3rd Gen 2011 Navigator Air Suspension issue - slow leak overnight

[914rrr]

Hi Everybody. Our 2011 Lincoln Navigator's rear air bags are slowly leaking down overnight. They aren't leaking down completely but enough to be visably noticeable. It almost seems like the passenger side gets a bit lower than the drivers side. As soon as we've backed out of the driveway, the ride height returns to normal. The air compressor pump was already repaced last year. The pump seems to be operating normally. I'd appeciate any troubleshooting / past experiences / tips for leak checking, VOM electrical tests, etc.

While web seaching, I found this article that does a fairly good job of explaining the system along with wiring diagrams, etc.:

Diagnosing and Repairing Ford Air Suspensions | MOTOR

No clue where to start when diagnosing an old-school air suspension? Here’s a common-sense approach to diagnosing old-school air suspension systems.

www.motor.com

 

[914rrr]

Looks like we have a leaky air spring. see pic. Ordering a pair of replacement air springs today. Hopefully I'll receive them before the old ones completely fail. I was looking for a DIY video for replacing the air springs (not swapping for coil springs) but only found Gen 2 so far. Anybody have a link to Gen 3 videos?

 

[914rrr]

Here's the video of the 2nd Gen front air spring replacement. It's not exactly what I was looking for, but at least it gives me an idea how it comes apart.

Air Suspension Bag Replacement Fix - Lincoln Navigator / Ford Expedition

you can buy parts here: https://amzn.to/3V7TDeP(search your vehicle)if you don't have an Amazon account, click here for a free month: https://amzn.to/2TSFS4a...

www.youtube.com

 

[914rrr]

Here's a video that shows how to remove the rear shock / air spring assembly on a Gen 3, but no details in regards to replacing the air spring.

SOLVED - Remove Leaking Air Suspension on 07-14 Lincoln Navigator - Part 1

SOLVED - Remove Leaking Air Suspension on 07-14 Lincoln Navigator | Coil Spring Lincoln Navigator | Hydraulic Suspension Lincoln Navigator | Convert your fac...

www.youtube.com

 

[914rrr]

Well, good news is, I was able to remove one of the rear shocks / air spring assembly and disassemble it.
Bad news is, the Unity Automotive brand replacement air springs I received from Parts Geek were wrong / defective as in didn't have to outer metal sleeve on the air spring, air spring was too long, all the o-rings were the wrong size and/or diameter, the solenoid was very loose in the air spring housing, etc., etc. Also, the air bag material felt thin / flimsy.

 

[914rrr]

Better Gen 2 air spring installation video.

How to Replace a Rear Air Spring on the 2003-2006 Ford Expedition & Lincoln Navigator

This video shows automotive service professionals How to Replace a Rear Air Suspension Spring on the 2003-2006 Ford Expedition & Lincoln Navigator with Arnot...

www.youtube.com

Ford Dealer parts diagram for 2008 Navigator Air Spring assemblies. Naturally, almost everything on the page is discontinued.

Shocks & Components for 2008 Lincoln Navigator | OEM Parts Online

ford.oempartsonline.com

 

[914rrr]

I have an urgent question:
Q: What kind of o-ring seals the shock / strut rod to the top cap assembly and where does it go (above or below the washer under the cap)?
I don't see an o-ring groove in the rod, only a raised "bump" on the rod near the top and a chamfered area inside the top cap opening.
When I disasembled the air sping, there was a piece of torn o-ring in the area of the washer under the top cap and what looks like an o-ring stuck / welded to the washer.
We only have 1 car (this Navigator) at present, so I re-assembled the air spring " to get me by" but now it's leakng air like crazy and I think the leak point is the rod to top cap area.
I can't find any illustrations showing the o-ring or it's location in relation to the rod, washer and top cap assembly. Any leads / ideas / videos would be greatly appreciated.

The 1st pic shows the washer with the o-ring stuck to it as I re-installed it.
The 2nd pic shows the washer with the existing o-ring removed (first one down) and the next 2 lower o-rings are ones I might use. Note the impression on the washer from where the o-ring used to be and the bit of loose 0-ring I found when I fisrt dissasembled it.
The 3rd pic shows the top cap with the washer and o-ring removed. Note the chamfered area around the opening. I think this chamfer holds the o-ring in place.

 

[914rrr]

Q: how can the air spring solenoid valve be opened to allow air into the air spring while it's out of the car?
I'd really like to test the assembly for air leaks before I re-install it in the car.

Update: I was able to inflate it off the car by removing the solenoid and inserting a rubber bung with a tapered nozzle in the solenoid hole attached to a 18v Ryobi inflator.

 

[914rrr]

I discovered it was also leaking from the 2 lower o-rings. When I re-installed the air spring the o-rings somehow stretched and were bunched up / rolled out of the grooves and were partially sticking out the bottom of the housing.

Update: I was able to fix the stretched out 0-rings by cutting them, removing 2 mm and re-glueing them back together with crazy glue.

 

[914rrr]

Happy to report I put everything back together enough to have it hold air, at least well enough to drive it. Still leaking down some overnight.

Most likely going with a rear coil spring conversion due to the apparent unavailability of air spring parts and a source for decent replacement air springs, unless someone here can convince me otherwise.

Suggestions for coil conversion sources would be appreciated.

 

[Duffer Waldorf]

When I disasembled the air sping, there was a piece of torn o-ring in the area of the washer under the top cap and what looks like an o-ring stuck / welded to the washer.

I found the same thing earlier today. The remaining OEM assembly has been slow-leaking for a while, but it has gotten a lot worse in the last couple days.

It's a little late for your situation, but here are the Arnott instructions for reassembly. Pages 8-9 show o-ring positions.

https://arnottinfo.com/manuals/A-2647.pdf

 

[Ixlr8nAk]

Did you convert? Rock autow had a nice set of front shocks with the air springs installed, and a set of ok rears with the bag on them as well. Great pricing compared to brick and mortar. Like half price or better. My rear set for gen 2, was all I could find for shocks. Found separate air springs, but no bare shocks for the air suspended.

 

[Deeser]

I'm also late to the party. My OE air struts on my '08 started sagging overnight about about 6 months ago with ~75k miles on the clock. I bought 2 Arnott air struts from RockAuto, installed them in an afternoon, and they have been fantastic. Nothing bad to say about them whatsoever.

 

[914rrr]

Went with the Arnott kit. Fairly easy install. Ride is pretty good, not much different than stock.
Performed really well towing a 24' Gulf Stream Camper, didn't sag hardly at all, which I was concerned about. I think towing also helped the springs settle in some more.

 

[GaryB]

Perfect timing on this. I'm about to start mine next weekend. Bought the Arnott Air Springs from Rock Auto along with new motorcraft shocks. I'm hoping I can transfer what is need off the old units for miscellaneous hardware.

 

[914rrr]

Hope your replacement air springs work out better than mine did. I bought another cheaper brand air springs and they were totally wrong. That's why I had to re-install the old stock air springs until I received the Arnott coil spring units.

 

[GaryB]

I'm having issues with my Arnott coil springs. Hopefully you are doing better. 1st one came in damaged(?). Now second one is leaking. I called Arnott, and they mentioned the top mount can warp causing issues. I have one from Ebay on the way because that seems to be the only place you can get them. Obsolete from Ford. Wish me luck. Also, if anyone knows exactly what goes where that would be a huge help.

 

[GaryB]

OK, I just wanted to post and close the loop. After the 3rd attempt, I got mine to work right. The Left side worked the first time. The Right side kept tearing the tiny o-rings on the shock rod. What I couldn't see in the detail drawing was the o-ring needs to seat well inside the washer's inner chamfer, so that it doesnt' tear. I had torn up all the replacement o-rings, so I was able to find one from a HF miscellaneous kit I purchased a while that did the job.

 

[914rrr]

Glad you were able to figure the placement for the top shock rod o ring. I couldn't find a good illustration of that anywhere.