Hodakaguy's 4wd Sprinter Build - Pic Heavy!

[Hodakaguy]

Time to get this suspension install going!

First up I jacked up the rear of the van and supported the van with two 5 ton jack stands, since I'm working on gravel (Yeah I know not ideal) I cut a couple pieces of 3/4" ply to support the stands. I put another pair of 5 ton jack stands on the rear of the vehicle under the hitch as a backup, these were just barely touching the hitch and were there for emergency back up.

Rear wheels removed and ready to go.

Stock Suspension.....by by.

Removing the stock sway bar links. The hardware will be re-used when installing the new longer links later.

Temporarily removing the tab holding the E-brake cable. I always place the hardware back in place so it doesn't get lost.

Removing the OEM shocks. Quite the difference compared to the Falcons that are going on.

Lower E-brake cable support tab removed, this tab will be re-located higher later in the install.

Removing the rubber bump stops, a pry bar makes quick work here.

Next up is removing the sway bar. The skid plate makes an awesome jack point.

Removing the brake line support on the spacer block in preparation to removing the block itself.

Removing the U-bolts.

And spacer removed.

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[Hodakaguy]

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Removing the alignment pin that's holding the two OEM leafs together. Here I'm using some Aero-Kroil to assist in removing the nut, the bottom portion of the pin can spin freely so a pair of vise grips keeps it from spinning while the nut is being removed. Notice the clamp on the two springs that keeps the lower spring from dropping once the pin is removed.

The lower OEM leaf slides onto the Vancompass spring pack then the whole assembly slides up onto the upper OEM spring.

Coating the bolts on the upper spring retainers with Anti-Sieze before assembly, if they every need to be removed down the road this step will pay off.

Using C-clamps to compress the leaf springs then torque the alignment pin. Even a shot of my ugly mug! lol.

Spacer re-installed and new extended U-bolts installed and torqued to spec.

Relocating the E-brake cable tab. Here I'm holding the tab in place and marking the locations where I will drill the hole for the new attach point, the tab will attach to the lower bump stop base.

Holes drilled and painted.

Next up I'm installing the bump stop spacers to drop the OEM bump stop down. You hold the bracket in place and use a pen to mark the hole locations, you then use a center punch and a step drill to make a 1/4" hole in each location. Now you attach the brackets with the provided self tapping bolts.

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[Hodakaguy]

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With the bracket bolted in place it's time to re-install the rubber bump stops. These are an extremely tight fit! After coating them with Windex to allow them to slip a bit they are inserted into the brackets. The first one I used a quick clamp and a flat blade screw driver to coax the bump stop into place. On the second bump stop I used a C-clamp and it was much easier!

Installing the spring pack on the drivers side.

Installing the second bump stop....Again a C-clamp worked MUCH better and the stop was installed in no time.

Installing the rear shock re-location brackets. Kiddo was out in the shop for a bit so I put him to work

Re-installing the sway bar.

E-brake cable bracket in it's new home.

Torquing the new Sway bar links in place.

Falcon shocks installed....excited to try these out on the road & trail!

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[Hodakaguy]

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Now it's time to mount up the new rear tires/wheels. Just a bit of difference!

Installed.

It's got that 70's hot rod vibe going on lol. I will fix that soon!

The 285/75-17's and Arsenal wheels play well with the sliding door....but only by about a 1/4".

The shock adjusters are easily accessed.

Rear is complete! Well almost, I still need to remove the small spare from the OEM location.

Lots more to come!

Hodakaguy

 

[Hodakaguy]

Well....time to get rolling on the front lift kit install. I installed the front lift and shock upgrade mostly by myself over a couple days this past weekend. The Vancompass instructions were spot on and very well done! I'll also compliment VanCompass on the quality of the kit, everything is absolutley top notch with awesome fit and Finish! I'd also like to thank Cory at Peak10Customs for the awesome service and for getting my 6.3 kit out to me so quickly!

Time to install the 2" Lift.

First up disconnecting the battery.

Separating the upper steering shaft from the U-joint.

Next I'm installing the provided hose extension on the low pressure side of the power steering pump.

Safety tip.....The edges of the hose clamps can be sharp, always have first aid supplies handy in the shop so you can keep progress going

Next the van was supported on some 7.5 ton jack stands, these stands have the height to reach the factory front jack points.

Removing the steering shaft.

Separating the speed sensor and brake pad wear sensor from their mounts.

Lower strut bolts removed and brake calipers removed. I always try and put the bolts back into the holes they come out of, it's a easy way of keeping track of them so they don't get misplaced. The caliper was supported from the sway bar with a snap tie.

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[Hodakaguy]

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Removing the struts. I marked them as they came out so they can go back in on the same side. Note, I also used a scribe to mark the lower bolt locations so I can get the alignment close again upon re-installation. I'll have the van re-aligned once everything is complete.

Removing engine mount bolts.

A bottle jack was used to support the transmission (not lifting here, just holding it in place).

In preparation for lowering the sub frame you need to remove the bolt holding the front diff breather in place as well as separating the wire harness from the sub frame on the drivers side.

Separating the transmission mount.

At this point another stationary jack is placed under the engine oil pan to support the engine and a floor jack was used to support the sub frame. All 6 bolts are removed that attach the sub frame to the van then the floor jack is slowly lowered to separate/lower the sub frame.

You only want to lower the sub frame far enough to install the provided spacers and no further. Both sides are completed at the same time.

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[Hodakaguy]

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Removing the upper transmission bracket to install the new drop bracket. The quality of manufacture on the VC kit is top notch!

At this point I ran into my one hang up with the VC kit...they forgot to prove the M10 bolts to bolt the transmission drop bracket back to the lower mount. A quick trip to Tacoma Screw fixed that issue.

Installing the new motor mount spacers. Everything is snugged at this point but not fully torqued yet.

Torquing the sub frame bolts.

Re-installing the power steering mount bolt, it's a LOT easier to get to with the lift spacers installed.

Diff breather line re-attached.

Installing the front Sumo springs in place of the OEM bump stops. A pry bar makes easy work on getting the springs in place.

OEM Bump Stop

And compared to the new Sumo spring.

The spring won't be in a bind against the sway bar once it's back on it's wheels.

On one of the Sumo Springs the stud pulled out rather easily (Full disclosure I wasn't using a torque wrench here)....Dang! Luckily the base is steel so it's over to the Tig machine to get back on track.

Cleaning off the paint to get a good ground in preparation for welding.

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[Hodakaguy]

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Using a counter sink bit to give some surface area for the weld and keep the weld from becoming to high (The steel washer needs to fit flush).

Since most of the spring is rubber I had to use the C-clamp for the ground.

Welded and painted...disaster adverted. I put a slight counter sink on the under side of the washer as well to clear the weld and allow the washer to sit flush.

Installing the lift spacers onto the struts and re-installing them onto the van.

Re-installing the brake calipers.

Modifying the steering shaft to install the extension adapter. You need to grind off the two tabs on the end of the OEM steering shaft.

And back in the van.

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[Hodakaguy]

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installing the brake hose drop brackets. I'll bleed the brakes at the end of the install.

A good shot of the front composite suspension. The sprinter uses a single transverse composite spring on the front, very unique setup.

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[Hodakaguy]

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Next up I'm installing the front Falcon shocks and mounts. This job is pretty straight forward and again the VanCompass instructions are excellent.

Installing the lower mount.

On to the upper mounts.

On the 17's there are a couple bolts on the drivers side that need to be cut flush. One of the bolts is back in the corner, a ultrasonic tool with a cut off blade makes reaching and cutting the bolts an easy job. I don't use this tool often but when I do it's soooo handy for situations like this one.

Cut and bare spots painted.

For the upper mounts you utilize the OEM holes and the supplied mounting tabs that are placed on the upper side.

Starting the first two bolts to hold the assembly in place.

The rear bolt utilizes a tab to fish the nut into place.

Drilling the hole for the lower front mount, I won't be utilizing the rear as this van has AC lines in that location.

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[Hodakaguy]

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Drivers side front shock going in.

On the passenger side these two tabs need to be removed, once again the ultrasonic tool made quick work here.

Using snap ties to hold the wiring in place.

Passenger side shock installed.

Trimming the inner fender liners to fit around the strut drop brackets and the upper shock mounts. A air powered saw works awesome for this task. A De-burring tool works really well for cleaning up the edges after the cuts. The instructions also cover further trimming to fit 35" tires, since I'm running 34" tires I decided to skip the further trimming and see how everything plays together before completing these steps.

Test fitting for clearance around the shock....just a bit more needed.

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[Hodakaguy]

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That's better!

Ready for the tires to go back on! Here I just finished bleeding the brakes and topping off/bleeding the power steering fluid.

First shot of the front wheels installed....oh yeah! Unfortunately the tires are rubbing pretty bad so the tires are coming back off to do some further trimming.

I'll be removing the mud flap and trimming back some metal as the tire is slightly touching here as well.

I'll be opening up the front area as well.

Trimming the front bumper.

With the opening in the lower front fender I didn't want the wiring exposed. Buy cutting the snap tie on the outer wire attachment and rotating it 90 Deg the wire will be hidden once again behind the fender and out of harms way.

Trimming the rear metal pocket under the mud flap. This area was full of dirt, at least having this opened up will keep it from filling and retaining dirt and water.

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[Hodakaguy]

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Paint-able marine sealant installed. Once this fully cures I can paint match. I'll eventually make a custom mud flap setup.

Trimming the inner liners to fit.

Lot's of clearance now and looks great!

And out driving it around! Spent a good chunk of the day driving the van, mostly in town with some highway. So far the ride is Awesome! I should have done this sooner!

I'll report back with a full review after I get some more time on the setup. LOVE IT!

More to come....

Hodakaguy

 

[craig333]

Curious to see how you adjust the shocks.

 

[billharr]

I need to stop reading your posts. Now I need that air powered hacksaw. Really like how the tires look. I need bigger tires on my Ford Transit 350HD glamper van.

 

[craig333]

I feel for you Bill. My tool collection has increased since I started reading his posts

 

[Hodakaguy]

Curious to see how you adjust the shocks.

I'll try and get a quick video, basically you just reach in and twist the adjustment knob on each shock, maybe a few seconds at each shock...super quick.

Hodakaguy

 

[Hodakaguy]

I need to stop reading your posts. Now I need that air powered hacksaw. Really like how the tires look. I need bigger tires on my Ford Transit 350HD glamper van.

You can never have enough tools

Hodakaguy.

 

[Hodakaguy]

I feel for you Bill. My tool collection has increased since I started reading his posts

Always great to have more tools!!

Hodakaguy

 

[Hodakaguy]

Next up time to start the air compressor install.

I'll be installing a VanCompass mount coupled with an ARB Twin air compressor. This compressor setup will be used primarily for airing up tires after we have deflated them for off road travel.

Typical VanCompass....parts came well packaged with great instructions.

First up you need to install two plus nuts into the factory open holes on the inner fender well. If your van came with the factory aux battery mounted here it will already have these attach points (You will have to remove the battery to run this mount).

You need to drill out the holes to fit the included Plus-nuts. I used a stretch of painters tape to capture any stray metal shavings (A magnet placed under the hole works great as well).

Cleaning up the inner and outer edges of the holes with the De-burring tool.

Painting the bare edges of the holes.

VanCompass included the two required plus nuts but didn't include an installation tool. I dug around in my parts bin and found a longer bolt, an oversize flared nut (Bolt needs to freely spin inside the nut) with serrations on the back side and a washer to use as an install tool. You need the serrations so that the cut digs into the plus nut and you can keep it from spinning while you tighten the nut into place. Simple tool and worked great.

Setting the plus nuts. Two wrenches work great as does a wrench and a socket/ratchet.

Remove the snap ties holding this wiring harness in place. The harness will be a snug fit around the Air Compressor mount.

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