I thought I would create a How-To for this Deaver leaf spring install since there is no leaf pack installation instructions out there.

I haven't done a How-To in a while so bear with me as I am sure I will be editing this thread many times.


Before:

38"s






I bought new Deaver leaf springs from PRG. A 9 leaf pack with 3 overload leafs that is 3"s thick and 2.5"s wide. It is designed to give 3"s of lift over stock and allow for over 400lbs of weight in the back on the X.

New Springs:




Prep Work: (Optional)
I decided to make my springs red for some added rust protection and because I think it looks cool.

Separate your pack by undoing the center pin and leaf guides. Lay your leaf pack down in the order you removed it and don't mix up the order the get assembled. Clean with acetone to remove unwanted dirt or oil.




Two coats on each side and let them drive overnight. Reassemble in reverse order.


Step 1:
Jack up the truck form the rear using a floor jack on the pumpkin and support the frame wit jack stands and the rear axle with jack stands as well. You should also have sprayed the leaf spring mounts and U-Bolts with some PB Blaster a couple days before hand to loosen the connections and breakdown as much rust as possible.






Step 2:
Remove Rear Tires & unscrew lower shock mounts on rear shocks so they swing free.





This may be a good time to replace any worn shock bushings such as I had.


Step 3:
Remove Rear Leaf Springs from Rear mounts on the lower part of the shackles.



You may want to use a flat head screw driver and a mallet to for the leaf springs out of the shackle. Be careful, as the springs may still be under a decent amount of pressure.


:Step 4:

Remove U-Bolts & Mounting Plates.

Most of mine were seized on and broke during removal. But, do not fret as you must replace U-Bolts every time you adjust or change leaf springs.


Old crap.


Driver's side free.


Springs free of rear axle.


Step 5:

Remove front of leaf spring from mounts. Save the bolts and nuts as you will reuse them for new leaf springs!

Save these bolts!

Step 6:
New leaf pack time!

I decided to go with a U-Bolt flip kit I also bought from PRG to be conscious of ground clearance. I bought some heavy duty U-Bolt from Stengel Bros. Inc. in PA.

9/16"s thread, 2 & 1/2" between threads and 8 & 1/2"s long.


Install the leaf packs in reverse order except you will attach the axle last as you need to lower the axle back onto the leaf packs together to assure the center pins will line up and sit properly into the axle.

I had some trail rash that banged up the front leaf mounts so some grinding was necessary.


Thanks to Dan for his grinding help that made the mounts work again.


You may need to use a bottle jack to get rear leaf pack mounts to squeeze back into the shackle.

Disregard the black on the springs, it was from the mallet we used.


Step 7:

Center Pin and Axle


Dave's blurry thumbs up before the axle is lowered.


Because of my flip kit, additional grinding was need to grind down the ABS brake mounts on top of the axle. No loss here, as the mounts still worked after making them flush.


U-Bolt flip kit fits.


You will want to remove the excess on the U-Bolts with a reciprocating saw or angle grinder.

Reinstall lower shocks to lower mounts.

New leaf packs on!


I put the shackle back on a lower setting this time to account for the greater arch in the leaf springs.

Step 8:

Put the tires back on and test it out.

After


39"s for 1" gain


Flexing




Did I miss something or are thee any questions? Feel free to ask.

Nice write up. Missing cost of things; spring pack, flip kit.

I did not see anything about the leaf bushings. Did you need to press them into the leaf pack? Did you go with the BAJA Bushings?

I know that load leafs are a must for hauling heavy stuff but never cared for them when wheeling because due to my lack of driving skill I always got hung up on them.

I?m digging the red accents with the black truck! I really like the flip kit!

Your truck looks great bro.

looks great and that red is trippy back there lol

did you look into going SOA or moving those shock mounts? im just asking since you said you had trail rash on the mounts and like tom said the SUA leafs catch on rocks and stumps easier.

i was looking into a u bolt flip kit myself for those reasons

Great write up and nice addition to the truck.

I like the color that you chose. I've been thinking about starting to repaint my parts in different colors as I start doing maintenance work on them.

Where'd you find the U-bolt flip kit on PRG's page?

I looked, but didn't see one listed there....

Jeff just keep in mind that the 2nd gens have an independent shock mount and ours don't so it wouldn't work for us. Unless you mount the shock independently.

The U-Bolt flip kit is from PRG, it is not listed on their website. The flip kit is from a Titan kit.

I went with bushings from PRG as well. They just press right in very easily with as rubber mallet.

I did not go SOA, because it would require new rear shocks and I personally don't think it is a safe way of lifting the rear of a truck.

I like the 3 overload leafs, because I am constantly hauling a lot of film/video gear for work.

The leaf packs were $250 a piece plus shipping. I got a deal from Greg, so I will leave it at that. I don't know how much the flip kit was, sorry.

I've been trying to find a reasonably priced flip kit for my D44 up front. I don't know why they cost so damn much.

Talk to Greg! He'll point you in the right direction!

looks great with the new springs man

i've been wondering for a while now, whats up with the hole in your rear bumper?!

The hole is for a relocation of the 7pin wiring harness for towing. I just haven't done that yet... one of these days.

OK, this is going to sound stupid, but what do the shocks have to do with the way the U-bolts go on?

one the first gens, the lower shock mount is integrated with the spring perch...if you flip it, it the shock mount will be in a completely different location

on the second gens, the lower shock mount it on the axle directly, independent from the spring perch

the closest the first gens can get to relocating the shock mount and spring perch is a set of the darlington offroad UBSkidderz

or you could just do a set of shock tabs on the axle and then do the u bolt flip

Nice write up!!
Love the red paint.