification.



Thanks for any insight on this. It is probably too long and I do not at all meant it to sound like some stupid sob story. I am keeping the truck in spite of my doctor and wife, but figure I can find a happy medium somehow. For a final comment, selling it for a 2WD or a newer/different is not an option either. First, it is paid off, and also in less than a year, I move to New York for 3 years, and will need the 4wd. After that, who knows. Could be anywhere from Alaska to Europe, so I do not want to loose all weather capability. Also, I have a lot of money in mods and maintenance(just did a full heavy duty trans rebuild myself--$2500 for parts), have an Edge with Attitude, full Stainless exhaust, huge and expensive but extremely useful Weatherguard toolbox, intake work, lift pump improvement mods, just spent a lot of time, effort, and $ to fix the dash that was falling apart, etc, etc.



thanks again.



Jon

 

[LBARTLETT]

first I thank you for your service!! I've always hauled big loads so I'm not much to help with this issue, one small quick fix would be to look at the type and load rating of your tires, a C or D rating will not have as stiff of sidewalls as a E rated tire, with what you haul a C should handle everything you need. you can also gain a little with your tire air pressure however mileage will suffer slightly, also look at your shock brand and design, adjustables could be ran on soft unless you are hauling heavy which you do once in awhile



my son's a tanker and trade his 01' cummins like yours for a pimped up conversion Avalanche, I asked if he had caught malaria although like you he had been in the wrong part of the world to catch that



good luck to you and I'll be watching this post to see what the experts, hope you find help because 01's are the best

 

[yunk]

http://http://www.thecarlisuspension.com/dodge-ram/components/frontendkit.html



Try this link.

I was looking into the same issue and carli suspension has several ways to go. I was thinking of trying the 5 leaf replacement of the overload spring... . tom

 

[foolkiller]

based on my experience... ...



the mini pack spring set ups will soften the ride a little bit. you're not likely to be impressed though. that option seems to work much better on the third gens. the lift blocks and a very flexible frame rails contribute to the bouncing on the 2nd gens.



if i had it to do over again with my 2nd gen, i'd have had thuren fab or good spring shop set me up with a full leaf replacement that gave me the desired ride height, characteristics, and eliminated the stoopid lift blocks they used in the 2nd gens. you will lose a little load capacity with this too but that depends on what you ask for.



for the short term... ... removing the bottom leaf from your current leaf pack will soften things up but you will lose some load capacity. i did this for about a year and even hauled a couple 5klb trailers with no problems. it is not good for the leaf pack though and over too much time they will sag over the edge of the perches on the axle. you will also get a little axle wrap. i did like the way the truck rode though. i added the minipacks after that and hated them. truck was stolen before i could continue the project.



what i did not try but wish i'd have thought of before the truck was gone, is flipping the bottom springs over. this may have worked out nice but i never got the chance to try it.



i have driven a couple trucks with full leaf replacements and it is the way to go if you're ok with the investment.



if you're looking to have it ride like a 1500, i don't think there's a many options that don't lose some load capacity. manufacturers will tell you the mini packs won't effect load capacity..... not true.



you can compensate for loss of load capacity with air bags though..... more $$.



if you can rebuild your own automatic trans,,, this problem is well within your skill set. just lay under the truck awile and look things over and the solution will come to you.



good luck, j

 

[hcole]

If I were you, I'd take the air ride seat approach. While I know nothing about them, I've heard a lot of positive comments about special OTR truck seats that take the harshness out of big rigs rides. Seems cheaper to modify the seat rather than the truck. My thoughts.

 

[EBung]

Flip the rear skackles. That really made a difference on mine and I did it after I put on add-a-packs. Huge difference.

 

[EKlem]

Right now, your springs are set up to carry a much greater load than you normally do. You could replace the entire pack with lighter springs but that will give you problems when you want to load it down. One option would be to remove one of the springs from each side and add airbags. The airbags tend to give a softer ride and you could inflate them more for greater load capacity. You may even find that you could take more than one spring out a side.

Another thing to think to complement a different spring setup would be shocks. They also play a role in the ride quality. I haven't replaced the shocks yet in my current ride so I have no suggestions but have done it in the past with great success.

 

[RLHannink]

Flip the rear skackles. That really made a difference on mine and I did it after I put on add-a-packs. Huge difference

How did you do this? Is there any kit available to make this easy?



I just went out and looked at my 97, it looks like flipping the shackles will really change the pinion angle. Also, did your shackle flip decrease the ground clearance by the shackle?



Interested in doing something like this for better ride especially off road. And possibly better suspension travel.

 

[WalterRyan]

I remember seeing a setup that sounds like it is perfect for you. It may have been Kelderman but I am not sure.

It basically replaced the rear spring hangers on the frame with a pivot bracket on each side. There is a square tube going across the truck with a small airbag on each side. The spring shackles then attach to hangers on the bar. This allows the first couple of inches of travel to be in the air bags and then the leaf springs take over after that (I assume there is a rubber bumper inside the bag, I know firestone has that option for large trucks). It works sort of like the overload leafs but in reverse. I have not kept track of this setup because I want to go with a full 5 link airbag setup without the leaf springs. That would be even better but it is expensive. If you have access to fabrication equipment you could make either setup yourself.



Walt

 

[EBung]

How did you do this? Is there any kit available to make this easy?



I just went out and looked at my 97, it looks like flipping the shackles will really change the pinion angle. Also, did your shackle flip decrease the ground clearance by the shackle?



Interested in doing something like this for better ride especially off road. And possibly better suspension travel.

You torch the rivets out, flip the hanger and reuse 2 of the original holes (the wider 2) redrill the other 2 put in four 1/2" grade 8s per side. You will have to trim the bed supports a little for clearance and it will raise the rear about 1". You will also have to cut the nipple off the upper shackle bolt to clear the frame rail when its all together. Trust me it made a big difference and I didnt sacrifice any load capability. I was a little scetchy about it at first when a guy said to do it but I am glad I did. Its not so much a shackle flip as it is a hanger flip.

 

[San Felipe Bob]

Full rear leaf packs and air bags

I had National spring make up full 12 leaf packs.

They eliminate the blocks!

They ride very nice.

I use Air lift air bags for when I have extra load.

Don't forget the front springs too!

Your best bet is to talk directly to Carli, Lorenz,Kore ect.

You will need cutom valved shocks too.

It's all about the right combination.

When I did mine it was before the above mentioned guys were around.



With the right springs and shocks you can achive a car like ride.

You will give up some high speed offroad stability but it will ride real smooth.



The cheapest way to fix it is to lower the tire pressure and add weight to the bed with sand bags. 300lbs to 800 lbs helps alot .



Thanks for your service !!!



SFB

 

[kenny61]

1000 lbs of equipment in the rear of mine always made for a nice ride~!

 

[JBodenhamer]

Thanks for the info so far. I am researching some of these suggestions and plan to look at the rear suspension this afternoon too. I know this sounds funny, but I am very comfortable rebuilding engines and transmissions as I have done this since I was a little kid with my dad, but I have never messed with suspensions other than to replace broken or worn out parts, so the work is certainly do-able for me but out of my comfort zone.