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How much shock travel?

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Old 07-25-2014, 02:00 PM
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I finally got around to installing the cryo'd hubs/rotors, and ended up going ahead and replacing the BJ's on both sides. Turns out the the longer heads on the XRF pinch botls were causing serious rubbing inside the ears of my rotating c-frames right below the calipers' upper mounting bolts, and this was exerting extra side forces on the upper BJ's which is why they died early deaths. I've now learned to grind the heads down to create more clearance to avoid future premature deaths on the BJ's.

Anyway... we also did the shocks this weekend. I stayed with the 3/8-24 pitch, but it was a real booger. I had to die the new threads twice to prevent the 24 pitch die from "shouldering" out on me. Since the stud diameter is larger than the outside thread diameter, the die pushes metal downwards instead of swarfing it off in pieces, and the "shoulder" jams the die and causes it to strip the threads completely off.

To avoid this, I used a 7/16-20 die to precut some of the extra stud diameter so that the 3/8-24 die would cut more easily and not have so much material to remove. This did create some minor compromises on a few of the new threads due to the difference in pitch counts on the 3/8 and 7/16 dies, but it is very minor. To compensate for this minor thread damage, I mixed a fresh glob of JB Weld and smeared it on the newly cut threads where the shock extender would cover, quickly tightened the extender down, and I now have completely filled thread gaps between the extender's internal threads and the shock stud's external threads.

I hope that makes sense.

I feel comfortable with the use of the JB Weld because all of my riding is on paved roads, so there should be minimal impact stresses on the shock studs.

Anyway, the ride is twice as good as ever and the truck corners through the turns with more rigidity, less body roll, and I have an overall firmer front end due to the combination of the new shocks and the extended stud heights.

So now, within the last two years, I've replaced literally every component in the front suspension except for the coil springs and the sway bar bushings. I'm leaving the springs alone, but will go ahead and take care of the bushings just to finish snugging up the front end.
Pete (F250_) -- PAA#19
'02 F250 PSD, CC, SB, XLT, 2WD: 273K miles
Basic reliability mods with a few minor performance enhancements.
'03 Excursion (Eddie Bauer) PSD, 2WD, 183K miles - Stock.
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Old 07-25-2014, 02:00 PM

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