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I bought a 99 Expy AWD at a police auction. It has a lift under it(used for high water rescue) but not sure exactly how much. My guess in 3". When I got it it had a bad sag in the rear. I put all new front suspension and both front and rear shocks along with new tires. So to get rid of the rear sag I put 3" coil spring spacer in. Now the ride height is perfect.
So my question is this.
After I added coil spring spacer in the back, it is very stiff in the rear suspension. How can I fix this? Will a new longer shock help and or am I just screwed due to the 3" coil spacer?
Not sure I have your answer, however there is a thought process.
The purpose of a shock is not to impact ride capacity or load capacity it is to dampen or restrict (not stop) vehicle movement that occurs over irregular road surface because the vehicle has springs that want to go on and on.
IF the stiff ride is due to high capacity springs the shocks are not in the picture. And the springs are not matched to the load. Increasing the load (a temporary thing to test) would give you a smoother ride. Like an over the road tractor with no trailer.
If the shocks have reached the end of their travel (in either direction) over the uneven road surface then the rough ride is a an abrupt stop in suspension travel in either direction because of the travel restrictions of the shocks.
Since the vehicle has been modified outside of the design it is difficult to know what is going on. An actual test drive and inspection of the suspension system would reveal more.
So to get rid of the rear sag I put 3" coil spring spacer in. Now the ride height is perfect.
By any chance is it equipped with air suspension? Deflated rear airbags will give a noticeable sag like you've described. Installing lifts only lifted the body it did not fill the air bags, leaving you basically riding without rear springs.
When I bought the Expy it had a 3 inch sag in the rear. I replaced the shocks with the factory size ones. A little while later I wanted to fix the sag so I added CNC milled aluminum coil spacers.
When the vehicle is under a light load, it seems to ride a little better. Under normal drive conditions it is very rough in the rear. It almost feels like the suspension doesn't move at all and it just bounces over the bumps.
Sounds like having stock shocks with a lift kit is limiting your travel. Then to add to this, rather then getting the proper length springs, you add spacers to limit your spring travel and stiffen the preload.
I'd get the right length of springs and measure the new travel to get the proper length shocks.
Until then, enjoy the bumpy ride.