2.5" coil over and springs rub, is there a fix?

Just doing a little front end maintenance and check up and noticed some rust build up and what looks like friction areas on the shock body. The inside of the springs in that area look polished and irregular vs the rest of the spring.

So I did a search and came up with a few things to look at before asking:
1) Check to see if shock alignment sleeve on the bottom bolt is installed correctly - yes, longer end towards front.

2) Running sway-bar? Yes, and sway-bar relocation bracket is installed.

3) Wrong spring? No, new Fox 2.5" coilovers with factory pre-load setting and factory springs.

The other threads gave items to look at but OP never returned with conclusions and I didn't find any definitive cause/effect or solution. Anybody got a suggestion?

 

one thing is springs look really close to strut? did you buy the already set package thing? if you take that picture and imagine it 'squished' the springs would hit the strut under articulation and compressed. I bought springs and struts separate for front end and the coils are not close at all to strut.

just my opinion

 

Seeing that pic would have me thinking the bottom spring perch is misaligned. Eventually that strut will pop, if the issue isn't resolved.

 

agreed. Looks like a perch is out, but yea those clearences look way too tight also.....

 

If it lines up properly, the clearance should be good. I'd take it off before going anywhere (maybe run to the auto store to rent a spring compressor first) and disassemble/ reassemble correctly.

 

i took this pic just now, if it helps.. LOL!, its dark outside, using a q-beam and my camera that is about as old as dirt this is the best I could get, but this is what mine looks like... if that helps

 

Yeah, I bought an All-Pro suspension package. The Fox shocks came in their original Fox packaging when delivered. I haven't adjusted them in anyway. Just unboxed and installed.

Thanks for the picture!

 

I'd contact all pro and see what they say

 

what would cause the bottom perch to misalign? I'm trying to look through old photos from when it was new. I think they've been like this.

 

If the spring is not seated right is one possibility

 

^^this

The coil terminates at each end with a flat cut, not a smooth taper to a flat surface. The bottom perch has a step down bend in it to mate with this. If the two are not mated properly, I imagine you'd have what we see here. Depending on how long it's been that way, you could have a real safety concern on your hands. Struts and shocks have a great deal of pressure bottled up in them.

 

Are you saying the bottom perch (shaped like a cone) should have some sort of step that the coil lays in? I understand what you're saying, but mine doesn't have one. It looks uniform all the way around. The coil installed appears to taper smaller and meets to a flat bottom perch. The end of the coil is 3/4 the thickness. Thanks for all the replies!!

I emailed a photo to All-Pro and they quickly replied asking for fore photos and likely will send back to Fox. Great service!

 

These are a different design than I have experience with. Is the side that rubs directly in line with the termination of the coil in the bottom picture? I'm glad to hear that All Pro is taking care of you. I've heard hit and miss experiences about their customer service.

 

The end of the coil relatively lines up with the shock body friction area, but looking at the inside of the coils parallel to the rubbed area and 2-3 coils down (from the rubbed area), these inner parts look polished and appear to be the point of most friction.

I live in San Diego county and I believe Fox Racing is local in El Cajon area. I'm hoping I can just drop them off for a warranty. Waiting to hear back from Tracy for a game plan, but I offered to drop them off.

 

something must be causing extra pressure on one side of the coil to make it bend into the strut like that though

 

I've got it sitting on the work bench and it just looks to sit closer on that side. Can't put my finger on why. But we'll see what they say Tuesday, they're still at the Overland Expo.

 

@58 Siesta Im pretty sure only stock type coilovers are setup that way. Fully adjustable coilovers will be flat cut springs with a flat perch.

Op it looks like you have some kind of a week spot in the spring and the spring has bowed. Notice the rusty side clearance is low while the clean side is far. the other pic posted his coils are centered around the shock as are mine. Take your truck over to Fox 750 Vernon Way #101, El Cajon, CA 92020.

The service department is great. They changed some stuff on my rear shocks in an hour and for free! I'm sure they will help you.

 

@2nd screen name did you have to make an appointment or anything? Or just un-announced showed up?

 

It was suggested that all I need to do is rotate the coil 45-90 degrees. Wouldn't that just relocate where it rubs?

 

So I didn't get an answer to what happened or why its happening. I didn't actually get to talk to any techs. All-pro as suggested from Fox said to rotate the coil. I ended up driving to DownSouthMotorsports in San Diego and I'm having them throw some King 700# coils in.