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RoverTym Suspension Install For a Discovery Series 1

by Tom Pearson

The following outlines the highlights from my install of the RoverTym Suspension on my totally stock 1997 Discovery SE. Many thanks goes out to AedoFab for the use of the garage, tools, & knowledge and to my other friends who did much of the work.

The following was installed:

RT Kit

Other Stuff

References


To perform the install, we made reference to the Haynes Manual for a Discovery a bit, but mainly just relied on eyeballing what was currently there and utilizing Kyle Van Tassel's description of a spring and shock install (also on this site). Since the basic parts of spring and shock install have been so well documented already, I won't go into that much. However, I'll be sure to include all the "lessons learned" during the install of this kit.

Starting Data and RT Parts Kit Information

Now, on with the install!
Luckily for me, I had some really knowledgeable friends and a great shop to do the install at.  Due to this, the install only took about 7 hours including a lunch break. Some basic tips:

RT Kit

Step 1: Rear Springs and Shocks (The bolt-off/on portion) Like I said, there are other good write ups on this, so I won't rewrite it here.  Follow those and you should be fine.  Take note on the order of the steps when the rear links and radius arms are involved.  We didn't have to use a spring compressor once since we removed the shocks, links, and sway bars before messing with the springs:
  1. Remove the stock spring mounts.  Here you can see that two people, and air gun, and a sweet attachment makes this go real easy.  This is the part that most folks bitch about on Discos  (front was equally easy using this method).
  2. Remove the stock shock mounts.
  3. Remove the rear trailing link.
  4. Either jack up or have somebody apply pressure to the other side of the truck to flex the axle. That way, you can just pull the spring out with a little muscle.
  5. Put on top shock mount, cones and new springs, using the axle flex method to get the spring back on.
  6. Attach rear trailing link..
Spring mount removal:

New rear trailing link being put on:

A shot of the other end of the trailing link with all the bushings installed.  Be sure to put the bushings on the side of the mount facing the rear.  Otherwise, you're not gonna do any good!

Step 2:  Rear Shock Mounts - The not so "bolt on/off" stuff:  In order to fit the lower shock mounts, you can mount them on the top or bottom of the existing shock mount according to RT.  To do this, you will have to grind off one of the cups that used to hold the stock shock bushings as well as drill a hole for the second bolt on the shock mount.
Grinding off the cup

Drilling the second hole

Step 3:  Finishing off the rear:  Once the rear links, springs, and shock mounts are on, the final thing to do is mount the Rachos and then revel in your success.  Here's some shots of the completed rear setup.  You supposedly can mount the shocks either way, but I choose to do it this way because it's easier to reach the adjustment knob.
Step 4:  Do the front!   Yeah, just one step right?  Unfortunately, in all the excitement and hub-bub and didn't take many shots of the front going in.  Fortunately, this is covered elsewhere.  Tips from me are to mount the Rancho adjustable knobs facing the front of the truck so you can reach in under the bumper to adjust them.  Of course, it doesn't matter if you get the in-cab adjustment kit.  Be sure to remove the drag link before messing with the radius arms or you will just be cursing yourself for not doing it.  Also, since I don't have any bumpers and a stock drive shaft, the front sway bar can no longer be used!  It rubs the drive shaft.  I looking into solutions for this problem & I will post some pics when it's alleviated

The Finished Product

I have to say that I really like the RoverTym components. Everything is built really stout and is up to taking a beating. The ride after the install is better than it was stock, and the 3" lift, in my opion, wears really well on a Discovery. Also, John was really helpful in answering all of my questions, even with regard to rims, tires, etc. It's always nice to get advice from somebody who's done it before, even better when it is the actual designer of the components himself.

 

(click for large images)

 

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