Mountain Off Road 7686-1 - Manual (Page 4)

STEP 8: Install both leaf springs (large eye) end into the M.O.R.E.™ items “A” & “B” brackets
(you must turn the leaf springs around). Use items "N" & “O" provided. Do not tighten at this
time. See figure 9. On the drivers side frame rail behind the motor mount is the brake propor-
tioning valve. Remove the two small screws that attach it to the frame and gently pull it away
from the frame rail. DO NOT REMOVE ANY BRAKE LINES FROM IT! This will give you clear-
ance to work on the frame rail.
Pivot the leaf spring by hand up to the frame and measure one inch (1”) between the spring end
and bottom edge of the frame. Use a jack stand to hold the spring at this distance. See figure
10. Insert item “G" through item "D" and into the spring bushing on the outside of the spring/
frame. Swing the shackle plate (item "D”) up, so it passes on the outside of the frame, With a
protractor on the front edge of the shackle plate, place the pointer of the protractor on 60 de-
grees. See figure 11. The top of the shackle plate should be behind the spring eye (tilted back
at the top). With a scribe, trace a mark on the frame rail through the upper hole in the shackle
plate. The steps above are for springs that are OEM or up to 2.5” of lift. If you have a spring
with more arch you should set up the angle with weight on the springs so you end up with the
shackle angle at 90 degrees or bottom edge back no more than 5 degrees. Call if you need as-
sistance.
Center punch the center of the traced mark. See figure 12. Now, transfer this center mark to
the inside frame rail by carefully measuring. Drill the punch mark with a 1-1/4” hole saw and
centering bit. See figure 13a & 13b. Use cutting oil for this procedure. After the outside frame
rail is drilled make sure the hole saw is level up and down and 90 degrees from the side of the
frame rail. Have a friend 'eyeball' your drill to get it as accurate as possible. Now, drill the inside
frame rail to 1-1/4". Do not snag the hole saw on any brake lines as it comes through the inside
frame. Repeat this procedure on the other side of the frame.
Next, insert item "E" into the hole in the frame. Center it so that equal amounts are protruding in
and outside the frame rails (approx. 1/8” per side). See figure 14. Weld the tubing to the frame
inside and out, full circle. See figure 15. After the frame has cooled to room temperature, wire
brush the welds and paint the area.
STEP 9: Install the urethane bushings items “F” into the tubes in the frame. Using a lubricant
(Permatex anti-seize works well), coat items “G” and insert them into items "D" and install them
on the springs and into the bushings items “F" in the frame. Install items "H" on items "G" and
just "snug” them up. Do not tighten! The springs are hanging in their new position now. Good
Job! It's down hill from here! See figure 16a, 16b, 16c.
STEP 10: Re-attach the brake proportioning valve to the frame. It will be necessary to bend the
brake lines slightly to clear the shackle plate. Use caution doing this! Bolt the axle housing to
the springs using the U-bolts removed earlier and tighten them to 75 lbs. ft. torque. Install the
shocks and hand tighten the nuts.
7686-1
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