Leaf spring shackles flipping forward

[CO MJ]

I made a post when I first installed Rusty's 4.5" lift kit as I was having trouble getting the leaf spring shackle angle correct. I think consensus was to put some weight in the bed and as the springs relax they should lengthen enough that the shackles will sit at the correct angle. 

 

 

Well, 6 months of driving around with a few hundred lbs in the back, I have had the shackles flip forward and stick against the frame more than a few times. The springs don't seem to have relaxed much at all either. See the photo for the issue I'm having and see the shackle in the background for the angle they're sitting at (still probably 20-30 degrees from where they should be).

 

Any ideas how I can fix this besides continuing to pester rusty to make it right?

[gogmorgo]

After running for six months you’re unlikely to get anything out of Rustys without involving legal action but it’s still worth trying I guess. Returning as defective would’ve been the thing to do but if that wasn’t going to happen that’s that I guess.

 

If you’ve got a local spring/suspension shop around you might try talking to them. They can re-arch springs so in theory they can also be de-arched, although you would lose lift height. They might have some other solution to correct it as well, worse comes to worst they can probably replace the main leaf with a longer one. 
Otherwise I think you’re looking at redrilling for a different mounting point either front or rear and I think that’s the wrong decision. 

[Pete M]

dang.   I'd seek out a local spring shop on google.  even if Rustys eventually does something about it eventually, ya gotta deal with it until then. 

[Htchevyii]

Wow, those springs have some serious arch! How much did they raise the truck?

[CO MJ]

2 hours ago, gogmorgo said:

After running for six months you’re unlikely to get anything out of Rustys without involving legal action but it’s still worth trying I guess. Returning as defective would’ve been the thing to do but if that wasn’t going to happen that’s that I guess.

 

If you’ve got a local spring/suspension shop around you might try talking to them. They can re-arch springs so in theory they can also be de-arched, although you would lose lift height. They might have some other solution to correct it as well, worse comes to worst they can probably replace the main leaf with a longer one. 
Otherwise I think you’re looking at redrilling for a different mounting point either front or rear and I think that’s the wrong decision. 

 

I had a long email thread where he ensured me these were correct and they would relax despite my comments to the contrary so I'm hopeful he will propose some solution seeing as he was incorrect, we'll see. I believe others have had the same problem with this kit. 

 

30 minutes ago, Htchevyii said:

Wow, those springs have some serious arch! How much did they raise the truck?

 

The kit is for 4.5" all around but just looking at the truck the rear sits probably 2" higher, maybe more

[ghetdjc320]

When the shackle isn’t inverted, what is the distance eye-to-eye?

[CO MJ]

24 minutes ago, ghetdjc320 said:

When the shackle isn’t inverted, what is the distance eye-to-eye?

 

I looked at my old thread and I think I measured them off the truck at 58" and stock at 56". Not sure how that could possibly be though, I'll remeasure on the truck

[DesertRat1991]

16 hours ago, CO MJ said:

I made a post when I first installed Rusty's 4.5" lift kit as I was having trouble getting the leaf spring shackle angle correct. I think consensus was to put some weight in the bed and as the springs relax they should lengthen enough that the shackles will sit at the correct angle. 

 

 

Well, 6 months of driving around with a few hundred lbs in the back, I have had the shackles flip forward and stick against the frame more than a few times. The springs don't seem to have relaxed much at all either. See the photo for the issue I'm having and see the shackle in the background for the angle they're sitting at (still probably 20-30 degrees from where they should be).

 

Any ideas how I can fix this besides continuing to pester rusty to make it right?

 

Check out the shackle angle on the drivers side... Is the truck sitting on the ground in this pic? 

[CO MJ]

28 minutes ago, DesertRat1991 said:

 

Check out the shackle angle on the drivers side... Is the truck sitting on the ground in this pic? 

 

Yeah it's on the ground, you can see it in the background, it's still maybe 30 degrees from perpendicular to the line between the spring eyes. The passenger side sits at similar angle when it's popped back into place but it folds forward every time I hit a pothole

[Ωhm]

Could just be an illusion caused by the camera, but that shackle looks shorter, bolt to bolt, than the other one.

[eaglescout526]

25 minutes ago, Ωhm said:

Could just be an illusion caused by the camera, but that shackle looks shorter, bolt to bolt, than the other one.

I concur with you. One side looks MJ and the pass looks XJ. XJ shackles are an inch or two shorter than MJ if I recall. Could be why his spring is constantly inverting.

[CO MJ]

35 minutes ago, Ωhm said:

Could just be an illusion caused by the camera, but that shackle looks shorter, bolt to bolt, than the other one.

 

9 minutes ago, eaglescout526 said:

I concur with you. One side looks MJ and the pass looks XJ. XJ shackles are an inch or two shorter than MJ if I recall. Could be why his spring is constantly inverting.

 

Nope, stock 4 3/8 on both sides

[gogmorgo]

The issue with the “run until it flattens out” suggestion is that in order for that to happen it has to swing the shackle down before it’ll move back. But the weight on the spring is going to push the shackle up, which is also forward, which moves the leaf spring eyes closer together, exacerbating the issue. 
If you can droop the axle down far enough, you might be able to hook a ratchet strap between shackle and rear bumper or hitch or something to pull them past centre so they sit properly (swung back) when you get the weight back on the springs. But no guarantees that’ll be a permanent solution, they’re likely to spring back forwards if you hit a big enough bump while driving. 

[CO MJ]

14 minutes ago, gogmorgo said:

The issue with the “run until it flattens out” suggestion is that in order for that to happen it has to swing the shackle down before it’ll move back. But the weight on the spring is going to push the shackle up, which is also forward, which moves the leaf spring eyes closer together, exacerbating the issue. 
If you can droop the axle down far enough, you might be able to hook a ratchet strap between shackle and rear bumper or hitch or something to pull them past centre so they sit properly (swung back) when you get the weight back on the springs. But no guarantees that’ll be a permanent solution, they’re likely to spring back forwards if you hit a big enough bump while driving. 

 

It's not permanent, I've done it several times now lol. I'm thinking this time I will keep adding weight to the bed until they are as close to correct angle as possible, and weld in a stopper to keep them from popping forward

[CO MJ]

Flipped it back and took some more pics with a string around the bolts to better visualize the issue. As you can see I'm probably 25 degrees off perpendicular on both sides, I'm confident the first bump I hit will send the spring right back up into the frame.

 

I think I may just weld a piece of steel rod to the bracket an inch or two in front of the shackles to prevent them from camming to the front, go get some more sand, and try to break them in even more while I wait on response from rusty.

[gogmorgo]

Just a tip, if you’re uploading from an iPhone and your pictures upload upside down, edit the pic from your phone and rotate it a full 360°. Fixes the issue. 
 

You need to be beyond perpendicular. Otherwise the weight pushing down on the spring will be forcing the arch tighter. Unless there’s enough arch that you can flatten it out and push the shackle the other way, having weight on it is only going to be detrimental. And those pictures don’t make it look promising. You’ll need to pull that shackle backwards at least two inches, so the angle between shackle and spring is less than 90°. 

For reference, this is how my shortbed sits, with its weight on the wheels, and this is about the lightest spec MJ you can get. Increasing weight just pushes the shackle further back. 

 

Looking at how yours is sitting I don’t know if you’re going to be able to make it work. You absolutely need your lower shackle bolt to sit further rearwards than the upper so the shackle pivots backwards as the spring flattens. Unless you can force the shackle back into that position before you put weight on it, you’re fighting against yourself. And it kinda looks to me like there’s not enough arch in that spring to flatten it out enough to gain two inches. 

[gogmorgo]

Reversed springs could put the axle in the wrong place, but it wouldn’t make the overall length of the spring too short. 

[DesertRat1991]

The part about the springs "relaxing" while under compression reads like a bowl of word soup.

 

If this is how the springs are designed, then they are not designed right for this application.  By Rusty's admission they are designed for a heavier truck.  You should not have to add ballast to your MJ for the springs to run right.

 

Maybe get a local spring shop to write up a technical assessment to back you up. Might cost a few bucks, but possibly worth it if it gets you a refund and free return shipment from Rusty's. 

 

At this point in our collective history, it seems like General Springs is the only reliable source for MJ leaf springs that won't screw up your suspension. Go with Hell Creek if you want your rear axle off center.  Choose Rusty's if you want to be told the design flaws are actually features.

[75sv1]

I'd wonder about a shackle relocation bracket. Not sure of drilling the present brackets some amount farther forward.

[gogmorgo]

1 hour ago, 75sv1 said:

I'd wonder about a shackle relocation bracket. Not sure of drilling the present brackets some amount farther forward.

This seems like an incorrect solution to springs that were supposed to bolt on. 

[75sv1]

23 hours ago, gogmorgo said:

This seems like an incorrect solution to springs that were supposed to bolt on. 

Ironman and Stinky Fab makes the relocation brackets for XJs. I think they made them for MJs.  IRO does say to use Boomerang shackles for their 3.5 lift springs, instead of relocation brackets. I do use them on my 2" lift. I doubt they would work here. Still worth a look. I did install a set of 3.5 OME rear Leafs. They are a bit short. I did use some IRO Boomerang shackles to compensate. It was at the +1 length though. I am having Ironman's Front and Rear 4-link installed. So, I wasn't looking for 'perfection', or even road use set up. 

       Also, it took me about 3-4 years for a set of Rough Country 4.5 leaf springs to settle from a 6-7 lift down to the 4.5. It seems to be holding at 4.5 for the past 3 years or so. 

[Eagle]

On 4/25/2023 at 11:57 AM, DesertRat1991 said:

 Choose Rusty's if you want to be told the design flaws are actually features.

 

In a world of constant change, it's comforting to find one thing that never changes.

[OldSch88L]

I just installed a set of these myself. Yes, they are finicky to install. They barely go on with the shackles flipped when in the air, and I had to help one shackle flip back on the proper side while getting the truck on its wheels. I did leave all my bolts loose though, bounced the truck many time before installing my shocks. It's been a week and the shackles are halfway between stock position and vertical, just by sitting in the driveway. Keep in mind that like the O.P., I also don't have my spare tire anymore. I'll put it back under the truck, drive it for a while, then loosen and retighten the leaf and shackle bolts to see if it settles better.