08/01/08

Michelle doesn't drive the truck because the steering can be a little dangerous, so we decided to fix the steering for our next truck project.  The operation will really start on December 2nd when we put the truck up on blocks to start the disassembly.  I will be upgrading the brakes, steering, leaf springs, shocks, and adding traction bars.

Some of the parts arrived that I ordered from Marlin Crawler:

I am going to make my own custom shackle hangers out of DOM steel tubing (1.75" OD with 0.120 wall).  I needed a bushing to fit inside the tubing so I ordered two types:  rubber and polyurethane.  I plan to run the rubber bushings on the front axle, the Poly bushings on the rear axle.  The Napa rubber bushing is Part # 274-6584, the Energy Suspension polyurethane bushing is part # 3.2124G.  The Energy Suspension catalog lists the part as # 3.2124, but when it arrived it had a G at the end of the number.....

My front tires are currently rubbing the inside of the front fender when I go off-road, and these modifications will only make it worse.  I am going to install the battery under the bed, then I can cut the inner fenders.  Here are the pieces that I have made into a battery tray and the spot where it is going under the bed:

installed and now I have more space in the engine bay:

Here are a few shots of the stock 1985 pieces that I will be removing:

So I removed the front axle and springs:

Then I had to remove the stock steering arm by hitting it with a hammer:

and the cone washers came right out:

I brought out the plasma and now the stock spring hangers are gone:

Here is the start of the new spring hangers:

I had to use a bunch of clamps to get all the pieces to line up correctly.  I also used a copper grounding rod to help line up the holes because it was exactly 9/16" outside diameter.

The front spring hanger is now tacked into place.  My new spring hanger has moved the spring mount down by 1.75" and forward by 2".

I mounted the steering box and steering stabilizer:

Just about finished, it is now sitting on all fours:

I also built a front traction bar to prevent axle wrap:

I also added bumpstops on both sides:

Finished photo:

I took it wheeling on Jan 12-14th and it performed great!

I was able to lower the front end of the truck about 1/2" to 3/4" total.

I measured the ride height of the truck before I made any changes.  The truck is sitting on 35" Super Swamper Radials at 30psi:

Frame Measurements
  Front crossmember to floor: 27
Driver's side:
  Front frame, no crossmember: 26 5/8
  Right in front of crossmember: 24
  Hole(in frame) in front of rear tire 24 1/2
  Rear frame by bumper bolt 33

Passenger's side:
  Front frame, no crossmember: 26 5/8
  Belly: Right in front of crossmember: 24
  Belly: Hole(in frame) in front of rear tire 24 3/8
  Rear frame by bumper bolt 33 1/8

Axle Measurements
  Driver
    front axle to frame: 11
    rear axle to frame: 15 3/8

  Passenger
    front axle to frame: 11
    rear axle to frame: 15 1/2