We developed this issue when installing a new set of 20% / 2'' short rear coil springs on the van. For 6 months things were fine, but several month ago, we hit a bad section in the road which caused the shocks to hyper extend and allow the rear springs to fall out. The OE shocks measure approx 18'' and the KYB shocks came in at 17.88 inches. In other words, the KYB shocks have too much up travel thus allowing the coil springs to dislodge form the upper and lower seats. I was beginning to fear that I'd not be able to locate a shock that will fit the van.
We got help from GAZ coil overs saying they can make a set up custom shocks for the van, but with the tariffs and other dues or fees I just wasn't willing to go through the hastile. I contacted the coil spring people asking what they suggested and I was about ready to send these springs back for a refund or at least the coil spring people were going to allow for this.
One thing I noticed is when GAZ sent their information about their shocks, they included a spec sheet detailing a custom set of shocks made for another Connect owner. But the measurement wasn't clear. I just knew a basic number to go by on trying to locate a shocks. As a test fit I tried a set of the Bilstein B8s which came in at 16.50 and these were too short.. the search continued. Until I located a sheet of all shocks as made by the manufacturers.. this sheet listed the type of shocks along with the limited up and down travel specs. I located a Monroe magnum shock which has a limited up travel of 16.88 but would this be enough or too much.
I found the Monroe 66608 shocks at fleet pride here in Maryland and at only 50.00 USD I took a chance that these would work for the van. Now I'm not a math expert, but the wife is, we sat down and figured out that we needed reduser sleeves.. going from the Monroe 3/4 OD down to 1/2 ID of the OE Connect bolts. Originally we figured the sizes and measurements wrong, so always measure twice, cut once.
Next we needed some sort of spacer to keep the shocks centered on the sleeves and between the Van's shock mounts. McMaster-Carr had us covered for that. ordering 8 thick washers to use as spacers and ( 1 ) 12'' cold rolled steel tube form amazon, I was able to cut 5 of the correct length reduser sleeves needed to adapt the shock loop/eyelet onto the 1/2'' Connect bolt.
My paper work looked good other than some of the numbers were wrong.. So before we test fitted everything, I used vaseline to coat the raw steel sleeve as this is the best known ways to protect the raw steel from rusting. here we test checked the shocks on the lower mounts with the thick washers as spacers, 1 per side. While the top needed two thick washers located on one side. This helped center the shock within the mounting brackets on the van.
I just know that when we installed the coil springs, the tech had to lift up the dead axle (approx 3/4 of an inch) in order for the shock bolts to be installed.. this was enough tension to retain the coil springs and not allow them to dislodge from their seats. mind you these are class 3-6 truck shocks and when we first installed them, the ride was a bit harsh.. but after a few weeks the shocks have been fairing very well. The best way to describe this set up, it's like coil over but without the single cartridge unit. The stiff springs in conjunction with the stiff shocks can make for a very stiff ride. But we like it.
Although the Monroe magnum 66608 shocks are all black, I resorted to painting the lower half yellow. This set up has been working flawlessly for the last 3 months. One would think that by adding a reduser sleeve, this could cause some rattles but we've not experienced any issues or noises.
