So I bought the truck in the fall of 2008. While off-roading in 2009...BANG! Driver's side (front) lower leaf snapped like a frozen candy bar. Replaced BOTH spring packs up front with new OEM springs and software (u-bolts, mounting bolts, and nuts).

Fast forward to last week. Driving down the paved boulevard and...BANG! Passenger's side (front) upper leaf snapped like a frozen candy bar. Seriously?!??

I've read from some Google-ing that this is not uncommon. But twice on 6 year old springs? That can't be right. I will caveat this with the fact that I purchased the OEM springs "new". This doesn't mean they were just made. I'm sure they were made some time in the past and put on the shelf waiting (possibly years) to be bought. My theory on OEM parts becoming "obsolete" is that once the production run is done on the part that they sit on a shelf until the last one is bought then that part number becomes "obsolete". I just re-upholstered my driver's seat (split open in 3 spots) and the only part Ford still stocks is the back pad. The bottom pad and both covers are "obsolete" as those are the ones probably most commonly replaced.

I'm not going OEM again as I don't know how old the spring packs are as the cross-section shows some serious rust through the metal (see picture below). I decided to go the ATS Springs route and get their "X Code" springs. Yes I know they are not true X Code and are actually V Code plus a little bit more (2630lbs per spring vice 2600lbs per spring for OEM V Codes). Their HD version of these adds a spring and bumps up to 6000lbs for each side and I'm not interested in wearing a kidney belt to commute to work. Hopefully these last longer than 6 years.

 

ATS is great people and I recommend them, they know their business and they are great to deal with. That being said I disagree with your thoughts on the age of those springs as having sat on the shelf for years. They are used on a lot of trucks and are most likely still in production. No so much other parts like seats as you described. You got a few years out of those springs but I agree that they should have lasted longer. However, I see a rust stain on your spring where it is broken, which indicates that it was cracked there before it snapped. Usually springs don't break without a good reason.

 

You'll like your ATS's. I have their rear mid level spring and love them. Their customer service is very good as well.

 

I agree but I don't think I'm overly hard on them. I do off-road on occasion but I don't go rock crawling or launch off of dunes. At almost 8000lbs and a 13ft wheelbase it is not the optimal off-road toy but it gets me around. Plus the fact that my wife keeps tabs on the cost-benefit analysis of keeping the truck or downsizing me to a Corolla .

I only mention the shelf life because the OEM driver's seat back pad was just as dark yellow as the one I took off. It definitely looked like was produced a long time ago and has been waiting patiently in a warehouse for a good home. Not to mention the fact that the bottom pad, top and bottom covers, and seat trim screws are all "obsolete" and unavailable.

I'm glad to hear more positive feedback on ATS. They were very helpful on the phone and all the reviews I found were very positive. I got everything in the mail and I put them on next weekend.