Well I Went & Did It.. Rocky Road Conversion On The Way.

Discussion in 'Intermediate CJ-5 and CJ-6 Tech' started by zila, Sep 21, 2017.

  1. Oct 22, 2017
    wally

    wally SSSSTER

    upper merrimack...
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    in your last post, i don't see pictures, i see a "minus sign" in a circle.

    for sure, check to make sure you have the correct placement of each bracket or anchor. there is a typo in the instructions as far as one of the hole sizes, i'll try to find my notes on that and post it.
     
  2. Oct 22, 2017
    timgr

    timgr Jeepin' Nerd Sponsor

    Medford Mass USA
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    Yeah, they are broken for me too.
     
  3. Oct 22, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Oct 6, 2003
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    Damn it . I tried linking in from my google photo account. I can see em. I was trying to not use the server here to save space for the forum. I'll try it again and edit.

    And I am having trouble getting the bushing into the bracket. I suspect I have too much grease in there and it is hydraulic locking. Gonna take it apart again tomorrow and re-group.

    loose bushings in bracket

    Bushing next to spring

    Sleeve clearance issue.
     
    Last edited: Nov 16, 2017
  4. Oct 22, 2017
    Stephen Gillett

    Stephen Gillett New Member

    Connecticut
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    Aug 31, 2017
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    Is it possible that there are several different lengths of sleeve with the kit? Seems possible given how similar the front and rear bracket look that you may have various sleeve lengths to fit the brackets vs. the shackles. Total speculation, my kit hasn't arrived yet...
     
  5. Oct 22, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    I only received 4. I am thinkin I need 8. I'll call tomorrow. Meanwhile I am going to try one more time tomorrow to get this mounted.. You would think it would slide right in.. But the rubber keeps pushing it out about the time I get to the metal sleeve.. There was a burr on one side probly from the powder coat. I am going to ask also tomorrow when I call. Maybe the powder coats needs removed in that area.
     
  6. Oct 22, 2017
    wally

    wally SSSSTER

    upper merrimack...
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    i believe the sleeve you are showing is the sleeve that goes through the boxed front portion of the frame, to keep the boxed section from caving in when tightening the bolts to hold the new bracket to the frame.

    the sleeves for inside the bushings are shorter.
     
  7. Oct 22, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    There are some loose shorter sleeves but the instructions call for a 3" X 1/2" X 3/4" These are that size. The others are too short. The sleeve should be flush with the bushing end.
     
  8. Oct 23, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    OK got the spring hung. I called RR and the tech said that sometimes the bushings are not as uniform as they could be. He told me to grind off a bit on the bushing to fit. He said do not grind on the bracket. So I ground approx 1/16" off both sides and measured, got it right at 2-7/8" that the inside of the bracket measured. Slide right in. placed a bolt in the hole and went to the back/shackle. The bolts holes were tight so I ran the proper size bit in the holes in the new shackle to clean the powder coat out. All bolted up. But the shackle is hanging funny. Another call to RR. Tech said this is normal til the springs get some weight on em .. He also said to only loosely install the bolts and finish all 4 corners before trying to get the shackles to rotate. The new springs need to be flattened and have weight on em to get them in the correct attitude so to speak. He also said he gets this question all the time. Pics below.


    Note bottom shackle bolt with threads to the outside to insure clearance of the skid plate.
     
    Last edited: Nov 1, 2017
  9. Oct 23, 2017
    wheelie

    wheelie beeg dummy Sponsor

    York, PA
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    Boy. Seems like their instructions or parts identification or quality control needs some serious attention. Maybe all three. Are they making these kits in a garage in an alley somewhere?
     
  10. Oct 23, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    I have been to their shop. it's big and well organized. And they seem organized. I believe the instructions are in need of an update. But every time I have called I got a person and a good answer.. Moving on I think I have the drill down for the rest of it..
     
  11. Oct 23, 2017
    scott milliner

    scott milliner Master Fabricator

    Seattle Wa.
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    The instruction were not the best. They could of included in it which shocks go on the front or rear. I got it wrong.
     
  12. Oct 25, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Progress today. Moved to driver side rear. Removed spring, looked at the situation. Now the muffler is dead in the way and I cannot get it off.. The pipe is crushed from the clamp.. Enter sawzall. Guess I'll cut it off close and get it fixed afterwards. My sawzall decides to crap the bed. Had enough and took my new rifle out pdawg blastin.. I'll start on the muffler in the morning. New sawzall first
     
  13. Oct 26, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Muffler is off. Be makin a trip to the muffler shop afterwards.. Now the end of pipe is in the way a bit. I'll work around it somehow. Got the drivers side bracket cut, trying to fit the new RR bracket over the old one and see what I have before drilling. I found on the pass side that it is easier to get the hole in the right place by clamping the bracket in place and using a 1/2" bit start the hole. Then remove the bracket and finish. I also cut the old bracket off just above the old bolt hole. I found on the pass side that 1-1/8" measurement was a bit too much. Now to get the new bracket over the old. Gotta grind the old bracket and clearance it for the new one to slip on .. PITA but gotta be done. I also noticed that the indexing holes on the axle perches are wobbled a bit. Just may order new ones and replace em with the proper size while I have things apart..
     
    Last edited: Oct 26, 2017
  14. Oct 26, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Driver side bracket mounted, bolts loose. I'll torque em tomorrow. Fought the exhaust all day. I removed the muffler and tail pipe but the pipe going forward was still attached and in the way just enough to screw me royal. Also the jack stand was in the way a bit and the release handle shoulda been towards the front. Also I shoulda raised the vehicle higher.. Didn't get the hole in the old bracket right. Finally got all the bolts in there respective places.. I am spent. I'll tighten everything up tomorrow.. Then hang the spring. Still on the fence about replacing the perches. May finish this project then buy some new perches and tackle it at a later date.

     
    Last edited: Nov 16, 2017
    tarry99 likes this.
  15. Oct 27, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Well crap. Went backwards today. Got the driver side mount on and bolted in. Installed the spring. Solid end needed a bit of flapper wheel to fit. Shackle end was twisted.. Got to looking and something at the front bracket aint square. Took it all apart and checked the frame with a square. It seems OK, but the OEM bracket may be fubar. That explains why the old bushing was ate up so bad on that side.. I'm done for today. Will take another look tomorrow and try to figure out WTF is going on..
     
    Last edited: Nov 16, 2017
  16. Oct 29, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Back at it.. Looks like this has been an issue for quite some time.. Looking at the front end the hanger doesn't look right either.. Got it closer to being true in the rear but not quite. Gotta do some more adjusting.. Sigh
     
  17. Oct 29, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    OK, I ended up placing a small shim under the front and inside of the new mount. My frame was bent up a bit there and causing part of the issues.. I tried everything to bend it back down.. Nope..Got everything mounted, spring slid in straight and everything bolted up. Tomorrow I'll hang the rear axle..

     
    Last edited: Oct 29, 2017
  18. Oct 31, 2017
    scott milliner

    scott milliner Master Fabricator

    Seattle Wa.
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    I didn’t use the axle shims.
    Do I use them on the front / back? The instructions didn’t have any info on them.
    I suppose if you had a D20 transfer case they my be needed on the rear.
     
  19. Oct 31, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Progress so far. Axle mounted on springs and U-bolts torqued to 55 FtLbs. Shocks mounted. Note the U-bolts had a ton of thread more than needed. I measured and cut 2" off each one. Still have some extra that I'll trim later to flush with the spring plate on and tight.
    I used a 1/2-20 thread chaser to clean up the threads after cutting. Screwed it on first then cut.. Still need to mount the tires and rims, but have to clean the wiring to the in tank pump I installed to feed my TBI.

    Edit: The rear shackle swung into the proper position once I put weight on the springs.

    Measuring to cut

    After cut

    Pass side view


    Rear shackle in position.
     
    Last edited: Nov 16, 2017
  20. Oct 31, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    These are axle shims I purchased. I had 5° shims in with my old setup and it was barely enough. I bought some sano 8° shims from WFO. My drive line angle as much better now. I only use them in the rear. After swapping out the OEM 3-speed tranny to a 4-speed I needed to do something when I put the BDS 3" lift springs on. And yes I am running a Dana 20 xfer case
     

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