Finally got the 2 1/2"shackle flip done. Only problem I had.....there is a short somewhere in the system and it might be coming from the fuel pump. When I went to the driver side door to unlock the passenger door with the power lock button, nothing happened. I turned on the head lights and nothing. I figured I had a dead battery. I opened the hood to switch the marine switch to battery #2 and it had a small popping and some smoke coming from right by the breakers. I switched it back to battery #1 and had power again. Checked the voltage and had 11.75 volts. The truck started but it sounded like it wasn't getting enough fuel pressure. I stopped after that and decided to work on it next weekend. Anyway, here are some pics on the install.
I really like to be safe as safety is #1 in my book and I hope it is in yours also. I had jack stands in the back and also about mid way towards the front. I never worked on it unless the wife was home and I had my phone with me just in case it collapsed. And I asked her to check on me every few minutes. Everything went very well.
As seen in the pic, there is a jack under the rear differential to help take the pressure of the rear leaf springs when I removed them. I didn't get any pics of the leaf spring removal.
Next was installing the zero rates so I could move the axle back 1 1/2" to center the tires in the wheel wells. I cut the center pin the required 7/8" and put it in the center hole of the zero rate. Next was the bolt that will go through the zero rate and through the hole of the spring pack.
Next was the removal of the old shackle brackets. I used an angle grinder and cut a slit down the center of the rivet. Then started by cutting off one half, then the other.
Once all the rivet tops were cut off, I used a 3 pound hammer and knocked out the rivet ends. I then used a large pry-bar and broke the old shackle brackets away from the frame until it just popped off. I cleaned up the holes, drilled them to the new 7 1/6 size hole, painted the frame and installed the new shackle flip and shackles.
I used a screwdriver to line up the bottom holes for the shackle brackets, but the new bolts will fall into place when you tighten the bottom side bolts. Tighten to 38 ft lbs.
I forgot to get pics of the install with the tires off......I was too excited to remember. But here are some with the rear leaf springs painted and the new U-bolts and spring brackets. All from ORD.
The 2 1/2" shackle, plus the zero rate, plus the extra 1/2" on the new Heavy Duty shackles gave me an extra 2" of lift for a total of 9" in the back. I am going to add a zero rate up front when I do the Ram Assist to give me 7" total lift in the front. I may switch from 4" springs to 6" springs and forget about the zero rate for a total of 8" in front. Need some overtime first but it will happen.
I also need to get new shocks because of the difference in the new lift height. More overtime.
Plus, I just sent my rear drive shaft to Tom Woods to have it lengthened. And more overtime.
