Rear leaf spring shackle questions

[johnwartjr]

Greetings

New member - have a stock 96 Explorer Limited. Been in the family since new.

We've done quite a bit of repairs to it over the last few years. Done what we could ourselves, otherwise used a local shop to do the repair.

Had a brake line break last week, and took it into a different shop to have the brake line repaired. While they were working on it, they suggested we replace both rear leaf spring shackles - one is broken, the other is really close.

We weren't aware, but reading threads here, it appears it's not uncommon!

The 2 shops I have dealt with in the past are quoting between $400 and $500 for the replacement including parts.

Is that price reasonable?

Comparing Ford to Autozone parts, the prices are pretty similar. Are the aftermarket shackles any better than Ford? Or vice versa?

I saw a thread that used the Warrior shackles, and they look much stronger than original. However, with the air ride, I wonder if it would cause any issues? The rear end *is* sagging a little bit.

Is there anything else we should consider replacing while we do this?

Any feedback is appreciated. It *almost* looks like something I could do in my driveway, but I am a little nervous about the process. So I probably should let a professional do it.

 

[ramren16]

if you look on this website you can find instruction on how to install the warrior shackles its not hard at all may take an hour or so i wouldnt pay $400 to have this issue fixed you can get the new shackle for $60ish and have no problem with interferance with the air ride

 

[sport97]

http://www.explorerforum.com/forums/showthread.php?t=212451

I helped my friend replace his on his f150, it wasn't that bad, and his shackle was snapped and jammed into the floor of the bed.
500 sounds pretty expensive. The warrior shackles are just about 80 bucks, im not sure about OEM replacements.

The only issues you could run into is rust. I'm not sure how big of an issue that is where you live. If you do it spray it all down with PB blaster before attempting it.

 

[KRWebster]

I paid $10 for a pair of used shackles for my '97 at a salvage yard. I was lucky in that someone had already extracted the rear axle and cut the rear springs off in the process. Bolts from the shackle to the frame came out real easy. Left me with two shackles....two shackle to frame bolts and two shackle to leaf spring bolts.

The real problem I had was extracting the shackle to frame bolts off of my car. Wouldn't budge. PB Plaster, Kroil, heat, air chisel, BFH.....nothing touched it. Finally cut the bolt and shackle down on the inside of the frame and pushed/pounded out the bushing. Used a ball joint press (can be borrowed for free from most auto parts stores) to push the bushing up to the frame then a large socket and my BFH again to pound it the rest of the way out. Wish I hadn't wasted so much time trying to save them as they were hopeless.

Bought two new bushings from the dealer for about $7 ea. These are generally not stocked so plan on a couple days to get them if you need them. Used a ball joint press and easily pushed the new bushings in to place. Used the bolts from the junk yard too. While I did clean the rust off of the used shackles, I probably should have used rustoleum to repaint them them, too. Just couldn't stand to have the thing in my garage anymore and wanted it out!

My advice would be to prepare yourself to install new bushings if you have to. Don't waste hours like I did trying to get the bolts out.....and certainly don't spend $400 to have this done.

As for your sag....welcome to the club. I used the add-a-leafs (it's what got me on the shackle repair in the first place, thankfully, as mine were toast) from Summit Racing and put me back to normal. $55 once I bought bigger center pins than the ones they sent me. Dorman Industries makes them. Ford does not offer them through the dealer...at least that's what two different dealers told me.

Also, swap the leafs from right to left and vice versa to account for the additional weight of the driver and gas tank that the left spring has had to support after all these years.

If you do the Add-A-Leafs as others have done and decide that you want the larger diameter bolts, just make sure the head fits into the bottom of the axle. I had to grind the tops of mine down just a bit to get the leaf to snug up to the axle.

Good luck, brutha!

 

[johnwartjr]

Well, we tackled it today.

2 new shackle kits from NAPA

6 hours + a lift at a relative's workshop

Had to cut 3 of the 4 bolts with a 4 inch cut off wheel, just wouldn't budge. 4th one (upper passenger side) came out real easy.

Ended up saving about $350 doing it ourself.

Looking forward to never replacing these again. 2nd one looked intact, but basically crumbled as we took it out.

 

[KRWebster]

Well I agree with you. That job is one big P-I-T-A. Funny how you can have some of those bolts just slip right out and others require a small tactical nuke to get them to budge. I used a TON of grease on the replacement bolts. Very satisfying when it's done for sure but....let's hope neither one of us have to do THAT job again.

Congrats on gittin' 'er done!

 

[BlueOvalProud]

Replacement Rear Shackles

I had the same problem with rusted out shackles on a '96. Ditto on a few of the bolts just not wanting to come out easy also. I ended up getting replacements on eBay. It was a complete set, bushings and all. Paid about $70.00. Had them in two days. Installing them took considerably longer.

Can't emphasize more the liberal addition of some sort of chassis grease to the bushings. I really think that the bushings froze up and that was what really did in the shackles. Five years of NWPA road salt started the process but froze up bushings led to failure.

 

[Samhogue410]

01. XLT rear end sag

Just wondering if rear end sagging is caused by bad leaf springs/shackles. Live in the city with no garage so cost wise what would it run me? I like off reading but noticed the sag has become worse over the last few months. Want it lifted before winter so within the next few weeks

 

[2TimingTom]

The sag isn't because of the old factory shackles- unless they are broke. The sag is because the leaf springs are worn out and flatten out over time.