Flatout GR40 coilovers install on badlands?

Victorsen

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Has anyone installed a Flatout coilover suspension on a badlands model without any modifications ie changes in the flatout’s springs that come with the GR40. I am doing an install soon and it has been hard to get details from the company itself.
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BroSpo

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Hi. How did this work out for you? I'm very interested in BS BL applications with the GR40.

The idea of gaining suspension travel with a higher quality shock body is very appealing to me!

Specific to the Badlands application, I'm curious if "we" are able to safely gain 2" over a "stock Badlands" model (is that one or two inches over the other trim levels?). I imagine you need the sub-frame spacer kit too. Thanks!
 
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Victorsen

Victorsen

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It did not work for me. Though it seems to have worked for others. I had a lot of issues after the install including cv axle failure etc. I returned it and just kept by spacer hrg . Yes you definitely need a subframe kit. If you are handy and are able to make the adjustments it may work for you. However if you off-road especially in the north east they way they are exposed with the threads etc it won’t work. One mudding event or brushing against a rock will damage these. In my opinion they are not for heavy off-roading just providing a lift.
 

BroSpo

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It did not work for me. Though it seems to have worked for others. I had a lot of issues after the install including cv axle failure etc. I returned it and just kept by spacer hrg . Yes you definitely need a subframe kit. If you are handy and are able to make the adjustments it may work for you. However if you off-road especially in the north east they way they are exposed with the threads etc it won’t work. One mudding event or brushing against a rock will damage these. In my opinion they are not for heavy off-roading just providing a lift.
Thank you, I appreciate that. I'm sorry you went through all that, but I can still see a way that some of us might use the G40 with success.

That reminds me -- what I really want is a rig like ours with an OEM Fox 2.5" suspension. Fairly light weight, clearance, and suspension travel. These days suspension travel and having a better Ford "HOSS" suspension...maybe a Bronco Sport Raptor?! I know that will never happen...

...and that got me looking recently at considering a Gladiator Mojave (especially with all the price drops!). I never gave it a second look, but now really like it. I'm only mentioning this for inspiration for how I'd like to see Ford develop the Bronco Sport and maybe even similar aftermarket options...
 
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Victorsen

Victorsen

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Yup I am also looking at my options I do love the bronco sport the car has been great and have had a lot of fun with it. I am now debating whether I can upgrade to a full sized one .
 


Bluebaru

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Thank you, I appreciate that. I'm sorry you went through all that, but I can still see a way that some of us might use the G40 with success.
probably
That reminds me -- what I really want is a rig like ours with an OEM Fox 2.5" suspension. Fairly light weight, clearance, and suspension travel. These days suspension travel and having a better Ford "HOSS" suspension...maybe a Bronco Sport Raptor?! I know that will never happen...

...and that got me looking recently at considering a Gladiator Mojave (especially with all the price drops!). I never gave it a second look, but now really like it. I'm only mentioning this for inspiration for how I'd like to see Ford develop the Bronco Sport and maybe even similar aftermarket options...
I was the first person to order Flatout GR+ coil-overs but for the purposes of this discussion, there is no difference. I highly suggest you search my user name and Flatout and you will find a lot of info. There has been a production change since I got mine, that involves the sway bar mount, on the front strut, now being welded rather than adjustable and I can see the pros and cons of that. I believe most/all of Victors problems came from a bad installation, as I've had numerous conversations with him. What I suggest, if you aren't installing them yourself, is to get someone you fully trust to install them right the first time! Measure your ride height at all four fenders and all 4 jack points, prior to the installation. Give your installer those numbers and tell them you want X amount of lift. I recommend a minimum of 1.5" in front and 1" in the rear. If going over 2" in front, you should probably buy a front subframe drop. If going up 1.5" or more you should use a rear subframe drop. I believe the GR40 now comes with (?) brake line relocation brackets, for the rear and you will want to use them for anything more than 1.5". My BS is now lifted 2" front and rear, which I did in a series of increments but I recommend you do it all at once. A more conservative 1.75" F&R may not be a bad idea.

A suspension lift does many things but if you don't already have a good, 29.5"-30" diameter A/T tire, 245/65/17 or 235/70/17, you should get some, assuming you are intending to go off-road.

I am in the process of replacing a bearing in one of my camber plates, possibly not a problem for those with the OEM style top mounts (and being replaced under Flatouts parts warranty) and one of my front CV axels, due to a leaky CV boot, after 8 months of hard use. Almost certainly caused by one of the many branches or small trees I drive over almost every time I go off-road. As examples of the kind of thing I do, check out any YouTube videos of Fladpole Knob/Union Springs , Bald Mountain/Big Levels or Wolf Den Run State Park. We post on YouTube under VABros Off-Road. Admittedly, not the best videos, but it's what we got. https://www.youtube.com/@VABrosOff-Road/videos
 

Flatout Suspension

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I believe most/all of Victors problems came from a bad installation, as I've had numerous conversations with him.
I'm in absolute agreement here. It was not the product, but rather the installation. While the installer has assisted in an install with us personally, they are primarily a Subaru shop. I think between our install and Victors, a lot of the little details were forgotten (we weren't present) which lead to a lot of the issues. The installer has since bowed out of wanting to do anything but Subaru.
 

BroSpo

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I was the first person to order Flatout GR+ coil-overs but for the purposes of this discussion, there is no difference. I highly suggest you search my user name and Flatout and you will find a lot of info. There has been a production change since I got mine, that involves the sway bar mount, on the front strut, now being welded rather than adjustable and I can see the pros and cons of that. I believe most/all of Victors problems came from a bad installation, as I've had numerous conversations with him. What I suggest, if you aren't installing them yourself, is to get someone you fully trust to install them right the first time! Measure your ride height at all four fenders and all 4 jack points, prior to the installation. Give your installer those numbers and tell them you want X amount of lift. I recommend a minimum of 1.5" in front and 1" in the rear. If going over 2" in front, you should probably buy a front subframe drop. If going up 1.5" or more you should use a rear subframe drop. I believe the GR40 now comes with (?) brake line relocation brackets, for the rear and you will want to use them for anything more than 1.5". My BS is now lifted 2" front and rear, which I did in a series of increments but I recommend you do it all at once. A more conservative 1.75" F&R may not be a bad idea.

A suspension lift does many things but if you don't already have a good, 29.5"-30" diameter A/T tire, 245/65/17 or 235/70/17, you should get some, assuming you are intending to go off-road.

I am in the process of replacing a bearing in one of my camber plates, possibly not a problem for those with the OEM style top mounts (and being replaced under Flatouts parts warranty) and one of my front CV axels, due to a leaky CV boot, after 8 months of hard use. Almost certainly caused by one of the many branches or small trees I drive over almost every time I go off-road. As examples of the kind of thing I do, check out any YouTube videos of Fladpole Knob/Union Springs , Bald Mountain/Big Levels or Wolf Den Run State Park. We post on YouTube under VABros Off-Road. Admittedly, not the best videos, but it's what we got. https://www.youtube.com/@VABrosOff-Road/videos
Thank you for sharing all that. Great videos too! How's your friend in the Subaru doing with his off-road adventures? Similar suspension setup?

I plan to do the job "myself" but really with the help of a great mechanic friend too. Good advice, all-around.

I can see a leaky CV boot happening, but that can happen to most any rig. Not too big a job, right?
 

BroSpo

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I'm in absolute agreement here. It was not the product, but rather the installation. While the installer has assisted in an install with us personally, they are primarily a Subaru shop. I think between our install and Victors, a lot of the little details were forgotten (we weren't present) which lead to a lot of the issues. The installer has since bowed out of wanting to do anything but Subaru.
I've had coil-over suspension upgrades for many vehicles and can say I haven't had too many issues with a pretty wide variety of aftermarket units. I think it can work wonders over an OE setup. Even my street cars with very little suspension travel in stock form were fine. About the only other thing I'd add is that some of this depends on your tolerance to the inherent squeaks and rattles that come with the territory. On that note, is there a big difference with noises between your GR Lite and GR40 units?

https://flatoutsuspension.net/products/broncosport-grlite?_pos=6&_sid=6e10e0e70&_ss=r

Anyhow, that got me thinking I may start with the GR Lite. I will almost certainly have another "hard core" off-road rig, and I really use mine like a little rally car for the most part. The draw here is still gaining the precious couple inches of suspension travel and having meaningfully better overall suspension than stock. I also think that might be good to keep "OEM-like" camber plates/front top plates to minimize issues on this daily driver.

Do I have that right? Your GR Lite product with "OEM hybrid" camber plates is intended to be more straight-forward and suitable for a daily driver? I guess I'm having a hard time quantifying the suspension differences beyond attributes like spring rate and resistance to fade that would come with the GR40's remote reservoirs (and may still go this route). If I missed a summary, please point me there (I did a few searches on this). I know this can get subjective but it reminds me of how I see ride quality differences between mono and twin-tube shock arrangements in the past (e.g., Bilstein vs. Koni and others).

Suspension upgrades are my favorite part of tuning a car/truck and look forward to it here on my BS Badlands too! Thank you.
 

Flatout Suspension

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I've had coil-over suspension upgrades for many vehicles and can say I haven't had too many issues with a pretty wide variety of aftermarket units. I think it can work wonders over an OE setup. Even my street cars with very little suspension travel in stock form were fine. About the only other thing I'd add is that some of this depends on your tolerance to the inherent squeaks and rattles that come with the territory. On that note, is there a big difference with noises between your GR Lite and GR40 units?
There's no difference in noise between any model. If you get a camber plate, you might hear a little chatter, but a GR Lite with an OEM Hybrid acts just the same as the GR40 with the hybrid. We have the GR Plus on our Bronco (camber plate) and it's perfectly quiet. I've had several people comment that they've never experienced coilovers like this and thought they all rode rough.

https://flatoutsuspension.net/products/broncosport-grlite?_pos=6&_sid=6e10e0e70&_ss=r

Anyhow, that got me thinking I may start with the GR Lite. I will almost certainly have another "hard core" off-road rig, and I really use mine like a little rally car for the most part. The draw here is still gaining the precious couple inches of suspension travel and having meaningfully better overall suspension than stock. I also think that might be good to keep "OEM-like" camber plates/front top plates to minimize issues on this daily driver.
Why not come in at the middle? Our GR Plus is basically a GR40 just without the reservoirs. We even (as of writing) have one in stock:

https://flatoutsuspension.net/products/bronco-grl-stock

We're even tossing in a set of our subframe spacers for free, and then sugar-coating it with a 10% discount at checkout. We only have one, and that deal is only for this one.

Do I have that right? Your GR Lite product with "OEM hybrid" camber plates is intended to be more straight-forward and suitable for a daily driver? I guess I'm having a hard time quantifying the suspension differences beyond attributes like spring rate and resistance to fade that would come with the GR40's remote reservoirs (and may still go this route). If I missed a summary, please point me there (I did a few searches on this). I know this can get subjective but it reminds me of how I see ride quality differences between mono and twin-tube shock arrangements in the past (e.g., Bilstein vs. Koni and others).
We market the GR Lite as a daily driver, occasional offroader that maybe just drives offroad mildly. Here's a breakdown on the variations if you haven't seen it...

https://flatoutsuspension.net/blogs/news/which-gr

Suspension upgrades are my favorite part of tuning a car/truck and look forward to it here on my BS Badlands too! Thank you.
Same, it's amazing what a proper suspension can do.

Grab that set of GR Plus we have in stock right now, you can thank me later!
 


BroSpo

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There's no difference in noise between any model. If you get a camber plate, you might hear a little chatter, but a GR Lite with an OEM Hybrid acts just the same as the GR40 with the hybrid. We have the GR Plus on our Bronco (camber plate) and it's perfectly quiet. I've had several people comment that they've never experienced coilovers like this and thought they all rode rough.



Why not come in at the middle? Our GR Plus is basically a GR40 just without the reservoirs. We even (as of writing) have one in stock:

https://flatoutsuspension.net/products/bronco-grl-stock

We're even tossing in a set of our subframe spacers for free, and then sugar-coating it with a 10% discount at checkout. We only have one, and that deal is only for this one.



We market the GR Lite as a daily driver, occasional offroader that maybe just drives offroad mildly. Here's a breakdown on the variations if you haven't seen it...

https://flatoutsuspension.net/blogs/news/which-gr



Same, it's amazing what a proper suspension can do.

Grab that set of GR Plus we have in stock right now, you can thank me later!
Thank you, I will reach out now...
 

Bluebaru

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Thank you for sharing all that. Great videos too! How's your friend in the Subaru doing with his off-road adventures? Similar suspension setup?

I plan to do the job "myself" but really with the help of a great mechanic friend too. Good advice, all-around.

I can see a leaky CV boot happening, but that can happen to most any rig. Not too big a job, right?
My Subaru friend, has the same 11" of ground clearance but he is still on stock struts but with strut top spacers and other suspension parts. He followed us, for everything except for the last downhill decent, to the exit, after we made a wrong turn and had to back out. He did everything we did but wasn't real happy about some of it. He also got stuck in one mud hole and had to winch himself out. He does have a nice setup.
 

BroSpo

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My Subaru friend, has the same 11" of ground clearance but he is still on stock struts but with strut top spacers and other suspension parts. He followed us, for everything except for the last downhill decent, to the exit, after we made a wrong turn and had to back out. He did everything we did but wasn't real happy about some of it. He also got stuck in one mud hole and had to winch himself out. He does have a nice setup.
Very nice. I'm impressed with that all around. I have a neighbor with an Outback and spacers for a bit of lift (same stock struts though). Really, only the CVT holds it back. Approach/departure angles could be better, but seems the CVT is the weak link.

I'm still torn here. Now that I know the GR Plus is an inverted front setup, that's probably the minimum -- but the GR40 calls me. Decisions!
 

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I have the GR40 kit on my BL BS.
 

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I was the first person to order Flatout GR+ coil-overs but for the purposes of this discussion, there is no difference. I highly suggest you search my user name and Flatout and you will find a lot of info. There has been a production change since I got mine, that involves the sway bar mount, on the front strut, now being welded rather than adjustable and I can see the pros and cons of that. I believe most/all of Victors problems came from a bad installation, as I've had numerous conversations with him. What I suggest, if you aren't installing them yourself, is to get someone you fully trust to install them right the first time! Measure your ride height at all four fenders and all 4 jack points, prior to the installation. Give your installer those numbers and tell them you want X amount of lift. I recommend a minimum of 1.5" in front and 1" in the rear. If going over 2" in front, you should probably buy a front subframe drop. If going up 1.5" or more you should use a rear subframe drop. I believe the GR40 now comes with (?) brake line relocation brackets, for the rear and you will want to use them for anything more than 1.5". My BS is now lifted 2" front and rear, which I did in a series of increments but I recommend you do it all at once. A more conservative 1.75" F&R may not be a bad idea.

A suspension lift does many things but if you don't already have a good, 29.5"-30" diameter A/T tire, 245/65/17 or 235/70/17, you should get some, assuming you are intending to go off-road.

I am in the process of replacing a bearing in one of my camber plates, possibly not a problem for those with the OEM style top mounts (and being replaced under Flatouts parts warranty) and one of my front CV axels, due to a leaky CV boot, after 8 months of hard use. Almost certainly caused by one of the many branches or small trees I drive over almost every time I go off-road. As examples of the kind of thing I do, check out any YouTube videos of Fladpole Knob/Union Springs , Bald Mountain/Big Levels or Wolf Den Run State Park. We post on YouTube under VABros Off-Road. Admittedly, not the best videos, but it's what we got. https://www.youtube.com/@VABrosOff-Road/videos
Awesome videos. This is what I am working on doing as well as far as trails are concerned.
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