How to Strengthen Springs in Mazda BT50/Ford Ranger 
So many businesses and families are choosing the new 4wd as their first choice of a vehicle because they are so versatile and can perform many tasks.
Unfortunately when the load you wish your vehicle to carry becomes significant that comfortable suspension is left lacking.
This is how we have strengthened the suspension in this vehicle so the driver could carry his load and with extra comfort.
NOTE: ALL IMPROVEMENTS ARE DESIGNED WITHIN THE VEHICLE’S LEGAL LIMITS.
View Video below in a step by step solution…
See how the rear end of the vehicle is sagging under this heavy load.
A closer look shows the spring has flattened and is inverting on one end. This is even more evident when we look from the rear of the vehicle and look ‘along’ the spring. See how the spring is bending backward.
You can see clearly now that the end of the spring on the swinging shackle end (the long end) is sagging under the current load.
And again from another angle, it is clear that the spring is inverted and is struggling to maintain any shape under the big load.
And here you can see that the 3 leaves of the primary pack are now fully engaged with the harsh second stage looking for some support.
Another view of the top 3 leaves (primary pack) fully engaged with the thicker second stage.
The challenge with the BT50 and Ford Ranger vehicles comes from their leaf springs being mounted “on top” of the differential which robs the spring of any camber at normal operating height.
The absence of height deprives the spring of the preferred gradual strengthening of the spring as it deflects. It is important to remember also that we cannot camber the spring too much because there are vehicle design limitations on how high we can go both front and rear.
Look here at our solution. Strength has been added to the spring by making a stronger wrap leaf that supports right out under the eye. Add another leaf and we now have a primary pack capable of handling those big loads without too much sag.
And when fitted to the vehicle there is no backward bend in the spring despite the big load.
From another angle, we can see the improvement better.
And from the same close up that showed the sag in the original springs, we now see a strong spring capable of carrying the big load but still flexible enough to offer ride and comfort because it is not yet engaged with the second stage of the spring.
1. And here we see a perfect shackle angle.
2. And the wrap leaf doing an excellent job of supporting the main leaf.
Understood and very happy customer.
Back on the ground and look at how level the vehicle is now. Compare it to before.
NOTE: ALL IMPROVEMENTS ARE DESIGNED WITHIN THE VEHICLE’S LEGAL LIMITS.