ToyRyd04s - Rebuild and Limit Hydro Bumps

While watching KOH '23 today for motivation, decided to work on bumpstops.

With Hydro bumps becoming more and more popular and the price tag finally starting to decrease, I decided to invest in some TG 2.0, 4" stroke Hydro bumpstops.



Quickly after these arriving and doing more research to figure out placement I soon realized I would need to de-stroke these. Being on leafs in the front, I only have about 4.5" of uptravel, so I decided that around 2" would be the end goal.

TG posted on their website that these are rebuildable, so I knew that I could take these apart and modify both the length, and spring rate that I will get into later.

So needed a few things before getting started. First was a Nitrogen No Loss manifold to get a pressurized before and after reading on the shocks. As TG site mentions, these were filled with 200psi of nitrogen charge. This King shock manifold threaded on the body and then the no loss valve threaded on. Two hand procedure so no picture in action.



After confirming psi, I let out the pressure (keeping the shock up right for no oil loss).

Then dumped the shock oil into a small bowl to keep and hopefully reuse/measure capacity and what amount was needed after the mods.

Now with those removed, disassembly can start. Removed the Allen set screw and unthreaded the collar that also hold the shaft seal.



Once that is unscrewed, you now have access to the sliding valve/shim assembly that is a solid machined piece. This needed to be pushed down in order to remove the C clip prevent it from completely coming out.





And a couple views of the c clip in the shock body.





Now I was able to pull apart the assembly and layout how it was assembled.



Going from the Top left to right

No loss nitrogen protective valve cap, locknut, and washer to mount the bumpcan housing onto.

Going from the Bottom left to right

Delrin washer that the end of the rod guide sits on, then the 6" rod body 1.25 diameter, sliding valve/shim assembly, c clip retainer, threader seal collar, o ring wiper, threaded aluminum striker body, and replaceable Delrin bumpstop striker.

Some close up shots.










To the right on the plastic bag is the (2) spacers needed to reduce the shock stroke. These will be added to the 6" rod body.

Purchased from Fox Shocks:

FOX 2.0 Air Bump Stop Shaft Spacer
1.25" Shaft, 1.7" Length
SKU: FOX-233-00-070-A
Part: FOX-233-00-070-A

Now showing a full parts diagram with the Spacer inline.





Machined .120 DOM tube spacer, exterior OD there is room but ID of the DOM spacer needs to be machined to .1255 which Fox sells directly.





Reassembly is the same as taking it apart.





Thread on strike body onto the rod shaft and the replaceable bumpstop is threaded on by two button head bolts.









That's all for now, still need to measure the amount of shock oil (5wt) that was used ***edit*** looks like 200ish CCs total for both shocks*** compared what's needed for the 2.25" stroke now, and refill. After that will start at 150psi Nitrogen recharge and tune from there.

Also working on a set of mounts that will fit between the typical Toyota U shock hoops.







Credit goes to Billavista article, great tips and overall instructions. After reviewing this web article about a King Shock bumpstop tear down, there's no doubt these TG bumpstops come from the same factory.
http://www.billavista.com/tech/Articles/Air_Bump_Tech/index.html


Updates to follow once I figure out exact mounting to measure and fully welded the mounts.
Stay tuned...

 

Good stuff dude!

 

Bit more progress working on the mounts. Got them full welded (besides gluing them on the frame).

Had to relocate the shock mounts, and brake hard lines from the initial SAS.

 

Progress, just need to cycle and drive them to make sure and burn them in the rest of the way.