New Dayton leaf springs lost 75% of arch after install...see pics

[84FLH]

Hello all.

Last week a local garage installed a brand new pair of Dayton leaf springs. Dayton pn 43-1159, direct replacement for F57Z-5560-A and B. Springs were purchased online, not from the garage.

The springs are now flat from front spring bolt to rear axle. There's some, but not a lot, of arch from rear axle to shackle. Worse, the springs have a subtle but distinct reverse bow directly over each spring/shock mount. It appears the vehicle weight on each end of the springs, tried to bend the springs down over those spring perches, and partially succeeded. To me this indicates the heat treat or temper or both is off. I have some experience with heat treated steel from owning a one man machine shop for many years. This combination flattening of the front 75% of the springs, and the reverse bow over spring perch, indicates poor heat treating, assuming correct, heat-treatable steel was used.

Has anyone had similar experience with Dayton leaf springs?

Thank you

 

[C420sailor]

I’d call them. I’ve got leafs from Michigan Truck Spring on both of my Explorers. Got nearly 100k on the set on my 4.0, and they don’t look as flat as yours. That isn’t right, IMO.

Unless maybe you’ve got a trunk full of concrete mix?

 

[84FLH]

I’d call them. I’ve got leafs from Michigan Truck Spring on both of my Explorers. Got nearly 100k on the set on my 4.0, and they don’t look as flat as yours. That isn’t right, IMO.

Unless maybe you’ve got a trunk full of concrete mix?

Yes, sir. Doesn't look right to me, either.

I called Stengel Brothers and sent Jack Stengel half dozen pictures. Jack's been honest and good as the day is long. He did me right when the first set of Daytons I got had cracked and improperly formed spring clips. Shipped me a replacement pair straight off and a UPS return label for the damaged springs.

This time he contacted Dayton and they told him they sold about 50 sets of these springs (pn 43-1159) in the last year with "no complaints or problems with heat treating". Despite Dayton's claim, the pics show a heat treat or bad steel problem with the springs I got from Dayton. The strongest part of the springs is the spring pack. The apex of the spring pack is strongest of the entire spring. The spring pack is meant to resist the downward vehicle weight. not flatten out under vehicle weight. It should never go flat in brand new springs. That it did indicates, again, bad heat treat/temper or bad/wrong steel. Who knows what goes on in the Mexico factory?

Jack told me Dayton will send me another set of springs but they won't guarantee they'll sit higher than what I already have. He also said he usually sells another spring for 98-01 Explorers that he's had good luck with. But the arch on those springs is lower than mine. I'm thinking he's talking about the 1,250 pound rated springs. I don't want that lower arch, though. Imight take Dayton up on their replacement offer. My other choices are a junkyard spring set from a 98 Ex for $130 ("A" rated with 140,000 miles on vehicle) or buying NOS at $350 each!

I'm going to ask Dayton to reimburse me for the install cost. The springs are defective. I may try to install the replacements they send, myself. There won't be any rust related issues trying to remove bolts. But I've no garage and at 65 yo I don't like working on the ground outside. If Dayton reimburses me I'll have the garage do it again.

 

[C420sailor]

That said, the truck looks like it sits okay...is the rear sitting lower than the front?

If not, and it rides well, you may be good.

My ride height appears the same, my springs just aren’t as ‘wavy’

 

[84FLH]

The entire truck is about 1.5" lower than it should be.

That's because two years ago I adjusted torsion bars to lower front end 1.5" to compensate for rear end sag. If the Dayton springs were true "made to spec", then the rear end would now be 1.5" higher than the front end, at least.

When front end was lowered it removed most of the spring tension from the torsion bars, causing my Monroe Sensa Traks to do all the work up front. Shocks aren't meant to take the place of springs, so the ride up front is harsh. Front end has to be raised 1-2" back to orig height to restore ride quality.

The new leafs improved rear ride greatly, but I think their lack of proper heat treat means they'll only get worse over time...as in a few months.

What I really need is a new vehicle.....

 

[84FLH]

Anyone ever have similar problem with Dayton leafs? Thank you.

 

[bitrunner]

Did you ever get the replacements? And if so were they good?

 

[410Fortune]

Looks like the springs were too soft for the application 1250 psi is a little weak for a 4’door explorer imo I would want a spring more in the 1500 psi range