leaf spring-shackle problem

[Joe]

Hi, I was working on a 90’s Ford E150 van, shackle rusted out and leaf spring (rear) came right up through the floor. I’ve done these before but this shackle would not come loose from the frame or the leaf spring. After much cursing I cut the lower rusted half bolt on both sides and finally got the lower half of the shackle out, but the upper half is still on the leaf spring. I could not remove the bolt or try to remove the rubber bushing; I tried a torch, pbblaster, much banging etc. What do you guys do to get these damn things out? The bolt would barely turn but the rubber bushing was just impossible. Do they make a special tool for this?

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[college man]

The Fords of this era are notorious for rotting out shackles. usually they bust off.
sometimes just cutting it with a saws all or cut off wheel may be the only means of it coming off. Instead
of wrestling with it I would cut it off and replace the components.

[Joe]

That worked for the bottom half-I used a cutting wheel on an angle grinder. But the top half has the bolt and rubber bushing stuck in the end of the leaf spring. If I cut the bolt head off I still will have the bolt shank and the rubber bushing stuck in the end of the leaf spring.

[college man]

[quote=”jcirafic” post=135691]That worked for the bottom half-I used a cutting wheel on an angle grinder. But the top half has the bolt and rubber bushing stuck in the end of the leaf spring. If I cut the bolt head off I still will have the bolt shank and the rubber bushing stuck in the end of the leaf spring.[/quote]

If you cut both ends off that rids the shackle from the leaf. Then take a punch and
drive out the shank piece thats left. What else you could do is drill holes all the way
around into the grommet then put a socket or hammer against it and try to drive it out.
This video may also help.

[Joe]

Thanks College Man. I did heat it up til it was smoking, just like the guy in the video. Difference was I didn’t have any room to swing the hammer since the leaf spring is still in the van . I was hoping to avoid taking the whole thing out but I can see I might have to. Same with drilling holes into the rubber-I’m pretty sure I’d have to remove the leaf spring to have enough clearance to get a drill into it. That means trying to get the front shackle disassembled which might be another nightmare. It will be 2 weeks before I get a chance to try. I’ll post if I give it another shot. Thanks for the help.

[college man]

[quote=”jcirafic” post=135762]Thanks College Man. I did heat it up til it was smoking, just like the guy in the video. Difference was I didn’t have any room to swing the hammer since the leaf spring is still in the van . I was hoping to avoid taking the whole thing out but I can see I might have to. Same with drilling holes into the rubber-I’m pretty sure I’d have to remove the leaf spring to have enough clearance to get a drill into it. That means trying to get the front shackle disassembled which might be another nightmare. It will be 2 weeks before I get a chance to try. I’ll post if I give it another shot. Thanks for the help.[/quote]

Not a problem. 🙂 keep us posted on your progress. 😉

[Joe]

Got back to this yesterday. I torched the rubber bushing til it was totally melted while wrestling with the bolt. This time I got it loose! I then took pliers and ripped the rubber bushing out of the leaf spring. I thought the hard part was over.
I went to put the new shackle on and….it would not fit in the end of the leaf spring. I oiled the new bushing and sleeve, heated the leaf spring end to expand it, banged on the new bushing even turned it down in my little 7×10 lathe a few thousandths-I ended up getting it partially in and used the new bolt with the nut and a washer to press it in since my c clamps would stay on it. Probably took another hour but I did finally get everything on and bolted in! Never so glad to see a job done and over.
Next-my 2005 Cavalier needs passenger side front axle/cv joint. I have time, its only making a little noise. I am taking a break.
Thanks College Man for the help.

[college man]

[quote=”jcirafic” post=140022]Got back to this yesterday. I torched the rubber bushing til it was totally melted while wrestling with the bolt. This time I got it loose! I then took pliers and ripped the rubber bushing out of the leaf spring. I thought the hard part was over.
I went to put the new shackle on and….it would not fit in the end of the leaf spring. I oiled the new bushing and sleeve, heated the leaf spring end to expand it, banged on the new bushing even turned it down in my little 7×10 lathe a few thousandths-I ended up getting it partially in and used the new bolt with the nut and a washer to press it in since my c clamps would stay on it. Probably took another hour but I did finally get everything on and bolted in! Never so glad to see a job done and over.
Next-my 2005 Cavalier needs passenger side front axle/cv joint. I have time, its only making a little noise. I am taking a break.
Thanks College Man for the help.[/quote]

Your most welcome. Try silcone spray on the rubber next time. Oil will expand the rubber. 🙂
Thanks for the update.

[Joe]

Ok.

[Ken]

I burn the tough ones out…. as you did.

Some silicone grease and alot of cursing should get the new one in, sounds like you figured that out too. A ball joint press can be helpful pressing them in, but be careful. A lot of energy can be stored in those little bushings if something slips.

[Author]

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