Envoy rear shock equivalent
Gabriel Ultra G63842
Ext. Length - 23.33 in
Comp. Length - 14.8 in
Stroke - 8.53 in
Gabriel Hijackers 49213
Ext. Length - 24.17 in
Comp. Length - 14.56 in
Stroke - 9.61 in
Difference
Ext. Length - +0.84 in
Comp. Length - -0.24 in
Stroke - +1.08 in
Hats off to Energysuspensionparts.com! Ordered the bushings early Friday afternoon and got them the next day, Saturday, with normal FedEx ground. Turns out the 9.8140G (black, graphite impregnated to reduce squeaking) bushings fit perfect. They come 2 to a package to do one shock...order 2 for both sides.
To do the pressing, I used a 6" bench vise and various socket sizes (some deep to accommodate the longer lower insert). Spraying them down with silicone spray helps loosen them. The vise was also very useful in holding the bushings and inserts while working on them.
After pressing out the the OEM bushings, the rubber surrounding the metal inserts must be removed in order to reuse the inserts in the new shocks.
Inserts removed from OEM Bilsteins.jpg
I removed the rubber in a series of steps, starting with a hacksaw to cut the bulk away, taking care to not cut into the metal.
Insert after hacksaw.jpg
Then I used a utility knife to cut closer.
Insert after knife.jpg
Finally I used a propane torch for 2-3 minutes to char the remaining rubber...it comes off easily with a wire brush.
Insert after wire brushh.jpg
Here is what you have before pressing in the new bushings.
Exploded shock.jpg
You can press the new bushings into the Hijackers, again using silicone spray on the bushings and inside the shock eyes. Go slow so that they go in straight. I supported the shock upright by hand and adjusted it to coerce it in straight while turning the vise handle.
The urethane bushings can be easily cut, so prior to pressing in the inserts, I used a flat hand file to round the edges of them. After coating the insert and bushing hole with silicone, they pressed in with ease. The inserts for the lower mounts need to be centered, so use a deep enough socket to allow this.
Afterwards, the Hijackers have new bushings and the reused OEM inserts.
Assembled shock.jpg
They install back onto the truck with no trouble and with clearance all around (insert photos of installed shock).
Routing the air lines is up to you. I wanted to mount the valve near the trailer hookup but there's not enough room on the back side. For now, I have the tubing bundled up and tucked in behind the left reverse light. I secured it to the fuel fill hose on the left side and the rear A/C hoses on the right with zip ties, adding a loop to allow for range of motion. For the right side air hose, I also routed it to the left side along a wiring harness and used the existing plastic hold-downs.
Fill the shocks with air slowly so the upper barrels seat. I initially set mine to 35 psi. The truck has a definite nose down stance this way. The ride is firmer but not harsh. Very pleased, but dropping the presure to between 25-30 psi reduces the truck-like stance some (25 psi is the minimum). My guess is about 27-28 psi is good for normal driving and add more when you want to level it out when towing.
All in all, this was a pretty easy swap once I got the replacements figured out. I'll answer any questions if needed.
Good luck to all!