Land Rover LR3 Suspension Lift

Land Rover LR3 / Discovery III D.I.Y.
2 Suspension Lift
The Belew Method Outlined here are the steps taken to lift my Land Rover LR3. This method incorporates 3 Steps. 1. Fabricate and Install air strut spacers. 2. Extend Air lines. 3. Fabricate, Install and Adjust ride height sensor connecting turnbuckles.
It is possible to lift the LR3 by only installing shorter ride height sensor connectors. This will trick the sensor and cause the air bag to inflate to a higher position. The limitation of this method is if a suspension fault occurs and the suspension lowers with larger tires installed. This could cause the larger tires to contact the inner fender well, causing damage or immobilizing the vehicle. This impact is prevented using these spacers. Before beginning I placed a piece of tape across the highest point of the fender arch. Measured from the center of the wheel center up to the tape and marked a line. Then I recorded the height measurement for each wheel at each of the 3 Ride Height positions.
Step 1: Air Strut Spacers
I began by fabricating 2 Air Strut Spacers. This requires 2 front and 2 rear. I chose 3/16 steal over aluminum due to cost and ease of fabrication. I used a hand held plasma cutter to cut out the circular shape and center hole. Both are non-critical dimensions and extreme accuracy is not required. I then drilled out the 3 holes for air strut studs and a hole for the air line. The next step was to cut 1-1/4 tubing to length and weld to the base. I used a bolt inserted through the hole with a washer whos diameter matched the inner dimension of the square tube for alignment. Rotational alignment of the tubing is not critical. Then I welded the tubing to the base all around. I did have the length of the tubes milled to length to ensure squareness. Take note of the orientation of the air line hole in the front spacer picture above. It is not symmetrical to the centerline of the base. The rear spacer air line hole is centered.
In order to install the spacers I released the air line from the air strut. Then release the spring by removing the lower shock bolt and the 3 nuts from the top of the strut assembly. Access to this is not easy. It is a very tight fit. With the spacer on top of the strut I attached the spacer using (3) M10 Coupling Nuts then extended the threads of the strut using a M10 Threaded Stud inserted into the M10 Coupling Nut.
Nut LR3 Frame
Brass Coupling Threaded Stud
Coupling Nut Spacer
Brass Nipple
Air Strut Assy. Step 2: Extend Air Line Using a Brass Threaded Nipple and Brass Coupling Nut from Lowes I extend the air line connection. I used thread tape to seal the connections.
1/8" Brass Nipple
1/8" Brass Pipe Coupling
I inserted the assembly back into the frame. Reinstalled the 3 Nuts and Shock Bolt. Being carefull not to hit the extended brass fittings. Then I reattached the air lines and checked for leaks with soapy water.
Step 3: Fabricate, Install and Adjust ride height sensor connecting turnbuckles. First I made some turnbuckles using eyebolts, coupling nuts and rubber gromets. Technically these are not turnbuckles as they do not tighten and lenghten with a turn of the coupling nut. Regardless, here is what I used. Parts are from McMaster-Carr.
This was the more complicated of the 3 steps. It requred some trial and error. I was unable to source the exact parts needed so I modified these to work. Front: To make the front I began by cutting the coupling nut down and shortning the eyebolts down to 1-1/4 as shown in the print. The stock connecting rod measured 3.66 center to center and I wanted to start with a length 1-3/16 shorter. To allow for proper height adjustment I did shorten the eyebolts a little more. Rear: It was only required to shorten one of the eyebolts for the rear. I again started with an initial lengh of 13/16 shorter. I used a regular nut to lock against the coupling. After inserting the gromets into each end and installing on the truck, I placed it in Normal Ride Height. The truck did complain about the compressor running to long as the air system had been completely bleed. So I took my time and let the compressor cool between adjustments. Measurements are key... With the truck in Normal Ride Height I took new measurements and compared them to the original. I then began shortening the connectors one or so turns at a time until I reached a measuremt 2 greater than my original measurements. After a few trys you tend to get a feel for how much adjustment will be required on the next one. After getting the normal height set I tried the other positions.
Offroad mode first. No issue, the truck raised to an oustanding new altitude.
Next was Access Mode. It was not going to be as simple. Each time the suspension would lower it would almost reach the full down position then rise back to Normal Height with an error Clear Obsticle. This took some trial and error to resolve. What was happenting is the 2 height ajustment was right at the limit of the sensors correct position. The solution was to shorten the connector a little more. By adding another 1/8 or so to the height it kept the sensor from detecting a false obsticle. So I wound up with 2-1/8 of lift at Normal Ride Height. Now all height modes function as normal. Now for new tires and a 4-wheel alignment. I went with a 275/65/R18. There is no rubbing and the ride and new look is great. I wouldnt recommend trying to go any higher than 2. This height was at the maximum for camber adjustment. I also found out I needed new bushings, more on this later. Comments Does the truck feel more top heavy? Yes, a little. With the new tires and the lift I did gain almost 3-1/2 of ground clearnce. Add another 1-3/4 in offroad mode for a total of ~ 5-1/4. Any suspension errors? - I will occasionally get a soft fault. (occasionally got them before the lift..it is a LR3 after allhaha). Cycling the key off/on clears it. Any ABS issues? - I will occasionally get a traction control ingagement when turning. I believe this is due to the larger tire diameter. The computer senses the outside wheel in the turn turning faster than the wheel to the inside. To be expected. So what did this cost to build? Less than $100.
Offroad Height
Normal Height
Access Height

Land Rover LR3 Suspension Lift

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What steps were taken to lift the Land Rover LR3?

What modifications were made to the air struts and air lines?

Land Rover LR3 / Discovery III D.I.Y.

Step 1: Air Strut Spacers

Nut LR3 Frame

Brass Coupling Threaded Stud

Coupling Nut Spacer

1/8" Brass Nipple

1/8" Brass Pipe Coupling

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