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Discussion Starter · #1 ·
Has anyone installed the Belltech Flip kit (6302) on their Astro (97-02 models) please. If so, do you have the installation instructions. Mine has come with the 93-96 instructions (6300) and is different :(
 

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Common Sense + Critical Thinking
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Discussion Starter · #3 ·
Thank you for your response. I found those too and although not much differences - the saddle is different and just can't work out which way up and which way round it goes :)
 

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Those aren't my pictures, they just weren't showing up in the post so I fixed them. Yes, they would be a bit different as that is the composite rear spring, but the kit should be very similar.

Maybe you can post some pictures of what you have and where you are getting stuck.
 

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AstroSharpy said:
Here are pictures of the saddles I have.
After looking at the parts and the installation manual, it looks like the following:
Drivers Saddle
Passenger Saddle
These go below the factory perches, between the axle and the leaf spring. Uprights towards the outside of the axle, u-bolts go on the outside and don't pass through saddle, bolts go through the holes in the factory perches, then the spacers are installed, then through those two holes in the above saddles towards the inside of the axle, then the spacers are installed, then through the backup plates.

Backup Plate w/ dimple(from instruction sheet)
These go below the leaf springs.

Factory leaf spring clamshell.
No, you wouldn't keep using these, because the leaf springs will be under the axle.
 

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Discussion Starter · #9 ·
Thanks for your reply. Dont forget the installatino instructions that are posted everywhere are for the other kit - the saddles are very different!

Howver, I believe we at least have the saddle up the right way and in the right location but it just doesn't sit properly - perhaps we have used the wrong side, although to be honest the two do not look any different from each other.

What we also don't understand is that we have 6 bolts left and the two u-bolts. the 6 bolts that are left are the two silver bolts which are not show as being on the parts list (but then the parts listed on the installation instructions are for the other kit!) and the four remaining bolts are gold coloured ones but two different lengths! Also, with regard to the spacers that we have left over - there are two different lengths.

Now we are confused!
 

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Discussion Starter · #10 ·
AstroWill said:
bolts go through the holes in the factory perches, then the spacers are installed, then through those two holes in the above saddles towards the inside of the axle, then through the backup plates.
This is not possible with these saddles. The bolts go through the factory perches, then the new saddle, then the spacers then the base plate however using the shorter bolt means we cannot get the bolt through the base plate.

Hope this makes sense. Attached are pictures showing what we have!




 

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Yea, I mixed up the order of the spacer, fixed it in the post above. but from the looks of it, those replacement saddles don't seem to fit properly anyway. Looks like the upright portion that has the axle tube cutout should be longer.

Have you tried contacting the MFG?

AstroSharpy said:
...however using the shorter bolt means we cannot get the bolt through the base plate.
What about without the rubber isolators? Also, the locating holes for the center bolt in the leaf springs should line up, are the lined up on the leaf spring?

Regardless, that saddle has to be parallel to the axle, and it looks really lopsided.

That plate looks upside down from over here ;)

Sucks to have to go an alternate route, but if you can return that kit, you could buy your own plates, u-bolts and weld on perches to be installed on the underside of the axle.

Here is what I bought for my lift, but you could use them to mount the springs under the axle as well.
[URL=https://sites.google.com/site/astrosafariinfo/suspension/lifting-your-astro-safari-van/rear-leaf-spring-lift:hnn9k7uh said:
Rear Leaf Spring Lift[/URL]":hnn9k7uh]Plates are 2 Crown Automotive # 52006421 ($8) cheaper on 4wd.com or http://amzn.to/2o4gCHy https://www.quadratec.com/products/56008_06.htm
Ubolts are Crown Automotive # 999210 2.75" axle 1/2" Diameter 8" Long ($5 each) cheaper at 4wd.com or http://amzn.to/2owO4Kf https://www.quadratec.com/products/56009_00.htm
Dana 44 Spring Perches (Fits 2.75" Axle tubes and 2.5" Wide Springs)Barnes 4WD B4W25028BP http://amzn.to/2opHLHW ($30 set)
 

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Discussion Starter · #12 ·
Thanks once again for your response.

Returning isn't really an option unfortunately, as I am in the UK so have paid a lot in shipping, import duty and tax I would be seriously out of pocket - we will contact Belltech direct to see what they say.

If anyone has the 6302 kit fitted on the van - can you please share some pictures of the centre saddles.

We can't be the only one to fit this kit so are there any other forums to check out?
 

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AstroWill said:
Regardless, that saddle has to be parallel to the axle, and it looks really lopsided.

That plate looks upside down from over here ;)
I agree. There is definitely something strange going on.
The bolts should sit flat on the washers instead of being pulled on an angle.
The bottom plate is upside down. The angled end should face away from the spring.
The saddle does not look like it sits flat on the axle. Try swapping them side to side.
 

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Discussion Starter · #15 ·
Ok sorry for lack of update but only just managed to get back out to play on van.

Have swapped the saddle with the other one and pleased to say it sits much better. However we still can't get it to bolt together with the rubber cushions in place. There literally is no room for them, so what we plan on doing is making our own cushions out of industrial 3mm thick rubber.

Hopefully this will be sufficient - will let you know how it goes once we've got the other side together.

Then begins the front suspension but hopefully we won't have as many issues.

Been such a learning curve - a stressful one at that!!!

Thanks for your help so far :)
 

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Discussion Starter · #17 ·
We haven't finished it yet - but hope to do so shortly.

I will, of course provide before and after pictures once done :)
 

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Discussion Starter · #20 ·
Ok - have spent nearly all day outside today working on her and have managed finally to finish the lowering of the back end and attaching the new sway bar - wow she looks good - low but good I think. Now to turn our attention to the front but as a teaser here is a picture whilst I was turning her around so we can get to the front........

 
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