How-to: 2" Astro Lift Install from Overland Vans
 

Here's a detailed page on how I lifted my 98 RWD Astro. The kit is from Dan at www.OverlandVans.com.

Here's the Kit Contents:

1-2" multi-Lift Shackles
2" Body Pucks
New Body Mount Bolts
Modified Emergency Brake Bracket
2" Raised Bumper Mounts
Rancho 5000 Shocks
OverlandVan Sticker
Instruction Set

http://i9.photobucket.com/albums/a72...ftContents.jpg

Here's the Van at it's stock height. I have 235/75/15 tires mounted already. The rear tires rub pretty bad when the roads get rough or I have a full load aboard.

http://i9.photobucket.com/albums/a72...BeforeLift.jpg

Front Height Before:

http://i9.photobucket.com/albums/a72...rontBefore.jpg

Rear Begining Height:

http://i9.photobucket.com/albums/a72...RearBefore.jpg

Rear Lift was First on the Worklist
 

I decided to do the rear lift first. TS Danny was threatening to rain on us and I wasn't sure how much I'd get done today. I did a couple of quick measurements and made sure I had room to work in the Garage and still be able to get the Van out.

So Let's lift this thing... the instructions are really good. I used the Van jack instead of my floor jack, it worked great. I went for max height, ended up with the tires about 1" off the ground.

http://i9.photobucket.com/albums/a72...ro/GetItUp.jpg

I put jackstands under the rear hitch as suggested.

http://i9.photobucket.com/albums/a72...ontheHitch.jpg

Okay now it's time to pull the shackles off. Here's what is going in...

http://i9.photobucket.com/albums/a72...chShackles.jpg

I used a small screwdriver to push the mount bolt out:

http://i9.photobucket.com/albums/a72...o/BoltPush.jpg

This went quick, I used a bit of grease on the outer edges of the new shackle bushings as it was a tight fit.

Here's the rear completed with the new shocks too.

http://i9.photobucket.com/albums/a72...ngComplete.jpg

Time for a test drive and a photo op. Took 1.5 hrs from getting tools out to this phase, with a couple of coffee breaks.

http://i9.photobucket.com/albums/a72...o/RearDone.jpg

Rear Lifted Height

http://i9.photobucket.com/albums/a72...o/IMG_0994.jpg

Break Time.

Time to Tackle the Front Lift
 

So the front requires the bumper to come off. This requires getting the face off the van. Pics are good so here's the breakdown...

Turnsignals come out first

http://i9.photobucket.com/albums/a72...ntTearDown.jpg

Then the grill, there are hidden screws behind the turn signals.

http://i9.photobucket.com/albums/a72...rillScrews.jpg

http://i9.photobucket.com/albums/a72...tGrillGone.jpg

Now the bumper facia comes off

http://i9.photobucket.com/albums/a72...ettingUgly.jpg

And finally stripped and ready to lift

http://i9.photobucket.com/albums/a72...eadyToLift.jpg

Body Lift Install
 

The Front lift is a Body Lift between the subframe and the body. There are three 2' pucks that go on each side. New high quality 10.8 Bolts are provided. The emergency brake bracket needs to come off too.

The goal is to get the Puck in there....

http://i9.photobucket.com/albums/a72...hisinThere.jpg

Loosen all 6 bolts then lift up the driver's side:

http://i9.photobucket.com/albums/a72...tJackSetup.jpg

Get the puck in, and loosely hold it in place with one of the new bolts. This is just to make sure the body comes down properly. I didn't use the washer or rubber isolator on the bottom side for this stage. I also did not apply locktite yet.

Here's the middle puck which takes the larger bolt:

http://i9.photobucket.com/albums/a72...CenterPuck.jpg

Once all the pucks are in, I then pulled the bolts individually, applied locktite and installed the lower washer and rubber isolator. Then Torqued to the specs provided.

The next thing is to put on the raised bumper brackets:

http://i9.photobucket.com/albums/a72...BumperLift.jpg

And the lift is essentially done...

http://i9.photobucket.com/albums/a72...toAssemble.jpg

We do have a few details to take care of. The Fan is now digging into the fan shroud. Let's fix that...

http://i9.photobucket.com/albums/a72...mTheShroud.jpg

http://i9.photobucket.com/albums/a72...dInstalled.jpg

I didn't get pics of the emergency brake cable bracket, but it's easy enough to figure out.

Now lets put the face back on and see what we have....

Almost Done
 

We'll we need a test drive first....

http://i9.photobucket.com/albums/a72.../TestDrive.jpg

Assembly is really just putting the stuff back on in the reverse order. I did test fit the bumper and adjusted the impact bar/ bumper bracket a little bit. It's still a hair too high, but the temp was way to high to worry about it. I also skipped installing the front shocks, the regular shocks are fine.

http://i9.photobucket.com/albums/a72...MoreLikeIt.jpg

And here's the final pic from the side:

http://i9.photobucket.com/albums/a72...o/IMG_1018.jpg

Front final height is:

http://i9.photobucket.com/albums/a72...inalHeight.jpg

Rear final height is:

http://i9.photobucket.com/albums/a72...RearLifted.jpg

Not bad for a days work. I'll get the new shocks in when it cools off.

Thanks Dan!

http://i9.photobucket.com/albums/a72.../ThanksDan.jpg

all jacked up!
 

that's a nice kit ,good install ,good picture's .should be done on all of them .

That looks awesome. I'll copy it to the Astro DIY right away. Great write-up and THANKS for contributing this to the forum!

Completed Pics
 

Finished up today... Front shocks went on after learning how to break off the old ones. You snap the top bolt of the shock by using a 9/16 Long socket on a rachet wrench as the lever. Takes just a few left/right bends to snap off.

Here's the fancy red boots inside the coil:

http://i9.photobucket.com/albums/a72...anchoFront.jpg

And the front BFG ATs went on to finish it up.

http://i9.photobucket.com/albums/a72...ete31Aug09.jpg

Glad everyone is happy with the post. I think the van looks great this way and I'll bet they would have sold a few more if a factory lift had been an option.

Ethan

That looks great. Glad you could provide us with the details. That really is appreciated!

Great post, this is going to be my holiday project.