This weekend I finally got around to installing my 4 inch leaf spring lift kit from Rusty’s that I have been having for a couple of years. I tried to put it in when I first got it and got frustrated for a handful of reasons and called it quits. Two years, a house purchase, full renovation and a wedding later, I am finally getting my weekends back and this was on the top of my “fun stuff to-do” list.
I read everything I could find on this forum and the mothership about installing the Rusty’s kit and other similar kits. The threads about this kit in particular were immensely helpful. If you wrote one, thank you. Just doing my part to add some knowledge...
My main tips/tricks/suggestions:
1.) Take your time. Unless you’ve done this type of thing several times before or do it regularly at your job, this won’t be a fast process. I consider myself fairly mechanically inclined being from a family of car lovers/restorers and it took me two solid days to install this kit by myself (one day for rear, one day for front).
2.) PENETRATING LUBRICANT. Don’t underestimate the power of this stuff. Take the suggestion and spray down all ubolts, leaf spring bolts, shackle bolts, shock bolts, etc. Basically any nut and bolt you need to remove, spray it every night for a week before you plan to start from every angle you can hit it. I did this and it all came apart without much fuss. The captive nut behind the gas tank also held strong thank the good lord...
3.) Work smart, not hard. The parts that go right into place where you want them are the exception, not the rule. In general, most parts will need to be pried/hammered/clamped/jacked into place. Don’t wear yourself out trying to muscle something into position or damage it by using a BFH all the time. Chances are if you step back and take a minute to think about it, you can make the part do what you want by jacking, ratchet strapping or prying. Ratchet straps are your friend when you’re working alone, which brings me to...
4.) Get a buddy. I did this by myself and I’m no expert, but it would have been much faster, more enjoyable and less grueling if I had a buddy to lend a hand.
5.) Start with the rear. Just my opinion here but I started with the rear and was glad I did. I think the rear was a little more difficult, mainly due to the springs needing to be arched into place. The lessons learned on the rear made the front seem more enjoyable as it’s essentially the same process but the springs are easier to get installed.
6) About the rear springs... I’m sure there are endless ways to get them arched into the needed position, but here’s how I did it. I had a spare piece of 4”x6” treated lumber and I cut it at 42” long so it fit on top of the leaf springs just inside the two eyes. I notched each end slightly so it kind of saddled the top of the leaf which helped it to stay in place. First I installed the frame side of the spring. I then took two ratchet straps, one on each side wrapped around the spring and the 4x6, and slowly ratcheted each one little by little. With very little effort, the spring began to flatten/lengthen. Every now and then, I would lift it up into position and check to see if it lengthened enough to line up with the shackle bolt hole. Eventually, it lined up perfectly and the bolt slid right in. I’ll try to get a pic of the piece of wood on one of the old springs for a visual, forgot to take a pic when actually doing it...
That’s my contribution on this topic. Nothing earth shattering for guys that do this type work all the time but for me, this was very helpful info that saved me many headaches. If anyone is planning to do this and wants a pep talk/advice, feel free to DM me. Happy to help.
I still need to install several things to make my ride roadworthy. Track bar relocation brackets, dropped pitman arm, extended brake lines (not needed but mine are in need of replacing anyway), extended sway bar links to name a few. I know some of those things are optional but I want GREAT road manners, not just “good enough” since this will be mainly an on-road vehicle. I also have several bushings in need of replacement and lots of wire wheeling and painting needed to pretty things up. I’ll post some update pics once I get that stuff ordered and installed.
After that, new tires and an alignment and I am hoping I’ll be good to go! Some during and after pics attached for your enjoyment...
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