Maybe I'm not doing this right, but I'm trying to separate the leaf spring packs in order to add a leaf. How do I remove the little clamps near the ends of the top 3 leafs? Do I need to grind/drill out the rivet? How do I reinstall the clamps when I want to put everything back together? A DIY would be great, but I can't find one. Any help is appreciated, I wanna get my truck back on the road tonight if possible. Thanks.

 

i didnt think the aal was long enough to touch the straps. i dont think you have to take the straps off, just unbolt the centerpin, throw your new leaf on the bottom and bolt it all together with the new (longer) pin.

 

Ya, the AAL goes above the overload spring, but below the leaf pack. So it will be the second leaf up from the bottom when you are all done.

 

sorry, i forgot about the overload. you dont have to remove the straps though, right?

 

No, the overload is independent from the leaf pack.

 

The instructions say that the new leaf should be placed directly under the leaf that is slightly longer than the AAL. They should always go from shortest to longest starting from the bottom, therefore I have to take the leaf pack apart. Are the instructions wrong? Anyone got a pic?

 

The instructions are for a vehicle without an overload spring. You should not have to take the main spring pack apart.

 

Here is a write-up I saw once, and seemed to work ok as a guide when I did my AAL. I can't recall who wrote this up, so use these steps at your own risk. This has you do it one side at a time, but I think you could drop the axle on both sides at the same time. Not sure, I did mine one side at a time. And I think I had to disconnect the shock at the axle too, which wasn't in this write-up. Again, use at your own risk.

"Add-a-leaf Install

Parts/Tools List
-----------------
-3/4 and 13/16 deep sockets. Other size sockets may be needed depending on year.
-Heavy duty jack stands
-Bottle or floor jack
-2 large strong c-clamps
-Long screw driver or steel rod, approximate diameter of the leaf pack center pin

I recommend just breaking loose the u-bolts nuts (do not loosen) while the pickup is on the ground. Makes it easier/safer then trying to do it while it is jacked up. Break loose the lug nuts on the wheel, jack up the back of the truck on one side, and place jack stands under the frame to support it. Put a jack under the axle. Remove the wheel. Put c-clamps on the leafs, one on each side of the u-bolts. Make sure you have all the leafs in the clamp.

CAUTION: Leaf pack is under a very large amount of pressure. Use extreme caution when you disconnect the u-bolts and remove the center pin.

Remove the u-bolts. With the jack, slowly lower the axle away from the leaf springs. Remove the very small plate on top of the leafs that goes around the center bolt. Undo the nut on the center bolt. You may need to hold the bottom with vicegrips. Remove the center bolt. Slowley loosen your c-clamps so the leafs begin to spread apart. Continue until the leafs no longer have pressure to them and you can remove the c-clamps. The block may fall out at this point too. Just make sure you note the direction it was installed, or look at the other axle if your not sure. Insert your add-a-leaf above the bottom smallest leaf. Leafs should always go from smallest to largest. Not that the bolt hole is not in the center of the add-a-leaf. Measure the bottom (smallest leaf) to see which side is the long side, install the aal in the same manner. Make sure the stabilizer plate (flat plate with 2 tabs, one up and one down) is installed the same way it came out. Insert a steel rod or large screw driver into the center bolt hole from the top. You don't want to insert the center bolt yet because the threads can be stripped from it as you clamp the leafs back together. Place the c-clamps around the leafs again making sure they will not be in the way of the u-bolts that need to go back on later. This can be difficult since they are so spread out. Begin tightening them down equally on both side. Make sure the steel rod or screw driver you inserted into the center hole stays loose. If it binds up because the holes are shifting, you will not be able to get your center bolt in later. Also keep an eye on the tips of the aal and leafs to make sure it is centered with the other leafs, and not turning laterally. Continue to clamp the leafs until the are all pulled together snug. Remove the steel rod or screw diver, and replace with the center bolt, inserting from the bottom. Put the nut on it and tighten to the torque spec. Leave the c-clamps on. Make sure the lift block is in its correct place. Jack the axle back up. Make sure the head of the center bolt goes into the hole in the block. Once the axle, block, and leafs are jacked back together, reinstall the u-bolts, upper plate, and bracket. Tighten snuggly. Once the u-bolts are in place, remove the c-clamps. Put the wheel back on, lower to the ground, and torque the u-bolts to spec."

 

Thanks but I'm still confused on where to put the new leaf. The leafs that I bought are a good 5" longer than the bottom leaf in the leaf pack. I have to take the pack apart don't I? The leafs I have are rough country 6124's

 

http://www.shockwarehouse.com/site/r...add_a_leaf.cfm