Front Body Lift

The easiest and most basic lift in the front is the 2inch(50.2mm) body puck/block lift for all models of Astro/Safari vans. You can also go up to a 3" body lift, but will require more work.

Also see Lifting your Astro/Safari van and Rear Leaf Spring Lift

Pucks/spacers:

The 2" body lift spacers/pucks can be done for about $50 if you buy everything new. You need 6 spacers/pucks and longer bolts to go with them.

• • The puck dimensions are as follows:

    • 2" tall and 3" in diameter, I paid about $3 each for mine, you need 6 of them.

      • https://www.summitracing.com/parts/pra-bb02

      • http://zoneoffroad.com/zone-offroad-products-body-lift-blocks-2in-/3296

      • http://amzn.to/2onpj0Z

      • $4 each with free shipping http://www.ebay.com/itm/Zone-Offroad-3296-Body-Lift-Kit-Blocks-2-Tall-x-3-Wide-Ships-For-FREE-/172609518304 ($24 for 6)

Optional Polyurethane Body Bushings

Replace body cushions/bushings/isolators at the same time black poly: http://amzn.to/2vEQjid or red poly: http://amzn.to/2wIuxal or DORMAN 924192/924193 or you can buy OEM. Prothane Black http://amzn.to/2CVX00V Prothane Red http://amzn.to/2CoJVMj Energy Suspension kit http://amzn.to/2E7jSJZ

Bolts, 6 total, 2" longer than the original for adding 2" pucks.(The original body to frame bolts are listed as 94mm, 95mm, 96mm, and 102mm in length depending on the year and position, 1inch=25.4mm, 2inches=50.8mm, 3inches =76.2mm)

• • Qty 4 M12x1.75x140mm (Original is Grade 10.9)

  • Qty 2 M14x2.00x140mm (Original is Grade 10.9)

McMaster-carr, bolt-depot, fastenal, zoro, ebay, uboltit, local supplier. I would find a local supplier first, but shop around, there can be big differences in prices. It's kinda expensive buying them individually, so see this thread for a kit that includes all 6 needed bolts: https://www.astrosafari.com/viewtopic.php?f=69&t=146126&p=1583024

Some bolts are also available from GM, some are longer: Surprisingly, these bolts from the dealer might end up being cheaper than buying from the most popular bolt shops once you figure in shipping. I have not tested any of the below listed bolts, may need a couple of washers??

GM GENUINE 11515458 Bolt Hex Flanged Head 12X1.75X140 10.9 6174M 24.7-Outside Diameter Cone Point.

GM 11517552 M14-2.00x140mm Hex Bolts Gm Gear Box Bolt 10.9

GM 11515119 BOLT, (M12X1.75X150mm, 10.9) HEX FLANGED HEAD, ,36 THREAD,26.6 OUTSIDE DIAMETER,GM4345M,HEADER POINT.(FRONT SUSPENSION CROSSMEMBER(03-10Savana/Express?)

GM 15717449 BOLT, (M14X2.00X152mm, 10.9) Auxiliary Spring BOLT,REAR SPRING FRONT HANGER aka 90-05 Astro/Safari upper rear shackle and upper leaf spring hanger bolts.

Installing lift blocks:

• • Do one side at a time, don't completely remove all of the subframe bolts at once.

  • Be careful, watch what you are doing.

  • Don't forget about the front bumper fascia bolts(on some models).

  • Make sure to torque your bolts properly

Front bumper:

• If you want to raise your bumper, you can make your own relocation brackets quite easily using some flat stock($5 at local hardware store). This is more for 95 and up. I have not relocated the bumper on my 1st gen with 2" pucks and really like the look. For 95 and up you can also buy some bumper relocation mounts from https://www.overlandvans.com/0104_exterior.html

Trim the lower fan shroud:

• • The body moves up while the engine stays in the same place, trim the lower fan shroud so the fan doesn't hit it. Another option is to go with electric fans, if that is in the plan now would be a good time :)

Emergency/Parking brake cable bracket/frame stop:

• Simply remove cable, drill a new hole higher up, remount(35nm-26ftlbs). Often there is an identical bracket on the passenger side, which is known as a frame stop.

For a 3 inch(76.2mm) body lift, the same things will be required, with the following differences:

$50 for bolts w/shipping from Fastenal, and $30 for pucks/spacers.

• 3inch wide x 3inch tall body lift spacers $5 w/free shipping http://www.ebay.com/itm/Zone-Offroad-3396-Body-Lift-Kit-Blocks-3-Tall-x-3-Wide-Ships-For-FREE-/182507578585 ($30 for 6)

  • Qty 4 M12x1.75x170mm or 160mm Grade 10.9 https://www.fastenal.com/products/details/0122039

    • OEM option?: GM 11516537 BOLT, HEX FLANGED HEAD,M12X1.75X170,36 THREAD,24.7 OUTSIDE DIAMETER,10.9,7114M,MACHINE,HEADER POINT(REAR SHOCK ABSORBER) Discontinued

  • Qty 2 M14x2.00x170mm or 160mm Grade 10.9 https://www.fastenal.com/products/details/0122053

  • Edelmann 71817 Power Steering Pressure Hose, straightened http://amzn.to/2nC1sx6

  • Extend/Modify transmission and oil cooler lines, ensure that they aren't under tension.

4 inch lift = 2inch or 3inch body spacers +:

• • AWD = Torsion bars, tightened or reindexed keys

  • RWD = 85-95 Get 1.25inches more out of http://amzn.to/2owElTQ @2000lb or http://amzn.to/2onidcD @2300lb(how much higher?)

Intermediate steering shaft extension(for 3" and taller lifts):

• • 90-95 AWD will require you to change out the intermediate steering shaft, get one from a RWD 96-2003 or have yours extended locally. GM Part # 26047898

Wimpazz on AstroSafari.com has done a detailed write-up, worth checking out!

http://www.astrosafari.com/viewtopic.php?f=40&t=121937 and http://www.astrosafari.com/viewtopic.php?f=40&t=109802