Higher Heights Coil-Over-Axle Rear Suspension - Trucks 4x4 @ Off-Road.com
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Higher Heights Coil-Over-Axle Rear SuspensionAxle Removal

Source: Suzuki/Geo at Off-Road.com
Click for a larger, annotated picture of the suspension components.Here's an annotated picture of the suspension components to get you started. Click the pic at left throughout this installation procedure for a larger image.
Jack up the vehicle, support the frame and remove the rear wheels.
Remove the bump stop bracket.
Remove the E-brake pin and spring from the backing plates.
Remove E-brake cable from the axle tube.
Remove the shocks from the axle tube and upper shock mount and set aside.
If you have a spring over, remove the upper shock tower.
Remove the brake lines from the frame and plug.
Remove the drive shaft from the pinion flange and tie it up to the frame. Support the axle.
Remove the U-bolt plates by removing the U-bolts. Remove the axle.
Remove the rear shackles and springs.

Axle preparation

Support the axle on a table.
Remove the brake lines from the axle.
Cut off the brake line bracket and save.
Cut off the spring-over saddle pads (if you have a spring-over) and lower shock mounts.
Clean all cut off parts with a grinder.

Frame Preparation and Installation

Remove your exhaust system.
Clean all undercoating off of the area next to the rear spring hanger. This is where the U-plate hanger for the A-arm will be welded. Clean all undercoating off the frame next to the stock upper shock mount. This is where you weld the upper spring and shock  mount.
Mount the new U-plate hanger to the the stock spring hanger. Mount them flush with each other and clamp them together with a couple of vise-grips.
Drill a hole through the existing spring hanger and into the U-plate hanger with a 9/16" drill bit. It might be helpful to start with a pilot bit. Just make sure that you drill the hole straight. Verify the trueness of the hole with the 9/16" bolt.
Tack-weld the U Plate hanger into place.
Move the axle truss and arms to the frame.
Attach the new track-arms to the spring hanger, then attach the A-arm to the new U-plate hanger. Make sure to use silicone grease on the bushing surfaces where they meet any metal.
Check alignment of the track arms by measuring from the 9/16" bolt in the hanger to the axle assembly. Make sure each side is equal by moving the large nut in or out. Do not over-tighten.
Insert shims into the U-plate to shim and adjust the side-to-side axle alignment
Move the axle into place and align the truss and arms to the frame.
Attach the U-bolts provided to the axle and truss and tighten lightly.
Mount the upper shock and spring mounts to the stock upper shock mount. You will need to trim the plate to make it flush with the frame. Do not remove too much material.
Mount the Sidekick/Tracker coils to the lower and upper mounts and tighten down the spring plates.
To set the pinion angle, mount the tires and set the axle on the ground to put the vehicle at a neutral stance. Verify the angles of the pinion and transfer case with an angle finder. To move the axle use a floor jack at the edge of the pinion to tilt it up.
Tighten the U-bolts and lift the vehicle
Weld the U-plate to the stock spring hanger and inboard frame.
Weld the axle truss to the axle, like a spring over, welding in a criss-cross fashion. Do not do continuous welding on the tube. Weld for a couple of minutes and stop, then continue.
Remove U-bolts.
Weld one of the five provided metal plates from the truss to the old spring under saddle pad. Repeat this process on all four corners.
The last piece of plate will be welded from the truss to the top of the differential housing.

Weld the upper spring/shock to frame.
Mount the bump stops to the top of the axle truss.
Attach and weld the old brake line bracket to the truss and axle tube.
Attach the brake lines to the bracket and insert the clips.
Attach the rigid brake lines to the axle tube and bend to fit. Be careful not to bend them too far or too much. Make sure the brake lines do not rub against any moving parts.
Attach the shocks.
Bleed the brakes. Mount the tires. Test drive the vehicle, then make sure you go through and recheck all your fittings.

--Aaron Andrews

Thanks to Petroworks Off Road Products and Higher Heights off Road for their assistance in the preparation of this article.

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Source: Suzuki/Geo at Off-Road.com,
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