Suspension Spacers - Tech Talk with Mic from Ironman 4x4

If you have followed our Ironvan Toyota Hilux Bush Truck Build series, you would have heard that we briefly discuss suspension spacers in the suspension episode.
(View the episode here: • Vehicle Build: "Ironva... )
Typically, the spacer lift kits consist of a thick spacer that is shaped more or less like the upper strut top mounting. The spacer is mounted on top of the upper strut mount between the upper strut mount and the chassis. This effectively increases the length of the strut assembly. The thickness of the spacer is now added to the overall length of the standard strut due to the fact that it is now the spacer that sits against the chassis and not the strut top mount pushing the complete coil-over strut downwards. This results in a lift in ride height at the wheel of approximately twice the thickness of the strut top spacer.
It is important to note that under full compression, with the lower control arm hard up against the bump stop rubber, the coil spring should still have gaps between the coils. This will certainly be the case with the standard strut and a well-engineered, up-rated coil-over strut assembly. Under full compression with a spacer fitted, the spacer robs the coil spring of compressible travel distance. On a number of vehicles that we have dealt with, the coil spring compresses completely before the bump stop comes into play. This will result in a solid metal stop which is noisy, uncomfortable and with enough force will certainly damage the strut and or chassis bracket.
With the standard shock length being the effective droop limit, any increase in the length of the strut assembly by fitting a spacer will drop this limit further down. This may result in the upper ball joint experiencing a rotation beyond its angle limit resulting in ball joint failure and a collapse of the suspension on that corner. Another issue is that the side shaft will be forced to operate at a more acute angle beyond its design specification. With the wheels being able to drop further down than what they were designed to handle, the inner C.V. joint may be able to disengage and failure is highly likely.
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