Clayton Overland Plus 2.5 or 3.5

[Flyin6]

I use the Clayton 3.5" overland springs along with Falcon 3.3's. I have also used the standard rate 3.5" and even the AEV 2.5" springs that came on my JT370.
The 2.5" AEV springs were fine until I started getting more aggressive, which is why I swapped to the 3.5" tall standard springs and the Falcon shocks. I got a bunch more travel, and it worked great. Then I added an RTT and overland stuff. That forced me to swap in the Overland springs, which really work great with the added weight. My JTR has had 37" KM3's since birth.
I wheeled that setup in Kentucky, New Mexico, and Colorado. It was in the San Juan Mountains where I noticed the rear axle/drive shaft angle getting pretty bad on big droop-outs. I installed some Terra Flex brackets, which fixed all that. I ran a double cardan front driveshaft from the first 3.5" spring until now.
I then swapped in the Terra Flex rear sway bar and put 5 degrees of caster in the front, and I have a killer setup that carries the weight, navigates the twisty Kentucky back roads, and can drive across the country in comfort.

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[fourfa]

@RedX Check your front shocks for signs of interference from the springs? I have a front left clunk at full stuff, it’s a Clayton 3.5” coil hitting the bottom edge of the shock body. More of an axle alignment issue than a spring issue tbh

 

[RedX]

@RedX Check your front shocks for signs of interference from the springs? I have a front left clunk at full stuff, it’s a Clayton 3.5” coil hitting the bottom edge of the shock body. More of an axle alignment issue than a spring issue tbh

I checked that and I see no signs of rubbing or interference. So I’m still at a loss. I appreciate your feedback. Hadn’t thought of that possibility.

 

[Donk]

I checked that and I see no signs of rubbing or interference. So I’m still at a loss. I appreciate your feedback. Hadn’t thought of that possibility.

It's probably the top coils of the rear springs contacting each other when hitting bumps. Had the same issue with my 2.5 lift yesterday. I simply removed the grey rubber spring coil isolators from the factory springs and installed them on the Clayton springs. Problem solved and noise is gone.

 

[fourfa]

@RedX Check your front shocks for signs of interference from the springs? I have a front left clunk at full stuff, it’s a Clayton 3.5” coil hitting the bottom edge of the shock body. More of an axle alignment issue than a spring issue tbh

Sorry to necro-quote myself, but this turned out to be mechanic error (me. I'm the mechanic.) The Falcon shocks have a bottom mount that's slightly offset from the center of the shock shaft, to give a little more clearance between the shock body and the coils. Unless some moron installs the offset the wrong way around, then you get LESS clearance and a clunk. Turned it around for MORE clearance and problem solved.

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