s14unimog

Here recently I have been searching for a solution for the all too common rear leaf sag that plagues the XJ stance. My personal truck here is a 97 4-door sitting at ~4.5". The setup is made up from IRO radius arms, 4.5" IRO coils, RC 3" leaf pack and RC 1.5" shackles; with the rest of the stuff needed to sort this height. Naturally I had decided to then relocate the shackle angle and installed a set of HD engineering "no-lift" mounts. As a result, the rear actually sat a tad bit lower (maybe 1"), producing a negative rake and hence spurring on this search for what I thought were only options between another leaf pack and/or adding leafs. Now I suppose it should be noted that my suspension is geared more towards down travel rather than up. I have stock flares (and intend to keep them) and when loaded, the rear bump stops I've installed to prevent contact regularly would come into play all too often when loaded. This could be a couple buddies in the back seats to a 3000lb SeaRay. There is nothing more annoying than that crash from a sacked out suspension...

After what seemed liked endless forum searching and product browsing, I stumbled across the Active Suspension kit from Roadmaster while researching a simple under-the-leaf helper spring. To my dismay however, I then find out that they don't actually produce a kit for the XJ (any Jeep for that matter). So before giving up, I decide to give them a ring and open up a discussion about it. After a good many back and forth emails and phone calls, it became clear that when this product was developed back in the early 90's they had intended to outfit Jeeps but for one reason or another chose to move away from them. The product's intention doesn't really fall in line with typical Jeep use. This kit is technically intended for those hauling loads close to their vehicle's maximum hauling/loading capabilities. However, I believe the XJ is unique in Jeep world and so I pleaded with them to configure me a custom kit. I sent over numerous leaf measurements and pictures and before too long - BOOM! I had it! Now on with the pictures.

So here is the kit... As described, it comes completely assembled right out of the box.



This next shot is how my rear was sitting when loaded - tires off and vehicle weight supported under the axle. A couple quick notes here. Yes, I realize my rear up travel is a bit short. This is the challenge with keeping stock flares over 32's. Notice the rear shackle angle is at a desirable position but that leaf is far too flat. You can also see where I ended up cutting out a portion of my body side bump stops to gain a little more room. This ended up simply making the bottoming out more harsh.



Another shot of the setup at full droop - tires off and vehicle weight supported by the receiver. This isn't a tremendous amount either but this was a sacrifice I wanted to make in order to raise my axle side shock mounts. I'm sure before too long I will relocate the body side mounts for more travel and go longer, but all in time. This range actually articulates very well.



Now with the addition of the Active Kit installed at full droop and set to their 1mm (0.039") coil gap pre-load.



Now loaded with the Active kit at their specified 1mm preload (instructions that are typically included with an F250 install). This ended up being FAR too much preloading and raised the truck almost 2.5-3" inches from before. In the next pictures I had reduced that preloading down to 0.01" gap between the coils - netting about a 1" lift increase.



Before (bottom) and After (top)




After thoughts...

Basically I'm in love with my Jeep again. Not only can I adjust the rear height based on loads, I can haul my 3000lb boat with little more than a few inches of squat (which I could reduce if I wanted to adjust for a long haul). The truck unloaded drives better than it has ever. The rear finally feels as nice as the front - a more progressive compression. Since installing the kit I have done more than a few higher speed offroad "trials" and even a few jumps. I cannot say it enough, I simply cannot fault the setup now.

I hadn't had time here lately to go flex the truck out but I plan to here soon and will update with those pictures. More to come.

lashonda

I looked up some information about Road Master's stuff a couple of months ago. I couldn't find any recent XJ relevant information. Now I know why.


How much did the custom kit set you back?

Ianf406

Really cool man. Sounds like that system has quite a few perks. Awesome they worked with you to make it. Also curious how much it set you back.

s14unimog

Right at $400 shipped.

Click-Click-Pull

Thank you for sharing and I'm very interested as I've been looking for a similar solution and this looks like the way I'll go.
Any idea if they'd help me out with a pair or any other XJ'ers?

s14unimog

Right on. I actually thought there would have been a lot more interest than CF is coming up with. I suppose I should have titled it, "no more saggy leafs!!!"

I spoke with the owner a few days ago as he was checking up on how the kit was working for me. It sounded as though they would do it for others but it would likely be a case to case sort of deal. The guy you need to start with is Ryan - call 800-398-5036 or email him at sales@activesuspension.com

As another update. I got out and cycled my suspension on the loading ramp yesterday evening. The kit didn't inhibit suspension travel but does provide extra ground pressure on the unloaded side - sort of like an anti-rock, which is nice. Check out the pictures.

ehall

nice write-up

s14unimog

Hey thanks!

Ianf406

Still think its pretty cool. I think you could just buy new/taller leaf springs in that price range though which is why more people aren't excited about it. Changing for loads is pretty sweet.

CobraMarty

My thoughts also. Could have dumped the worn out leafs and bought new Rubicon Express or similar springs.

They are very interesting. An easy to add, overload capacity spring. Don't even have to remove the old spring. Super easy, fast install.

SilverHaze

Does it ride better?

s14unimog

You could, sure, but the advantages are still limited and the life expectancy of a coil spring in extension is WAY longer than a leaf. These will/can be retained and used on the next set if I see a reason to swap them. I also believe people are skeptical of doing something different. A leaf pack alone is an incredibly economical way of positioning an axle while providing suspension. That doesn't mean it's the best. Short of fabricating coil buckets/coilover hoops and adding control arms, it's a great addition to a leaf based system.

Again, then I have a fairly fixed rate. If you are driving your jeep for the road too, it's really nice to change the rear rate for what you're carrying - or not carrying. With my cut fenders and folded rear quarters, it's merely seconds with a pair of adjustable wrenches. It definitely doesn't hurt that they are easy to add but the advantages are still WAY better than a helper leaf that has no progressive intervention.


It's great and one of my favorite additions to the XJ. I am not one to jump on a bandwagon and own an idea either, if you could see other projects of mine, past and current, it would be apparent.

Teephphah

Wow! I just learned about these like maybe a week ago. s14unimog did a post about cutting his rear fenders and he had some roadmasters on his rig that looked like they might be just the thing to fix my sagging a$$. Looking into it, I thought I had convinced myself that I'd be just as well off either upgrading to the RE 3.5 leaves to match my springs in front, or adding an S10 leaf from the JY.

Noooow, I see that you've already GOT the leaves I had my eye on, and extended shackles are kicking their butts too. Dag-nabbit! Is that just the way it goes? Extended shackles just flatten the heck out of your leaves? If so, that kind of sucks. A lot. Could have sworn the forums were not saying too much about that. Guess that's what I get for being a newb.

Still not sure the Roadmasters are going to work for me though. I'm going kind of low COG and cutting heavilly to allow for stuffing. It doesn't look like those things are going to get along real well with bumpstops, or is it just me? I mean, considering what they do, it probably won't be an issue, since they'll probably stop any squish before it gets that far. . . I think . . . right?

Anyway, I don't haul anything except for a few bikes, so I don't think I need anything that heavy duty in the long run, but, boy, the ability to fine-tune the tension on those just seems really , really cool.

s14unimog

Not that I have seen. Again, this is not a, "everyone go out and buy these" type thread. I think the design and principles behind it's operation provide me what I am after and it's a good product. As a product developer and Mechanical Engineer myself, I got behind it. Now at this point in this XJ's life, as a streetable, relatively low COG type build, it works great. it actually doesn't interfere with the bump stops at all. Now if I had the springs dialed up for hauling a boat and then went wheeling, that might be another story. You can see in the updated pictures above that I can still reach my fully bumped setting. This is another shot of the rear bumped out.

Jordo218

So I jus ordered rubicon express 3.5 coils with full 3.5 leafs along with the control arm drop I have a .50 coil spacer I will install if needed with bilstein 5100 shocks. I have a set of core upper and lower adjustable control arms currently run 31s and have a set of 33s ill trim to fit it has a cheap spacer lift at the moment. How do u think the set up will work and has anyone did the same or close looking for input on maybe some things to add on to my set up or jus general knowledge kinda new to the game. Have a untouched 2001 xj no rust 160000 grandpa miles im working with.