Follow Up

[LostInTransit]

As part of our continuing experiment of upgrading the suspension of a 2020 Transit Connect, for the last 2 years we've been testing the Cobra Suspension rear lowering springs on the van. When first installed, these springs were listed as being 40mm lowering springs which was actually the distance between the tire edge and the fender edge. But over these last 2 years, the springs have started to sagging, and the tires have been hitting the fender edge on a regular bases. They went from the 40mm down to 34mm. At one point we've attempt to have a tool made that would curve or bend the fender edge inward. But never got around to having this tool made.



Our most recent project include a custom set of rear springs that are 2'' shorter and 20% stiffer than factory, which were installed on the cargo version of the van. we had a spring company design a set of rear springs for the van based on the desired specs and they completed this task in less than 4 weeks. We got the springs 3 weeks ago and test fitted them just to make sure the specs were spot on. All doubts where pushed aside when the springs went right in.



With the springs now verified, we had the springs sent to our powder coaters where they laid down a thick bright red color.. got the springs back last week and installed them for the last time.



These new springs are very tight and stiff so much so that the front factory springs seem to bouncy more often now. which means these will also be upgraded to a stiffer shorter set from the same spring manufacture.

 

[LostInTransit]

it's been 20 days since my last update and the van has been handling and performing very well with the new truck shocks. The only issue we've run into not shock related is bad fuel form either exxon, shell or sunoco.. These stations along with others, in a pinch tend to buy fuel from a company called Carroll fuel and according to several family members, they had to replace their fuel injectors along without fuel related devices because of the bad carroll fuels. I don't have any proof of this other than the van was sputtering and running poorly. Switched to the BP fuels and the van is running smooth again.

 

[LostInTransit]

Ongoing fuel issue with the van. Again seems to be something with the fuel we're using and I've switched up several time. However I made a discovery last week when checking my handily work of a few prior of checking under the hood. I thought best to get rid of the BG products AFt and opt for the Valvolina AFT. What attracted my attention is that some point along the build the small air vent tubes running from the grille to the airbox had become dislodged. this could be one reason for the bad fuel economy because the engine wasn't getting enough air. This 3 part air tube thing was broken along the way buy one of the shops we've been using to repair or replace parts on the van. So instead of trying to fix these tubes, I simply removed them amn what a difference. So when driving at low RPM around town the van runs silent.. but punch it and the engine comes to life sound very similar to that of the Subaru Impreza. Oddly I've yet to installed a better exhaust system so all one is hearing is engine noise.

Another issue we've run into is that the 2 year old Bilstein B6 struts are failing or failed. I've hired a youtuber to install the new Monroe Struts and New Godspeed end links as the end links have a flush design to them which was done for clearance. Once we video the installation, he'll post this on his youtube channel for content.

 

[LostInTransit]

The youtuber, declined to install the struts and new top hats, So I have to locate another shop to do this installation for me.. However, while waiting for this install, we drove to PA then to western maryland.. somewhere along that route we hit a bump in the road which cause a knocking on the passenger front.. we limped home. I took it to a unknown shop where I wanted the tech to installed the struts, Instead he located the issue with the knocking/clunking sound.. turns out that the passenger side top hat/strut mount was completely destroyed.. metal shards were stuck in the rubber isolator. I ran home ordered to new Monroe mounts which would replace the damaged KYB mounts.. We drove the van for 1 week cause this was our only means of transportation. the parts arrived and we drove back to the shop. it took the guy 3 hours to get the broken strut and strut mount out of the van. but once out.. the damage was clear.. the top hat or metal plate that mounts to the strut tower was completely destroyed. I've never seen anything like this.. structural failure on the KYB mounts. sadly because it was so hot I wasn't going to lug the camera or my phone around. So pics of the damage mount were not taken. Roughly, I'd say the mounts lasted 10 mounts with a 1 year warranty.

THe new monroe strut and monroe mount was installed, but it took the tech another 3 hours to do it.. he was just having a difficult time at this and several times I had to enter his shop to show him how it was done.. The main thing here, was he was beat and couldn't do the full installation.. so the drivers side has the Bilstein B6 struts and the KYB mounts. While the passenger side has the Monroe struts and Monroe mount.

The wife always tells me to trust my gut feeling.. so something was telling me I needed a second opinion on how well or not so well this tech handy work was. We drove to Meineke where the tech there is nicknamed "the Doctor" I was mainly going there to have the Dr check the suspension.. But along the way.. we starting hearing a knock/rattle.. I'm like not again.. We've had this rattle, knock since last year Sept.. I told the Dr to take the van for a test drive.. but all he did was pull the van into the shop. that short drive from the lot to the shop bay was all he needed to figure out what was wrong.. 20 mins later he pulled the van out and handed me the keys.. "hey take it for a drive" he said.. in less than 2 mins and before I hit the main road.. the knock was gone.. silence.. Months of knockings, rattling gone.

Turns out one of the pervious shops did not tighten down the sway bar or the sway bar links.. I came back to the shop and screamed.."YEAH!" then asked him how much I owed him, he said nothing.. But I gave him $100.00 tip. he asked if I needed the drivers side struts and mount replaced, but we've had it for a while and told him he would be the one we get to have this done. he said when you bring the van back I do the install free.. Almost 6 different shop and all of them installed something wrong or never followed up on what they installed.. so As long as the Dr is in the house.. he's going to do the work on our van from now on.

Oh as for the newly installed Godspeed end links.. so far so good.. the links are not making contact with the inner firewall like those other links we've tired. I'll keep and eye on all of this stuff as we have a major 3 week trip coming up.. so many of the roads may not be so forgiving.. also, the OE links measure 13'' inches, Since Lowering the van, I've had the GodSpeed links adjusted to 11.50 inches and installed on the closest mounting hole on the sway bar.

 

[LostInTransit]

Seeing how this thread was closed: (https://www.eng-tips.com/threads/co...d-kuga-will-fit-the-2020-ford-connect.524535/) I'll have to post Hardrace reply here.. I've been sending them comments and images about the successful installation of their hardrace 28mm sway bar designed for the ford Kuga on our 2020 transit Connect. Months past and nothing,.. till a few days ago. They told me that simply cannot change the website description based on my findings and they would have to do product testing themselves, but their not willing to do this for a discontinued van. They went on to say that they can not jeopardize their customers lives based on my findings.. With that in mind.. we've been driving our 2020 transit conant with the hardrace 28mm sway bar on the van for 1 year without any issues. This is a mild upgrade for the transit connect owner who wants a bit more stability when cornering. However Not all news is good news.. if you've followed along you will see that we've went through 8 different end links in and order to find the correct links suitable for the suspension. We've recently installed a set of the 280mm-310mm GodSpeed links which have a different ball joint design offering more clearance where we need it. So even though Hardrace refuses to acknowledge that their sway bar fits the van.. with the right set of end links (which we're now testing the Godspeed links) this is a very formulable option for the sport connect owner. Hopefully I can continue to report good things about the GodSpeed links on our transit connect.