Dorman Front Bump Stop Height

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Jul 11, 2023 | 01:36 PM

95Z28A4

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Trailering

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From: Louisiana

Dorman Front Bump Stop Height

I removed the Zone Offroad 4" lift kit the previous owner installed on our 2000 6.8L 4WD Ford Excursion. I replaced it with C code rear springs and V code front springs. I kept the front and rear FOX 2.0 Adv Series IFP Shocks that were installed with the lift kit. The shocks currently have 4000 miles on them and are basically new. I installed Energy suspension 9.9155G rear bump stops and the rear shocks have adequate travel to work with the C code springs.

The front shocks are a bit long for the V-code springs. There is 6" between the frame and the top of the U-bolt spring plate. The front shocks have about 2-1/2" travel before bottoming out. I have one deteriorated factory bump stop that is 3-1/8" tall. I purchased a pair of

Dorman 523-085

bump stops and they are exactly 3" tall - not tall enough. I need a bump stop that is close to 4" tall. Does anyone know the actual height of
Dorman 523-086

Dorman 523-086
bump stops? Amazon lists them as 3.9" tall in the product description. On Amazon this could be box dimensions. I could not find this information anywhere - not even on the Dorman website.

Thanks for the help!

Jul 11, 2023 | 02:09 PM

WE3ZS

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From: Media PA

I’m no help with the rubber bump stop height question but I think that you actually need new shorter shocks. Even with new taller bumps you will bottom out the front shocks, which they are not designed to do and will most likely ruin them, they aren’t designed to be the suspension limiters in either up or down travel. The bump stops were a planned part of the active suspension on these big wagons, and they do compress a good bit on heavy impacts or bumps, so even a taller set will squash down a good bit when needed.

Jul 11, 2023 | 04:25 PM

95Z28A4

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Trailering

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From: Louisiana

Quote:

Originally Posted by WE3ZS

I agree. I may bottom out the front shocks and shorter shocks are preferred. The Dorman bump stops like the energy suspension rear bump stops are made from polyurethane instead of the rubber-like OEM bump stops. I believe they won't compress as much as the rubber bump stops.

With that said, I already own the nearly-new FOX shocks. If longer bump stops prevent the shocks from bottoming out, then all is good. If I damage the FOX shocks, I'll buy new shocks. If the FOX shocks had high mileage, I would have already purchased new shocks.

As the old adage says......nothing ventured, nothing gained.

Thanks for replying.

Jul 11, 2023 | 05:45 PM

pirate4x4_camo

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Joined: Apr 2011

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From: Northern California

2.5” shock up travel… ouch that’s gonna hurt

dorman stops are rubber just like the originals. Polyurethane bumps have no place on a Ex. They do not compress.

Jul 11, 2023 | 06:59 PM

95Z28A4

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Trailering

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From: Louisiana

Quote:

Originally Posted by pirate4x4_camo

2.5” shock up travel… ouch that’s gonna hurt

dorman stops are rubber just like the originals. Polyurethane bumps have no place on a Ex. They do not compress.

The Dorman 523-085 bump stops are made from polyurethane. I have a set in my possession. The 523-086 may be made of rubber, but the photos look like polyurethane. Instead of spending $100 for bump stops that may or may not work, I think I'll make a set of spacers from 1 inch 6061 aluminum plate I have in stock and try the 523-085 bump stops I already own.

If using the FOX shocks prove to be a bust (pun intended), then I'll call Junior at ATS and order some Bilstein 5100s for all 4 corners.........Or should I just order the correct length FOX shocks for the front? Anyone have experience with FOX 2.0 vs Bilstein 5100s?

Jul 12, 2023 | 09:33 AM

95Z28A4

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Trailering

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From: Louisiana

I think I found the correct FOX 2.0 shocks for the front. The part number is 980-24-654. Riffraff sells them for 7.3L Excursions. They are pricey. I can purchase 3-1/2 Bilstein 5100s for the price of two FOX shocks. I pasted some of the specs below. Does this look correct for a V10 Excursion with V code springs?

Reservoir: Internal IFP mono-tube reservoir design
Shaft: 5/8" hard chrome plated heat-treated alloy steel
Seals: Redundant sealing pack system main seal, wiper seal, scraper seal
Oil: JM92 Advanced Suspension Fluid for improved performance at variable temperatures
Bushings: Quiet nitrile rubber allows for increased suspension articulation
Travel (in): 8.100
Compressed (in): 14.550
Extended (in): 22.650
Top Mount: Eyelet
Bottom: Mount Eyelet

Aug 21, 2023 | 09:01 AM

95Z28A4

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Trailering

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From: Louisiana

FOX Shock part numbers

I called Junior at ATS and ordered a set of Bilsteins. Upon receiving them I realized the rear shocks would only have 3" up travel installed. In my opinion the rear Bilsteins are too long for an Excursion with C code springs and factory blocks. The FOX rear shocks that came with the Zone Offroad lift kit (I removed the kit and replaced it with ATS V,C springs) have 4-1/2" up travel. I decided to return the set of Bilsteins and order a pair of FOX 980-24-654 shocks for the front. The FOX 980-24-654 front shocks have 4-1/4" up travel installed. I have 2-3/4" between the front axle and the bump stop. In case anyone is interested in using FOX shocks I've listed part numbers with specifications below.

FRONT - 980-24-654
Reservoir: Internal IFP mono-tube reservoir design
Shaft: 5/8" hard chrome plated heat-treated alloy steel
Seals: Redundant sealing pack system main seal, wiper seal, scraper seal
Oil: JM92 Advanced Suspension Fluid for improved performance at variable temperatures
Bushings: Quiet nitrile rubber allows for increased suspension articulation
Travel (in): 8.100
Compressed (in): 14.550
Extended (in): 22.650
Top Mount: EB2
Bottom: Mount ES1

Rear - 984-50-762
Reservoir: Internal IFP mono-tube reservoir design
Shaft: 5/8" hard chrome plated heat-treated alloy steel
Seals: Redundant sealing pack system main seal, wiper seal, scraper seal
Oil: JM92 Advanced Suspension Fluid for improved performance at variable temperatures
Bushings: Quiet nitrile rubber allows for increased suspension articulation
Travel (in): 11.59
Compressed (in): 18.46
Extended (in): 30.05
Top Mount: BP8
Bottom: Mount EB1