How should you upgrade the suspension on your overweight Ford Transit 250 camper van conversion? Read on to find out!

Overweight Ford Transit Campervan Conversion

We’ve added quite a bit of weight to our 2015 extended cab Ford Transit 250. And while we are still within the GWR of the vehicle, the van clearly needed some suspension modifications – at least if we wanted to drive it anywhere.

This was especially the case given that our travel plans included doing some rough – and off-roading. This means not only driving around Mexico – rife with poor road conditions and an excessive number of speed bumps. But it also means driving off road to access off-the-grid campsites.

Symptoms of our Overweight 2015 Ford Transit 250 Cargo

Yep. She’s heavy. Before our suspension improvements, the van sat low. With so much weight in it (especially the rear), the rear bumper sat measurably lower than a comparable Ford Transit 250. This can mean the back end of the vehicle scrapping driveways, when pulling out of gas stations, etc.

Also, there was a lot of body roll. This was exacerbated by the fact that the cargo van version of our 2015 Ford Transit 250 came without a sway bar. (As I understand it, the passenger van Ford Transit do come equipped with a rear sway bar.)

Upgrading the Rear Suspension on a Heavy 2015 Ford Transit 250 Cargo Van

Our first fix was installing airbags in the rear of the van. This was automatically a major improvement. The rear of the van no longer sagged. Our headlights were pointed where they needed to. (Without the airbags installed, the van had a negative rake, with the front of the van pointing skywards.) Whatsmore, the van less “floaty” or squirrelly at speed, with the airbags sufficiently inflated.

Given the set up of our van, we’re currently running ~85 PSI in the airbags – with the tires set the factory-suggested PSI of 44/71, for front/rear respectively.

Rear Shock Upgrade on our Ford Transit 250: Bilstein B6s

While the airbags definitely resolved the ride height issue, the rear suspension still needed addressing. With 110,000 miles now on our van, our rear shocks were not only worn out because of their age – but simply inadequate given the increased weight on the van.

After some research, I went with Bilstein B6 shocks for the rear of the van. Bilstein’s B6 line of shocks are designed to be an upgrade over the factory shocks, (and over Bilstein’s B4 shocks – which are meant to be an OEM replacement). That is, the B6 shocks are designed to be a sport, or heavy-duty upgrade.

I opted for the B6’s over the popular Fox Racing shocks set up for a couple of reasons: cost and time. Given our time table, we didn’t have the time for a set of the Fox shocks to be tuned and shipped our way. Also, a set of B6’s was roughly half the price of the Fox Racing shocks.

And while the Bilstein B6 shocks certainly reduced bounced over the (blown) factory shocks, they didn’t eliminate excess bounce completely (or at least not to the degree I’d like). The speed bumps in Mexico are omnipresent and omnipotent. Where I to do it again, I’d opt for the Fox Racing shocks.

One modification we did not do was the installation of a rear sway bar. And the van could certainly use it on city streets. But, given that rear sway bars aren’t necessarily the best solution for off-roading (which we plan to do a little bit of), we did not go with a rear sway bar.

Front Suspension Upgrades for a Heavy 2015 Ford Transit 250 Van Conversion

With our rear airbags installed (but without yet installing upgraded rear shocks), the van still had significant dive and body roll. To address the body roll issue (and without spending $400+ on rear sway bar that may not have been ideal of off-roading anyway), I tried out the Coil Sumo Springs.

I was skeptical that the product would improve ride performance. Inserting a giant bushing in between the factory spring coils seemed like a gimmick. But, given the price point and that it was really the only option that I could find, I gave it a shot.

Installation was relatively easy (although the kit could do with including more zip ties).

I was surprised by the difference that the inserts actually made. Dive and roll were noticeably reduced.

Was the product a silver bullet? Absolutely not. But, it certainly made a bigger difference than not having it there at all. Given the price, the ease of install, and the lack of alternative solutions, I am quite pleased with this product.

Aftermarket Front Struts for a Ford Transit 250

Bounce was still an issue. So, the blown factory shocks (with 110,000 miles on them) were replaced. In front, we installed Bilstein’s B4 struts.

B4s are meant to be an OEM replacement. Using the B4’s (over the B6’s), was meant to create more ride comfort.

However, even with new shocks installed, there is still noticeable bounce when driving over the rough roads of Mexico. Were I to do it again, I’d be eager to see what the performance of the B6 struts would be like on the front of the van.

Recommended Upgrades for a Heavy 2015 Ford Transit 250 Cargo Van Conversion

Of all the products we tried, the Coil SumoSprings and the Airlift airbags were the best. The rear Bilstein B6 shocks and the front Bilstein B4 sturts may not have enough power to limit the excess suspension travel on our van. Something heavier duty is needed.