How to Replace Leaf Springs and Lift your Truck

Introduction

In this tutorial, you'll learn how to replace leaf springs, shackles, and mounting brackets on your truck or SUV. This guide will help you save money and improve your vehicle's suspension performance. We'll also cover how to remove rust and apply protective undercoating to extend the life of your vehicle's components.

Step 1: Gather Your Tools and Safety Gear

Before starting the project, make sure you have the following tools and safety gear ready:

• Torque wrench
• Extendable ratchet
• Rounded bolt/nut sockets
• 12-ton jack stands
• Angle grinder (with dust mask and eye protection)
• Wire wheel for rust removal
• Jack for lifting the vehicle
• Safety glasses and dust mask

Step 2: Prepare the Vehicle

1. Chock the Front Wheels: Place wheel chocks on both front tires to prevent movement.
2. Lift the Rear of the Truck: Use a jack to raise the rear of the truck as high as possible.
3. Secure with Jack Stands: Place 12-ton jack stands under the frame of the truck, ensuring it is stable before working underneath.

Step 3: Remove the Old Leaf Springs

1. Remove the Wheel: Take off the lug nuts and wheel to access the leaf springs.
2. Disconnect Leaf Springs:
   • Identify the front and rear mounting brackets.
   • Remove the nuts from the u-bolts securing the leaf springs to the axle.
   • Use an extendable ratchet for extra leverage if necessary.
3. Remove Stubborn Bolts:
   • If a bolt won't break loose, try using a breaker bar or a jack to apply hydraulic pressure.
   • If a bolt spins in place, use a pry bar to apply pressure while unscrewing.

Step 4: Remove the Mounting Brackets

1. Remove Rusty Bolts:
   • Use a hammer and socket to remove the bolts; a twist socket can help with swollen nuts.
2. Remove Rivets:
   • Use an angle grinder to grind the rivets flat.
   • Use a hammer and metal punch to pop out the rivets once ground.

Step 5: Treat Rust Areas

1. Wire Brush the Area: Remove any loose rust using a wire wheel attachment on your grinder.
2. Apply Rust Reformer:
   • Spray an even coat of rust reformer on the exposed metal.
   • Allow it to dry completely, ensuring no rust remains.

Step 6: Install New Mounting Bracket

1. Position the Bracket: Align the new mounting bracket against the frame.
2. Secure with Bolts:
   • Apply medium-strength threadlocker to the bolts.
   • Hand-tighten first, then torque to 75 foot-pounds.

Step 7: Install New Leaf Springs

1. Prepare Leaf Springs: If reusing leaf springs, replace the bushings as necessary.
   • Cut any excess rubber from old bushings.
   • Use heat to help push out the old bushing and install new ones.
2. Install the Shackle:
   • Attach the new shackle first, using threadlocker and hand-tightening.
3. Install Leaf Spring:
   • Position the leaf spring on the axle and secure it with u-bolts.
   • Hand-tighten, then torque to 80 foot-pounds.

Step 8: Final Assembly and Undercoating

1. Torque All Bolts: Ensure all bolts are torqued to specifications.
2. Apply Undercoating:
   • Tape off any surfaces that need to remain clean.
   • Spray a rubberized undercoating over treated areas to protect against future rust.

Conclusion

Congratulations! You've successfully replaced your leaf springs, shackles, and brackets while treating rust and applying protective coatings. This project not only improves your vehicle's suspension but also enhances its longevity. For future maintenance, regularly inspect your leaf springs and undercoated areas to prevent rust and damage.