Downey 1.5inch HD Rear Coils
Disclaimer: these are the steps that I took to install my coils. I do not claim the following steps I took are correct nor do I claim they are safe.
Note: I bought the springs used so I didn't get the BPV bracket nor the stainless
steel extended brake lines that normal come with the Downey kit. I did, however,
fabricated the BPV bracket later.
Tools needed:
•The usual metric hand tools (sockets, open/box end wrenches, etc)
•Floor jack with several pieces of 4x4s to raise truck
•Jack stands
•Wheel chocks
•BFH (Big F-ing Hammer)
•Penetrating oil like WD-40 or Super Wrench
•Small crowbars
Prep work -- soak the nuts and bolts in oil at least 1 day in advance. These
included:
•Top and bottom of shocks
•Bolts for the Anti-sway bar mounts on the outside of the frame in the
wheel wells
•Panhard bolts (we didn't need to remove this though)
•Various bolts for mounting brake lines, bolts for BPV valve on the panhard
rod, and ABS sensor lines to the axle.
The first thing we did was chock the front tires. Then we removed the spare
tire from under the Runner and removed both shocks completely. Wow there is
a lot of room under there now. Then, all the bolts for the brake lines, BPV
valve and the ABS sensor were loosened and the parts were allowed to hang freely.
Next we jacked up the axle with the floor jack and removed both tires. With
the tires out of the way, we unbolted the anti-sway bars from the outside of
the frame.
We then lowered the axle onto jackstands and lifted the truck from the hitch until the axle was off the jackstands. Once the axle was off the jackstands, we place 2 more jackstands under the hitch, in case the floor jack gave out.
The springs came out pretty easily, we just pushed down on the axle and used the crowbars to wedge the springs out. When we compared the stock springs and the used, Downey springs, we found the Downey springs were about an inch longer and much thicker.
To get the Downey springs installed we had one person stand on the drums while the other person pushed the spring in part way. This is where the BFH came in. To get the bottom of the spring over a dimple we used the hammer to tap it in all the way.
An alternative method, and probably safer, is to use a jack to lift the opposite side of the axle. This will in turn lower the side one is working on.
We reinstalled everything and drove it around to let the springs settle, then we measured how much of a lift I got. 2.25 inches from the original sagging height.
Since I bought the springs used, I didn't get a BPV bracket nor an extended brake line. I figure I won't need the brake line unless I get longer shocks. However, I did notice a difference in braking performance which needed to be remedied. With some scrap 1/4" aluminum I made a bracket to raise the BPV 1.5 inches. After installing it I noticed an immediate improvement in braking.
So that was it, only took about 2 hours.
Here's a pic of the Downey springs and
the BPV bracket I made.