Grande Airbag Retaining after a Lift

[TexGX Lurker Find all posts View Profile Close TexGX]

During a trip to Colorado, my driverside airbag popped off during a driver side turn up a switch back with a small lip. I ended up switching to OME coils and I will have to say I like it better. I will miss the leveling feature, but the confidence I gain is worth it. The shop I used had to make custom upper and lower coil mounts, but the ride hieght came out perfect. I ride is smoother then the bags with extra air.

TexGX

[Troy1 Member Find all posts View Profile Close Troy1]

Hi TexGX,

Thanks for that, thats interesting. I debated on doing that to mine, ditching the air bags and doing a 3inch lift. Although will be expensive and not sure how I will go getting them legally certified for the vehicle.
Troy

[kevdebbi Senior Member Find all posts View Profile Close kevdebbi]

Hi everyone and thanks for all the valuable info in this thread. I have just finished lifting my 03 petrol Grand and it was very straight forward thanks to everyone who shared their experiences.

For my lift I used the following:
Front Bilstein F4BE5-A712-M1 shocks with King Spring KTFR101H
Rear Bilstein F4-B46-1478-H1 shocks and 35 mm alloy spacers

Before the lift the front measured approximately 715mm and the rear 780mm. The front had sagged a bit as I had recently fitted a steel bull bar, winch and Traxide dual battery system.

After the lift the front measures 795mm and the rear 840mm, looks great now.
The front was straight forward other than the front struts being stuck firmly in place; lots of pulling got the LH one out. I had to use spring compressors on the RH to disassemble it in place and then use a slide hammer to get the top out. A real PITA!!

[kevdebbi Senior Member Find all posts View Profile Close kevdebbi]

I seriously thought about using the R pin method for retaining the rear airbags as it looks simple and effective, however in the end I decided to make 35mm alloy spacers. My reason for this is in order to get the extra height from the airbags without the spacer they need to run higher internal pressure. I was a little worried how this would affect their longevity and their full range of travel. By using the spacers the airbags are operating much closer to the factory setup and I still have my full range of up and down travel.





I made the spacers from alloy approximately 75mm wide and 35mm thick, they have a raised section on the bottom to help locate them on diff and are drilled and taped so they can be bolted in place. The top part of the spacer has a 21mm hole drilled for the pin on the bottom of the airbag to sit in. All painted black so it looks almost factory

[kevdebbi Senior Member Find all posts View Profile Close kevdebbi]

I adjusted the sensor fully up in its slot to give as much lift as possible.



I then worked out that I needed 6mm spacers under the sensor bracket to give the required lift.



All finished, almost looks factory

[Peterpilot Avid PP Poster! Find all posts View Profile Close Peterpilot]

Nice solution kev, did you machine the raised section at the bottom of the spacer yourself or was it already there?

[jeffmutuku Lurker Find all posts View Profile Close jeffmutuku]

Hi Kev,
I have gone through the entire thread and your solution is the best. I did not really like the look of the airbags with retaining clip when stretched to the limit.
I have done the lift on my Prado with Bilsteins and KTFR-101 springs and would like to secure the airbags.
Only one problem...I would not know where to start in making my own spacers. Was wondering if it is something you can do at a price for a very impressed customer.

[kevdebbi Senior Member Find all posts View Profile Close kevdebbi]

Thanks guys for the positive feedback, I made my spacers from some offcut alloy round stock. I am lucky enough to have an old lathe at work and was able to knock them up in some spare time between jobs. Any engineering shop that does lathe work would be able to quickly knock up a set. I will do a drawing with the dimensions if that helps. Out of interest I would be interested in what they would charge.

These spacers so far are untested as I only fitted them on the weekend and have only driven around 100km since, and no off road. So far though they seem fine and the car drives beautifully with the new suspension. The ride is not harsh and feels very stable with good control of body roll.

I just talked to the wife and I have “booked” in this Sunday to head up to Chichester State Forrest behind Dungog for a bit of a drive, Its ment to be nice and sunny. I am keen to see how it all handles off road.



Looks so sexy now

[kevdebbi Senior Member Find all posts View Profile Close kevdebbi]

Here is a rough picture of the spacers I made, sorry for the poor quality but I only had MS word to do it with. I made mine from alloy as it is light and easy to work with and won’t rust, however they could be made from many materials such as steel or stainless. The sizes are all very approximate and not critical. The most important it the hole for the airbag pin. The pin measures 20.5mm and around 20mm long. I used a 21mm drill bit and a hole depth of approximately 25mm, this gives a good firm fit but is still easily removable if need be.

I drilled and taped a 10mm thread on the bottom of the spacer so it could be bolted in place to stop any movement. I used a large body washer, about 25mm, a lock washer and some Loctite so it didn’t work loose. It’s a little tight but the bolt and washers can be inserted from the front of the diff with the aid of long nose plyers. Once done up nice and tight the airbag can be dropped in from the top. Fitment is as simple as that.

[Guest Close Guest]

Hi Kev,

That looks great. If OK with you, I will ask my machinist how much he charges for that spacer. I am thinking of cross drilling through one side for a set screw to positively lock the airbag pin in place. I would like to get this done on my Prado now that it was lifted (finally) over the weekend.

[Peterpilot Avid PP Poster! Find all posts View Profile Close Peterpilot]

Andrew,

If you do end up making more than one set, I'd be interested a set for mine
How did you go with those Dobinson C59-302 front springs?

[Guest Close Guest]

Peter, as with anything, it is cheaper to do more than just one.

The C59-302 are OK, maybe I had higher expectations because I drove around in Gunnell's FJ and that drives like a billy cart. So I expected something in between the factory and Gunnell's but I don't think my ride has firmed up at all. However, the new shocks are better at soaking up the bumps with ease.

I wouldn't mind trying an Oz spec Bilsteins and the super special TD adjustables for the fronts.

[craigm Addicted PP Member Find all posts View Profile Close craigm]

craigm Likes This!!!!!

Nice work Kev! I'm watching this thread closely and look forward to hearing how the articulation is as a result of your mod.

[Guest Close Guest]

The airbag spacers are $70/set if I estimated the anodising correctly. Haven't been to the anodisers yet but guesstimating based on past experience. All fasteners included in the price.

[1coolbanana Avid PP Poster! Find all posts View Profile Close 1coolbanana]

The airbag spacers are $70/set if I estimated the anodising correctly. Haven't been to the anodisers yet but guesstimating based on past experience. All fasteners included in the price.

Hi Andrew
That sounds great, when are going to be making a few sets?
Cheers
marc