Rusty Suspension Springs

[John S]

Here's my public service announcement to anyone considering replacing their OEM suspension springs with something from the aftermarket: Modern suspension springs are cold-wound from high tensile strength (and notch-sensitive) chrome based alloy steels and corrosion protection on the finished spring is critical for proper performance and fatigue life. Cold-wound springs are "low temperature" stress relieved so there are high residual coiling stresses contributing to the applied cyclic operating stresses and the spring's fatigue life is dependent on the quality of the wire surface condition, especially on the inside diameter of the spring.

OEM springs have specific salt spray and coating requirements to prevent corrosion and any reputable aftermarket spring supplier also respects the importance of protecting the wire surface quality from corrosion. The attached images show an example of a popular Steeda lowering spring set I installed on my son's Mustang GT after 7000 miles of Detroit's mild winter weather. The car has the lowered stance many people prefer but this kind of rust damage is unacceptable as it will introduce stress concentration points and significantly reduce the spring's fatigue life. Steeda doesn't warrantee their products for rust, including suspension springs, so do your homework when making decisions that can affect the safety of your vehicle.

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[ice445]

Imo every spring in the rust belt looks like that after a few years, lol. Maybe it's better now but like 15 years ago oe stuff would rust in 5 seconds

 

[John S]

For reference, the OEM springs on my clapped out 2009 Dodge minivan are still rust-free. Once spring manufacturing changed from hot-winding and quenching to cold-winding and stress relieving, proper coatings became an important part of the manufacturing process.

 

[shogun32]

Im curious who steedas odm is. You'd think it would be impossible to get a substandard spring coating.

 

[WD Pro]

Going off at a tangent, but this is a huge problem in the UK and it seems to be getting worse (probably linked with the increase in traffic calming measures / speed humps).

Both rear springs broke on my parents BMW a few months out of the (3 year) warranty - BMW assisted as good will.

My wife broke a front spring on her mini at about 8 years old - that took out a two week old tyre and a drop link.

My Kia broke both the pigtails of the rear springs just out of the (7 year) warranty - Kia assisted with parts and labour cost.

My Kia (now 12 years old) has just broken a front spring - I can't complain at that age.

My Kia spring - I understand the rubber sleeve is to prevent the spring from causing a blowout if / when it fails (it did hold it in place, I had to tear it to remove the broken piece of spring from within the remaining coils) :

The lowest number of speedhump's I cross on any route leaving my house is 13, so I have a minimum of 26 speed humps per journey ...

From another thread, some of you may know that I walk four miles (two miles each way, there and back on the same pavement) for a family breakfast every Saturday morning and I collect the disposable vapes I see on the way - well I also see a lot of pigtails, FIVE on my walk last saturday ...

@John S - the pattern in the failed coating on your sons spring is interesting :

I wonder if the coating cracked in that manor due to spring compression, with the cracks letting the elements in to start the corrosion.

I wonder if a more flexible / compliant coating would have fared better ?

WD

 

[Skye]

My Tacoma was previously recalled to have its rear leaf springs replaced. While visually they appeared OK, Toyota recalled all Tacomas (and possibly other models) for the same issues being discussed here: corrosion and stress fractures leading to spring failures while under load.

 

[robvas]

Another reason to park your car in the winter if you live in the great white north

 

[NGOT8R]

From what I see in the pic, it looks like the coating is flaking off just as some of my Steeda parts have done and/or are doing. Looking at the metal on my components where the coating has chipped off, it’s smooth and not pitted or roughed up as is typically done via sandblasting to prep the metal before coating it, so that the powder coating will have a good surface to adhere to.

https://nwmetalfab.com/2022/03/shou...ating will have,you haven't sandblasted first.

 

[shogun32]

if a more flexible / compliant coating would have fared better ?

Sure looks that way.

 

[Headless Horseman]

From what I see in the pic, it looks like the coating is flaking off just as some of my Steeda parts have done and/or are doing. Looking at the metal on my components where the coating has chipped off, it’s smooth and not pitted or roughed up as is typically done via sandblasting to prep the metal before coating it, so that the powder coating will have a good surface to adhere to.

https://nwmetalfab.com/2022/03/should-you-sandblast-before-powder-coating/#:~:text=The powder coating will have,you haven't sandblasted first.

Here's my public service announcement to anyone considering replacing their OEM suspension springs with something from the aftermarket: Modern suspension springs are cold-wound from high tensile strength (and notch-sensitive) chrome based alloy steels and corrosion protection on the finished spring is critical for proper performance and fatigue life. Cold-wound springs are "low temperature" stress relieved so there are high residual coiling stresses contributing to the applied cyclic operating stresses and the spring's fatigue life is dependent on the quality of the wire surface condition, especially on the inside diameter of the spring.

OEM springs have specific salt spray and coating requirements to prevent corrosion and any reputable aftermarket spring supplier also respects the importance of protecting the wire surface quality from corrosion. The attached images show an example of a popular Steeda lowering spring set I installed on my son's Mustang GT after 7000 miles of Detroit's mild winter weather. The car has the lowered stance many people prefer but this kind of rust damage is unacceptable as it will introduce stress concentration points and significantly reduce the spring's fatigue life. Steeda doesn't warrantee their products for rust, including suspension springs, so do your homework when making decisions that can affect the safety of your vehicle.

Just fucking WOW! @SteedaTech??

 

[WD Pro]

I wonder if a more flexible / compliant coating would have fared better ?

WD

Sure looks that way.

Yes, but I really should have been clearer, especially based on the post above (#10).

In this instance I'm not bashing Steeda's ability to surface prep and powder coat (If you search my name you will see my thought, findings and fixes for that elsewhere ...).

What I was suggesting / hinting at, is even if the coating was applied perfectly, with good surface prep and without any voids etc, I still wonder if it would have failed due to being to brittle, cracking, and allowing corrosion to start.

Coating brittleness may not be from incorrect specification, it could also be from incorrect application parameters - oven temp etc (possibly restricting it to batches and / or suppliers).

I don't know for sure, but I suspect Steeda don't coat these in house, and it's likely done by the spring manufacturer / supplier ?

WD

 

[MrMike]

I feel like there's been this discussion about other Steeda pieces rusting and the warranty not covering them, like the jacking rails and the subframe support braces. You can powder coat, POR-15 or Rustoleum those pieces but not much you can do about these springs.

I'm wondering if this is a failed/faulty coating.

 

[robvas]

I feel like there's been this discussion about other Steeda pieces rusting and the warranty not covering them, like the jacking rails and the subframe support braces. You can powder coat, POR-15 or Rustoleum those pieces but not much you can do about these springs.

I'm wondering if this is a failed/faulty coating.

People powdercoat springs all the time. That's how they come from companies like Eibach. You can paint them if you want as well.

Like you said, they probably didn't prep or coat these ones right.

 

[Crew4991]

Yikes, that is a bit surprising to see that much rust on the springs on such a newer vehicle but realistically any car in the salty road winter areas will probably have that problem.

Definitely more than just surface rust for sure.
Not going to lie, I actually don't mind a floaty suspension like an old Cadillac.. it is definitely not mustang sports car suspension oriented but it is kind of fun to go over bumps and feel like you are on a boat going over a wave.
Handling really sucks though with bad springs.

 

[sms2022]

They are not a safety hazard at all. Not one bit. Ugly, but completely safe.

mild winters are actually worse for rust btw, the salt on the roads corrodes exponentially faster above freezing. Your son has a nice car btw I’ve seen it around metro Detroit.

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