Urgent 2002 Front suspension problem, Help please!

Hey all, I have an urgent need that keeps me from working. I need to work, thus I need your expertise!

In replacing the front shock absorbers to my 2002 v8 Tundra, I ordered adjustable front shocks, from 0 to 2.5 inch lift in 5 increment choices. These are assuredly the right shocks. (Bilstein Toyota Tundra FRT, BE5-6929-H1, Part 24-188265)

I pulled out the old shocks from the coil and measured 18 and 7/8 inches (18.825") from centre of bolt hole (bottom) to top of suspension support. (Metal disk.) They were aftermarket parts, and destroyed, as they have no gas left, are cracked, and they had to be cut off.

However, with the new shockes - regardless of lift settings - the space is 19 and 3/4 inches (19.75") and they are too long by that once inch. I can only toggle the top retainer nut setting about 1/8th, it doesn't help.

I tried prying the lower control arm down to try and get the bolt in, but to no avail. I am even tempted to take out the one inch thick rubber damper over the suspension support plate to get it in, and rattle my teeth for awhile.

Please tell me what I am doing wrong, as my truck and I are stranded.

 

Good idea in the above post. I would say removing the lower ball joint would be the easiest method. If that does not work, or the jack does not work, consider unbolting the sway bar. The control arm is quite capable of moving plenty of distance. It's limits are based on the knuckle and upper suspension, as well as the sway bar. Pictures would be nice to have if you can post em!

 

That is one great move with the jack! I was considering it, but didn't under assumption it would slip off.

It turned out that the previous owner had gotten one inch thicker rubber blocks to extend the shock as half of the lift height.

Luckily the Haynes manual diagrams showed that the stock rubber is minuscule or non existent, placing the majority of work on the two cushions and lower suspension support rubber. The suspension support's bolts had been removed for longer ones to accommodate the blocks.

With those upper blocks gone I was able to pry the control arm down the next 3/8 inch enough for the bolt to go in.
Success!

I had tried the spring compressors being on while trying to position it in, but it was too tight. Good idea though.


I have to say, I'm pretty impressed with the amount of helpful feedback in only a few hours, way to go guys!
You rock, and I'm on the road.

 

I am glad you found the issue, and were able to correct it!

 

When I installed my coilovers on my 2000 Tundy, I had to use a long pry bar amd a 4x4 block and pry down on the UCA. I would have thought the same about the jack slipping, or even damaging the fender well.

 

To be honest a pry bar is just as likely to slip on you. The jack does have the advantage of allowing you to have BOTH hands free though while working.

The one thing I do try to say is that no matter WHAT unique working methods you use, always play it safe and if you ARE working on something dangerous, don't do it alone. Have someone nearby just in case. I know it can't always be done, so another thing I have used is to call a family or friend nearby and tell them you are working on something and that if you do not check in every 30 minutes or so, to call you, or come over if you can't be reached. It SOUNDS kinda stupid, but your life can be saved sometimes with something simple.

 

I used the same method, but used a piece of 2X4 in between the steering knuckle and lower ball joint to lessen the amount I had to extend the jack and how far the upper control arm had to be pushed down.

 

That's why I do the prying, and I have someone else slip the bolt through. I usually always have someone else with me if I have the truck off the ground.

 

For those who have an Auto Zone in their area you can do their "borrow" (they sell you the tool and refund when you return it...I think for liability reasons). Spring compressors, tailpipe expanders etc. Their Spring compressors are scary, but work OK....did both my Tundra and my nephews 4-runner with them. I hate spring compressors! Good source for tools to use, they have a big list in the store of what is up for "Loan".