Steering and Suspension overhaul thread

I really like the look of the KO2s, I'm glad they were on sale.

 

These are some of the videos I watched in preparation for this project. I watched some others but I found these the most helpful. Since I was replacing everything it made something's easier, for instance the struts were a lot easier to install with the ball joints detached. The sway bar links were different and way easier on my truck, if you're going to replace the bushings you might as well replace the end links for $14 each.


Rear axle:

Rear Leaf Springs:
https://www.youtube.com/watch?v=6sPBOzj6u9U

Rear bearing and seal:
https://www.youtube.com/watch?v=ELTp5QqjTKA

Rear Differential Breather:
https://www.youtube.com/watch?v=jea_uo82ekQ


Front axle:

ball joint:
https://www.youtube.com/watch?v=qaQCb894F_M

https://www.youtube.com/watch?annot...&feature=iv&src_vid=aPbL9HTHZg0&v=37NgLM4tIzw

Tie rods:
https://www.youtube.com/watch?v=AVQHgcXEhpE

Control arm bushings:
https://www.youtube.com/watch?v=aPbL9HTHZg0

Sway Bar mounts:
https://www.youtube.com/watch?v=VnrARhxhaSo

Rack and Pinion:
https://www.youtube.com/watch?v=fRG3e-tRlck

Struts:
https://www.youtube.com/watch?v=Qp9OH13jIx8



Other Misc:

Body Mounts:
https://www.youtube.com/watch?v=KR8s4YFBn9k
https://www.youtube.com/watch?v=DhXprbo6Bqk
https://www.youtube.com/watch?v=pF7PjhM2v-o
https://www.youtube.com/watch?v=2jttN5T-Dk0

Washer Fluid Reservoir:
https://www.youtube.com/watch?v=VJRY0Xbs2JA

Headlights:
https://www.youtube.com/watch?v=12UT7uGvIYM

Radiator:
https://www.youtube.com/watch?v=NvDQLBqMfu8

 

I'm not sure why the guy in the Rack and Pinion video removes the rag joint to pull the rack but the way I did it was different.

• Turn the wheels straight
• use a cam strap to tie the steering wheel in place, otherwise it could jack up the airbags if you turn the steering wheel while it's detached.
• drain the power steering fluid
• Pull the bolt circled in the picture, you have to take the bolt all the way out.
• pull the rubber power steering hoses on the opposite side of the picture
• remove outer tie rods
• pull all other mount bolts

 

sub'd

 

Soooooooo......... I'm a little over a year but here's a partial update. The ride is still smooth as a babies butt accept I've been out in Los Angeles for work for the last 2 months and I don't think anything can make these roads smooth, holly crap this place sucks. I now have 139k miles compared to the 115k I had when I did the job. With the exception of the roads out here the truck has been riding great. My one complaint is the load complicity with those Doorman Leafs. Without a load in the back everything is great but as soon as I get more than 400-500 lbs in there it starts to really squat so I have finally purchased the

$321 Air Lift 59537 Ride Control Rear Air Spring Kit , Black

Air Lift 59537 air bags. I unfortunately have a load of about 400lbs in the back of the truck now so I can't check the ride height but I will post it once I unload on Friday.

Last weekend I drove out to Colorado and picked up some of my gear, since it looks like I'll be in LA a little longer than I originally thought, and I was squatting pretty bad on the drive back. I would say that if you are not going to haul anything heavy around the Doorman's are great, I do however appreciate not having a stiffer suspension driving around this pothole infested, broken concrete that isn't flat pile of crap road system that is the greater LA Area. I'm not unhappy with my decision, I do like the smoother ride when not loaded down, I think once I install the air bags It'll be the best of both worlds. Since the Air bags are part of the suspension I will post about those in this thread as I install them this weekend. On a side note, I never got around to reinstalling my brush guard bumper or the plastic piece for the stock bumper I had ordered so I will be doing that as well.

For new problems, My truck has been popping out of first for a little while now but it has gotten way worse since I've been in the land of traffic. Fortunately I had a friend buy a truck exactly like mine as a parts truck and he didn't need the trany. I just purchased a heavy duty clutch today and I'll be installing it all as soon as I get the time. I may start a new thread on that but I won't post it in this thread since it's not suspension or steering.

 

I forgot to mention, I just had the tires rotated and inspected and they said everything looks great and I have minimal wear, like less than normal for 24k miles.

 

Write up on the tranny and clutch removal would be great. I'm going to be doing my clutch soon as well and would appreciate you sharing any issues you ran into and solutions you came up with along the way

 

Cool, glad to know you're interested. I will definitely make a thread.

 

Hey Rschap how's the air bags with the Dorman springs holding up? I ended up putting Dorman leafs in my 97 and figure they'll need help with some airbags when I put the snowmobile in there..