Installation Guide

Home / Suspension / Struts / 2.5 Performance Elite RIP Kit for Sprinter 2500 4WD/AWD by Agile Offroad Installation Guide

Fox 2.5 Performance Elite Series Front Strut for 2015+ Mercedes Sprinter

SKU: AOR8614-01, AOR8614-02, AOR8614-03

Installation Manual PDF Download Video Warranty Additional Information

Installation Manual

INTRODUCTION

Thank you for choosing FOX direct-replacement shocks for your vehicle. FOX products are designed, tested, and manufactured by the finest professionals in the industry.

FOX recommends that you become completely familiar with the handling characteristics of your modified vehicle before operating it under rigorous conditions, helping to avoid potential rollover situations and other loss of control events. FOX further recommends that you use appropriate protective equipment at all times when operating your vehicle.

To achieve the best performance and product longevity, periodic service and maintenance is required. Please refer to the Service and Upgrades section for more information.

IN THE BOX

  • Front Struts or Rear Shocks
  • Supplied Hardware (Rear Only)
  • Installation Guide

SUPPLIED PARTS (FOX PN | DESCRIPTION | QTY | NOTES)

FRONT STRUT ASSEMBLY

  • 883-16-000 | FRONT KIT, PERFORMANCE ELITE | N/A |
  • 983-16-000-L/R | FRONT STRUT, PERFORMANCE ELITE | 2 |
  • 883-16-001 | FRONT KIT, FACTORY RACE | N/A |
  • 983-16-001-L/R | FRONT STRUT, FACTORY RACE | 2 |

REAR SHOCK ASSEMBLY

  • 883-26-150 | 2500 REAR SHOCK KIT, PERFORMANCE ELITE | N/A |
  • 983-26-150-L/R | 2500 REAR SHOCK, PERFORMANCE ELITE | 2 |
  • 883-26-151 | 3500 REAR SHOCK KIT, PERFORMANCE ELITE | N/A |
  • 983-26-151-L/R | 3500 REAR SHOCK, PERFORMANCE ELITE | 2 |
  • 883-26-156 | 2500 REAR SHOCK KIT, FACTORY RACE | N/A |
  • 983-26-156-L/R | 2500 REAR SHOCK, FACTORY RACE | 2 |
  • 883-26-157 | 3500 REAR SHOCK KIT, FACTORY RACE | N/A |
  • 983-26-157-L/R | 3500 REAR SHOCK, FACTORY RACE | 2 |

FRONT MOUNTING HARDWARE

  • 026-000-012 | MOUNTING HARDWARE: TIE, CABLE, BLACK [8.00 TLG] | 4 | wires to strut assembly

REAR MOUNTING HARDWARE

  • 803-02-212 | KIT: MOUNTING HARDWARE, 19-ON MERCEDES SPRINTER 4WD/AWD REAR | N/A |
  • 019-01-289 | FASTENER, STANDARD (METRIC): WASHER [M14, 28 OD X 2.5 THK] CLASS 10.9, ZINC | 2 | Replaces OE hardware for rear upper shock mount
  • 241-02-242 | FASTENER, CUSTOM (METRIC): BOLT [M14 X 1.5 X 130MM LG] HEX HEAD, CLASS 10.9, ZINC | 2 | Replaces OE hardware for rear upper shock mount

SAFETY INSTRUCTIONS

  • FOX direct-replacement shocks are designed to fit and allow proper clearance with the stock suspension. If aftermarket suspension components are installed it is the customer’s responsibility to ensure that interference between the FOX shocks and other vehicle components does not occur at any point in the shock stroke.
  • FOX direct-replacement shocks should always be installed as a set for maximum performance.
  • Proper installation and service procedures are essential for the safe and reliable operation of the suspension components, requiring the experience and tools specially designed for this purpose. Installation and maintenance procedures for this product must be performed by a qualified service technician to avoid potentially unsafe vehicle handling characteristics, which may result in SERIOUS INJURY or DEATH.
  • Modifying your vehicle’s suspension will change the handling characteristics of your vehicle. Under certain conditions, your modified vehicle may be more susceptible to loss of control or rollover, which can result in SERIOUS INJURY or DEATH. Thoroughly familiarize yourself with the modified vehicle handling characteristics before any rigorous vehicle operation. Wear protective body gear and a helmet when appropriate. Installation of vehicle roll bars or cage is highly recommended.
  • FOX direct-replacement shocks are gas-charged and are highly pressurized. Placing shocks in a vise or clamp, applying heat, or attempting to open or service the shock without the proper tools and training can result in SERIOUS INJURY or DEATH. Do not attempt to modify, puncture or incinerate a FOX direct-replacement shock absorber.
  • Any attempt to misuse, misapply, modify, or tamper with any FOX product voids any warranty and may result in SERIOUS INJURY or DEATH.

INSTALLATION GUIDELINES

  • Always use a chassis lift for the installation of shocks, and make certain that the raised vehicle is securely attached to the lift to prevent the vehicle from slipping, falling, or moving during the installation process.
  • DO NOT install any FOX product without the necessary special tools, expertise and chassis lift or you will subject yourself to the risk of SERIOUS INJURY or DEATH. If you elect to not use a chassis lift (which may result in SERIOUS INJURY or DEATH), ensure that the vehicle is: (1) on level ground, (2) that all tires on the ground during installation are blocked to prevent vehicle movement, (3) that at least two tires are on the ground at all times, and (4) that adequately secured jack stands are used to support the vehicle. NEVER get under the vehicle until you have checked to ensure that the vehicle will be stable during installation.
  • FOX direct-replacement shocks are designed to fit your vehicle’s shock mounts without modification except the reservoir placement on specific models and applications.
  • If a preload adjustment is necessary for your application DO NOT adjust preload with the coil-over on the vehicle. Remove the coil-over from the vehicle and use a spring compressor to remove the spring retaining hardware and spring. Once the spring is removed, you can adjust the preload ring. DO NOT exceed more than 1” of additional preload. If more than 1” of preload is required, you will need to go up in spring rate or get a longer spring that fits the application.

FRONT SHOCK INSTALLATION

  1. Please read the INSTALLATION GUIDELINES for instructions on how to properly lift and secure the vehicle.
  2. Record the front vehicle ride height to ensure the proper lift is attained after kit is installed. READ INSTALLATION GUIDELINES ON HOW TO PROPERLY ADJUST PRELOAD.

NOTICE: Medium-strength thread-lock is recommended on all bolts.

NOTICE: Do not exceed manufacturer Gross Vehicle Weight Rating (GVWR) for your model.

NOTICE: Performance Elite struts do not fit 3500XD (dual rear wheel) models. Must purchase Factory Race Series struts.

NOTICE: If using OEM wheels and tires, a minimum of 16mm wheel spacer is required to clearance FOX strut assembly.

NOTICE: If using larger than stock tires, a minimum of 16mm wheel spacer PLUS the below is required to clearance FOX strut assembly.

  • 2500/3500 single rear wheel models: front wheels must have maximum 6.200 inch backspacing
  • 3500 dual rear wheel models: front wheels must have maximum 8.000 inch backspacing

Installation Steps

1 STOCK STRUT REMOVAL

Remove both front wheels from the vehicle.

2

Place a jackstand under the lower control arm.

3

Unclip the ABS and brake sensor wires from the rear of the stock strut (Fig. 1).

4

Unplug the speed sensor from the hub (Fig. 2A).

5

Place a cover over the CV boot to prevent damage (Fig. 2B).

6

Secure a ratchet strap on the hub end to prevent the CV from unseating (Fig. 3-4).

7

Remove the lower clevis bolt from the strut assembly.

NOTICE: Do not discard any OEM bolts, many are reused with the new FOX strut installation.

8

Insert the bar into the lower clevis hole to stabilize it during removal (Fig. 5).

9

Remove the upper clevis bolt from the strut assembly. NOTICE: Do not discard any OEM bolts, many are reused with the new FOX strut installation.

10

To expose tophat bolts:

  • Passenger side: Use a screwdriver to turn the fasteners and remove the footwell floormat, then unclip the tool tray to expose the tophat bolts (Fig. 6-8).
  • Driver side: Use a screwdriver to remove the fasteners from the section of the door step trim, then lift the footwell floormat to expose the tophat bolts (Fig. 9-10).

11

Remove the tophat bolts. Leave the alignment plate in the footwells.

NOTICE: Do not discard any OEM bolts, many are reused with the new FOX strut installation.

12

Carefully remove the stabilizing bar from the lower clevis hole and remove the strut from the wheel well. Do not damage the CV boot (Fig. 11).

13

Make a note of the orientation and order of the tophat components, as you will need to reinstall them in the same way in a later step.

Remove the nut and tophat components from the stock strut. Remove the lower washer from the strut boot (Fig. 12-13). Inspect and replace these components as necessary.

NOTICE: Do not discard any OEM hardware/ components. If in proper condition, they may be reused with the new FOX strut installation.

1 FOX STRUT INSTALLATION

Slowly remove the tophat nut and the spacer sleeve from the FOX strut (Fig. 14). Discard the spacer sleeve.

NOTICE: The spring ships at nearly free length to help avoid injury.

2

Install the OE tophat components onto the FOX strut in the same orientation and order they were removed from the stock strut. Make sure the dished sides of the washers face away from the tophat (Fig. 15).

3

Install the supplied tophat nut onto the FOX strut (Fig. 15), then torque it to OE specification.

4

Install the strut onto the hub with the bolts loosely installed into the clevis. Make sure the tophat is aligned with the plate inside each footwell and that the reservoir is pointing toward the rear of the vehicle (Fig. 16).

5

Torque the tophat bolts to OE specification. Passenger side: Re-install the tool tray and replace the floor mat. Driver side: Replace the floormat and the section of door step trim.

6

You will now need to set the alignment to full negative camber to avoid aggressive steering while driving to the alignment shop. Do this by “justifying” the hub angle to the end of the slot on the lower clevis bolt hole farthest from vehicle center (Fig. 17).

7

Torque both clevis bolts to 160 ft-lbs.

8

Remove the CV cover, ratchet strap, and jackstand from wheel well area.

9

Use the supplied zip ties to secure the speed sensor and ABS wires to the bracket on the rear of the FOX strut. Plug speed sensor back into wheel hub (Fig. 18).

NOTE: Ensure the wire runs between the strut body and the strut hose (Fig. 19).

NOTE: Ensure the zip tie is high enough along the wires that the wires will not hang below the bottom of the strut.

1 CHECK AND FINAL DETAILS

Reinstall the wheels and torque to OEM specifications.

2

Set the vehicle back on the ground and drive back and forth several feet to allow the suspension to settle.

3

Measure the ride height and adjust if necessary. READ INSTALLATION GUIDELINES ON HOW TO PROPERLY ADJUST PRELOAD.

4

Check that the suspension has proper clearance by steering completely in both directions.

5

It is required to have your wheel alignment checked.

WARNING: Failure to maintain proper wheel alignment will result in premature tire wear and changes in vehicle handling.

REAR SHOCK INSTALLATION

NOTICE: Medium-strength thread-lock is recommended on all bolts.

WARNING: Please read the Installation Guidelines of this manual for instructions on how to properly lift and secure the vehicle.

1 STOCK SHOCK REMOVAL

Remove the rear wheels from the vehicle and support the rear axle.

2

Remove the upper and lower shock mount bolts. Set the lower hardware aside for reuse at a later step (Fig. 21).

3

Remove the rear stock shocks.

1 FOX SHOCK INSTALLATION

Position the FOX shock with the thicker upper reducer facing toward the frame rail, and with the reservoir facing toward the rear of the vehicle (Fig. 22).

2

Install the provided bolt and washer in the upper shock mount. Torque to OE specification (Fig. 23-24).

3

Reuse OE hardware in lower shock mount. Torque to OE specification.

1 CHECK AND FINAL DETAILS

Reinstall the wheels and torque to OEM specifications.

FOX FACTORY DSC EVO

DUAL SPEED COMPRESSION EVOLUTION (DSC EVO) ADJUSTER SETTINGS

ON-ROAD: SETTINGS FOR ALL SHOCKS (RIDE STYLE | LOW SPEED | HIGH SPEED)

  • Comfort | 2 | 2
  • Balanced | 4 | 4
  • Sport | 6 | 6

OFF-ROAD: SETTINGS FOR ALL SHOCKS (RIDE STYLE | LOW SPEED | HIGH SPEED)

  • Comfort | 2 | 2
  • Balanced | 4 | 4
  • Sport | 6 | 6

MAINTENANCE

PROPER INSPECTION AND MAINTENANCE IS ESSENTIAL TO MAINTAIN THE PERFORMANCE AND RELIABILITY OF YOUR SHOCK ABSORBERS.

To avoid corrosion, you should keep the shocks and springs clean, free of dirt and moisture. The wiper seal will clean deposits from the shaft, but the shock won’t necessarily fully compress every time. This means you could accumulate dirt at the bottom of the shaft and underneath the jounce bumper. Make sure you clean these areas completely to prevent shaft corrosion. Avoid using a high-pressure washer near the shaft seals or adjusters, as this could drive dirt inside the shock.

Make sure the ends of the spring and shock threads are clean and free of dirt before adjusting the preload ring. This will make the adjustment easier and reduce wear.

Ideally, the shocks should be clean around the adjusters. Use a small amount of contact cleaner or brake cleaner before making adjustments will keep these parts clean and operating smoothly for years

NOTICE: Keep the shock and spring clean and free of dirt or water to avoid corrosion. Keep the shock shaft clean and free of mud. Avoid using a high-pressure washer near the shaft seals and adjusters. Before adjusting preload or the crossover ring, clean the threads of the shock body for easier adjustment and mitigating wear.

FOX SERVICE AND UPGRADES

HAVE YOUR FOX SHOCKS SERVICED BY FOX TECHNICIANS. CALL OUR OFF-ROAD AND TRUCK SERVICE CENTER AT 619.768.1800 TO GO OVER THE SERVICE AND UPGRADE OPTIONS AVAILABLE FOR YOUR PRODUCT. ONCE YOU’VE SETUP YOUR SERVICE AND/ OR UPGRADES YOU WILL RECEIVE A RETURN AUTHORIZATION NUMBER AND SHIPPING INSTRUCTIONS.

COMPLETE SERVICES

100% street use: every 50,000 miles
50% street/ 50% off-road use: Every 10,000 miles

SERVICE MENUS AND PRICING

visit ridefox.com/service