Building a rear van axle

[shackwrrr]

None of the rear lowering options for the van really fulfill my satisfaction. My thoughts are to build a complete axle from scratch to suit my needs.

Here are my goals:

3-4" of lowering
Limit loss of ground clearance at axle beam
Fit disc brakes
Limit loss of suspension travel
retain load carrying capacity and ride

Part of my plan includes mimicking the "drop" in the center to allow exhaust and provide under body clearance, I would like to mount the axle on top of the springs to keep the wheel mounting close to the center of the axle beam for strength. I was thinking of using either 3x3 or 4x4 box tubing as my main beam, not sure on wall thickness yet though. I would like to use the 11in vented rear brake setup on the axle. Shock mounts could possibly be lowered to keep some suspension travel or some kind of different style shock could be mounted. I was thinking of some rear shocks meant for lowered small trucks possibly.

Any inputs on this Idea? I'm horrible at paint and drawing freehand so no pictures.

[Vigo]

It sounds kinda like you are describing a solid front axle like people used to use in gassers and T-buckets etc. Have you looked into those? All we need to bolt our brakes on is basically a 4-bolt pattern drilled into a 3x3x3/8" plate.

Once i swap the suspensions between my vans i should have pics of what an AWD axle tube and raised spring perches looks like as far as underbody clearance for exhaust.

I personally wish there was an established solution for good rear shocks for a majorly lowered Caravan more than i wish for more underbody clearance.

[shackwrrr]

It does sound similar to those applications but since those have kingpin setups I would need to find a way to lock the toe. I was interested in running the AWD axle at first but I don't like drum brakes at all. Yes they are simple and work well but they are dirty rusty eyesores that require lots of maintenance when used in dirty environments. I big reason for me to retain some ground clearance is the 2 miles of dirt road that I have to drive everyday to reach a country 2 lane. Everything gets destroyed on the road and if it's low enough to drag, it will get ripped off...

[2.216VTurbo]

Wouldn't it work for you just to start with a stock axle and chop the ends off, weld up some plates that will accept discs and relocate the spindles kind of like AJ did? Is there not enough real estate for a big drop? De-arch them leafs, they'll still carry load if you put some bags under there

[shackwrrr]

Wouldn't it work for you just to start with a stock axle and chop the ends off, weld up some plates that will accept discs and relocate the spindles kind of like AJ did? Is there not enough real estate for a big drop? De-arch them leafs, they'll still carry load if you put some bags under there

The ends of the axle are cast I believe. My axle needs replaced anyways. The shock studs were snapped off, poorly drilled out and severely undersized bolts used in their place.

I did think of going with a de-arch, not sure how much it cost but the spring place near me doesn't have good local reviews.

[black86glhs]

3x3 1/4" wall box tubing would allow you the carrying capacity with more room for under car stuff. Maybe able to use 3/16" wall 3x3. I wouldn't want to use anything thinner for a beam axle. But I rather over build it than find out the hard way like a broken beam going down the road.

Come to think of it, 2x3 rectangular would allow more under floor room.

[Vigo]

One thing that would be cool but probably not easy would be to get rid of the whole crossbeam and just run a swing-arm type rear suspension on each side. I briefly owned a caravan-based Aeromaster cargo van and it had that kind of setup so that it could get a crazy low load floor. Im sure those type of things are available for trailers, i just wouldn't know how to find them.

EDIT:
So apparently it's difficult to find a pic of what i'm talking about. Annoying! The thing i'm talking about just bolts to the framerail and is totally contained to that side of the vehicle. It has a trailing arm coming off a spring-loaded pivot. Similar to a motorcycle swingarm except that the forward pivot would be bolted inboard of the tire instead of directly in front of it. I would have thought this was a common thing for trailers that need to get very low but i cant find a single picture of it.

[shackwrrr]

One thing that would be cool but probably not easy would be to get rid of the whole crossbeam and just run a swing-arm type rear suspension on each side. I briefly owned a caravan-based Aeromaster cargo van and it had that kind of setup so that it could get a crazy low load floor. Im sure those type of things are available for trailers, i just wouldn't know how to find them.

EDIT:
So apparently it's difficult to find a pic of what i'm talking about. Annoying! The thing i'm talking about just bolts to the framerail and is totally contained to that side of the vehicle. It has a trailing arm coming off a spring-loaded pivot. Similar to a motorcycle swingarm except that the forward pivot would be bolted inboard of the tire instead of directly in front of it. I would have thought this was a common thing for trailers that need to get very low but i cant find a single picture of it.

I understand what you are talking about. Ive seen the design used on a few different trailers for offroad or just air suspension trailers.



I'd love to do something similar but it would involve some custom stuff, also the fuel tank would interfere with the left side one.


Here is something very similar to what I want to build but I want the tubing to have a drop in the center for underbody clearance. If I cut the tubing and stack it then weld it back together I think this will give me enough drop.

http://www.easternmarine.com/78-squa...-3500-lb-49859

This also shows me that 2x2x.250 box tubing is of sufficient strength to handle the back of my van.

[Vigo]

Here's a bad pic of the AWD axle on stock fwd springs with stock turbo exhaust (i have a cutout on the downpipe that i dont think i've ever closed on this van).

It kind of does what i think you are saying as far as raising up in the middle for clearance, and it looks like there is plenty of room for exhaust. It would be difficult to get around the drum brake thing, though.

[moparman76_69]

I'm using an AWD axle (obviously) and have rear discs.

[Vigo]

Is it already bolted up? I knew later vans had awd and discs but didnt know if anyone had bolted one up yet. Maybe i should refresh myself on your build thread.


EDIT:

The '01 AWD hub/brake assemblies bolt onto the 93 axle with ease.

correct. You can use the '01 AWD disc hardware on the 93 AWD axle beam.

[shackwrrr]

Is it already bolted up? I knew later vans had awd and discs but didnt know if anyone had bolted one up yet. Maybe i should refresh myself on your build thread.


EDIT:

That would probably fulfill my requirements but I'm unsure if I could find an AWD van in the yards near me. let alone a newer one.

[moparman76_69]

Yep it's bolted in the van. Factory '89 FWD springs and hangers, '93 AWD axle, and '01 hubs and brake hardware. The only difference is the '93 hub has 5 bolts and the '01 uses 4. I just bolted in the '01 hub and left out the 5th bolt. Don't hold me to it but some of the later vans used the same bolt pattern on the FWD rear hubs as the AWD ones. There's a chance you could run the '93 AWD rear beam and later FWD hubs. This is just from looking at parts in junkyards so there is no guarantee.

'01 FWD rear hub




You can't use the '01 axle beam because the spring pads are an inch farther apart due to increased track width on the newer vans.

[shackwrrr]

Yep it's bolted in the van. Factory '89 FWD springs and hangers, '93 AWD axle, and '01 hubs and brake hardware. The only difference is the '93 hub has 5 bolts and the '01 uses 4. I just bolted in the '01 hub and left out the 5th bolt. Don't hold me to it but some of the later vans used the same bolt pattern on the FWD rear hubs as the AWD ones. There's a chance you could run the '93 AWD rear beam and later FWD hubs. This is just from looking at parts in junkyards so there is no guarantee.

'01 FWD rear hub




You can't use the '01 axle beam because the spring pads are an inch farther apart due to increased track width on the newer vans.

So the backing plates are from a FWD too or would work? Also bolt pattern is 5x4.5 I assume as well? This opens possibilities even farther. Thanks for the input, If only I could find an AWD axle...

[moparman76_69]

I'm thinking that on the later vans they standardized the axle and just had fwd hubs and awd hubs so the brake backing plates and even the axle itself is the same. But its only conjecture at this point. All the hardware I'm using is awd stuff.

[RoadWarrior222]

I personally wish there was an established solution for good rear shocks for a majorly lowered Caravan more than i wish for more underbody clearance.

I wish there was good shocks for a Caravan period, hated everything since the originals gave out. .... and I swear with only one of them holding pressure they STILL did better than their replacements, which also all seem to die about a month after warranty is up.


Wheelchair conversion vans may do something funky, only you might need to flip it.

I'm trying to think, somewhere I've seen a tube axle like ours, but it was offset with a stamped piece, so it had a stub one end to the hub.

[moparman76_69]

I have KYB gas-a-just for the rear on mine.

[RoadWarrior222]

I'll have to source some of those online if I'm keeping it, think I tried to find any in an hour or so range and drew blank a few years back.