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Redneck shock repair

We were driving across I-40 in Arizona on January 4th at about 9:30pm about 25 miles from Holbrook where we were planning to stop for the night.  I happened to see a spark in the mirror.  I slowed down and watched closely and saw another one but not constant.  My mind was racing as the sign for Petrified Forest 2 Miles passed by.  The shoulder wasn't great so I decided to get to the exit.  I pulled off safely and found that the rear shock on the drivers side was dragging.  The top bolt had broken.  About 15 minutes later we were on our way after duct taping the shock to the sway bar. :o 
We drove to Holbrook and I was very surprised that there was really no difference in the ride.  I took the shock off the next morning and we continued to Surprise.  We arrived back home last night after about 2000 miles with no shock.
The same shock bolt had broken sometime in the past based on the patches above the mount.  I'm guessing that over-extension broke the bolt but would welcome any other ideas. 
Dave and Kelli
1997 U295 40' Build #5188 CSGI
1995 U240 36' Build #4621 SBID-SOLD
2006 Jeep Wrangler Rubicon

Re: Redneck shock repair

Reply #1 –
Good job,only way I could improve on that is to use a couple of zip ties.
96 U270 BUILD 4810
85 380SL
Drummonds TN.

Re: Redneck shock repair

Reply #2 –
If you can't fix it with duct tape, bailing wire, or zip ties it probably can't be fixed b^.^d  - Ric
Previously:'66 VW Bus"Turtle 1";'65 VW Riviera Camper "Turtle 2";
';'91 VW Syncro Camper"Syn";'92 Barth 30' -"The Big Easy"
Currently: 2000 FT U270 40', #5634 -
"Le Bons Temps"; 2003 CRV
Ric & Leslie
"Laissez les bons temps rouler!"

Re: Redneck shock repair

Reply #3 –
Quote from: Turtle –
If you can't fix it with duct tape, bailing wire, or zip ties it probably can't be fixed b^.^d  - Ric

Ya forgot yur chewin gum! :))
Len and Deb Speiser
1999 U270 36'
2017 Jeep Wrangler Unlimited
You're either on the bus, or you're off the bus!--Ken Kesey
If you're lucky enough to live in a bus, you're lucky enough!

Re: Redneck shock repair

Reply #4 –
Be sure to verify RIDE HEIGHT.  If too high, the shock can pull apart on extension (not designed to support the weight of the axle!). If ride height is too low, the shock or mount can be crushed.
Brett Wolfe
EX: 1993 U240
Moderator, ForeForum 2001-
Moderator Diesel RV Club 2002-
Moderator, FMCA Forum 2009-2020
Chairman FMCA Technical Advisory Committee 2011-2020

Re: Redneck shock repair

Reply #5 –
The ride height is ok @32.5".  Our '95 has only 1 shock per corner, so I drove appx 2000 miles with NO shock on the RR.  We were on some very rough roads.  The coach didn't bounce, rock or jiggle any more than usual.
Dave and Kelli
1997 U295 40' Build #5188 CSGI
1995 U240 36' Build #4621 SBID-SOLD
2006 Jeep Wrangler Rubicon

Re: Redneck shock repair

Reply #6 –
Dave,

Sorry, didn't take note of your coach-- Torsilastic suspension.  And, yes 32.5" is perfect ride height for your coach. Many came with shocks too short-- pulled apart on extension or more likely wallow out/pulled loose the upper shock mount.  If the upper mount is loose, let me know, we can discuss options.

This from a document I shared with Foretravel and Koni a decade ago:

FSD Shocks for the 1991-1995 Foretravel U240

Front axle: Rockwell FD931 9,000 capacity 8,500 actual weight
Rear axle Rockwell RS15120 15,000 capacity 14,800 actual weight
New 19K rear springs: 06-81-6015 from B.F. Goodrich (19k vs OE 15k springs)

Factory ride height spec:  32-33".  Set to 32 1/2"

The above is the recommended set up we are doing to a lot of this series coach based on IPD's recommendation.


FRONT SHOCKS:

Shock length: Koni 88-1547 SP1 Acceptable.
Ideal shock length:
Shock pin to pin length: At ride height of 32": 18.05". At 33": 18.95"
Therefore:
18.05" minus 4" allowable suspension travel on compression with coach at minimum ride height spec= 14.05" Compressed length (or less)
18.95" plus 3 ½" allowable suspension travel on extension with coach at maximum ride height spec= 22.45" Extended length (or more)

Attachement: Standard attachments for 88-1547 SP1.

 Valving: Currently running 88-1547 SP1's backed off only ½" (not turns) FROM FULL FIRM. Good over big bumps at speed, a little stiff over expansion joints/small bumps and too much movement over large dips at low speed.

REAR:

Length: Koni 90-2256 SP1 marginally acceptable (only allows 2.75" of travel on extension with coach at maximum ride height).
Ideal shock length:
Shock pin to pin length: At ride height of 32": 18.65". At 33": 19.61"
18.65" minus 4" allowable suspension travel on compression with coach at minimum ride height spec= 14.65" Minimum length or less)
19.61" plus 3 ½" allowable suspension travel on extension with coach at maximum ride height spec= 23.11" Maximum length (or more)

Attachment:  Standard lower attachments for 90-2256 SP1 (mounts on 3/4" stud). 20 mm bolt upper attachment (unique on our coach to correct for wallowed upper mount bolt).

 Valving: Currently running 90-2256 SP1's 1.5 turns firm. Fine over big bumps at speed, a little harsh over expansion joints and small bumps and way too much movement over large dips at low speed.


 Brett Wolfe
Brett Wolfe
EX: 1993 U240
Moderator, ForeForum 2001-
Moderator Diesel RV Club 2002-
Moderator, FMCA Forum 2009-2020
Chairman FMCA Technical Advisory Committee 2011-2020

Re: Redneck shock repair

Reply #7 –
Brett, thanks for the reply.  The upper mounts were fine when I installed the Koni shocks 3 years ago.  The upper bolt broke off and part of it is still there.  It could be a challenge getting it out.  I haven't had a chance to get my hand up there yet, but I don't remember there being much room by the nut.  I may have to weld a smaller bolt to the remaining shaft so that I have something to hold while trying to remove the nut(taking the proper precautions for welding on the coach). 
There were a few times when we hit dips that were not perpendicular to the road rocking us side to side and very likely had the shocks at both ends of travel. 
 
Dave and Kelli
1997 U295 40' Build #5188 CSGI
1995 U240 36' Build #4621 SBID-SOLD
2006 Jeep Wrangler Rubicon

Re: Redneck shock repair

Reply #8 –
Dave,

DO verify that your shocks have the proper "travel". Actually compressed length/extended length. If too short, this will occur again-- replacing with a proper length shock will be a huge improvement. 

BTW had the same issue with Bilsteins on the U240-- again not a shock issue, but specing the proper shock "priceless".

Brett
Brett Wolfe
EX: 1993 U240
Moderator, ForeForum 2001-
Moderator Diesel RV Club 2002-
Moderator, FMCA Forum 2009-2020
Chairman FMCA Technical Advisory Committee 2011-2020

Re: Redneck shock repair

Reply #9 –
Does the sway bar have a bent at the end or is that a normal radius ?
Just wondering if a jack had been under it, sure looks interesting.

Re: Redneck shock repair

Reply #10 –
Quote from: Dave M –
Does the sway bar have a bent at the end or is that a normal radius ?

At least the side in the picture has the end link lined up/vertical.
Brett Wolfe
EX: 1993 U240
Moderator, ForeForum 2001-
Moderator Diesel RV Club 2002-
Moderator, FMCA Forum 2009-2020
Chairman FMCA Technical Advisory Committee 2011-2020

Re: Redneck shock repair

Reply #11 –
The shocks are the Koni 90-2256SP1'S.  I measured the travel today: appx 14 1/2"-22 1/2".  I think the sway bar looks the same on both ends.
Dave and Kelli
1997 U295 40' Build #5188 CSGI
1995 U240 36' Build #4621 SBID-SOLD
2006 Jeep Wrangler Rubicon