BigOffroad 6" leaf springs

Nov. 01, 2005 By ORC STAFF

Many people want to run bigger tires so they can run the tougher trails with not just rocks, but boulders. Up until recently the only way to get high enough to clear those big meats was to get custom springs made, which takes a long time and is often pricey. Well John at BigOffroad decided he wanted big leaf springs for his xj and his customers did too The BOR springs drop shipped directly from Alcan spring are heavy duty military wrapped springs that are built specifically to run an XJ offroad. With plastic gliders between each leaf and bolt spring clamps make these things setup for flex. John knows that with the cargo room XJ's have that people like to haul gear with them. Tools, spare tires, coolers for that cold soda on a hot day. It all adds up and with most springs they barely provide the advertised ride height with nothing in the cargo room. John designed his spring sets to give the advertised lift with 350 lbs of gear in the back. Empty they provide almost 1.5" more than advertised.

The 6" spring packs provide the 6" easily. Actually they gave over 7" empty. The ride is not too soft so the road ride is good. There is still PLENTY of flex though.

 

The BOR leaf springs

 

The Poly bushings

 

Springs with the bushings installed

 

 

 

 

The installation is similar to any other leaf spring install but we'll tell you how anyway.

First you'll have to jack up the rear of the truck and support the frame on jackstands. It needs to be high enough to let the rear axle hang free. Also it's time to remove the rear tires. Unbolt the shocks, and then support the rear axle assembly with a jack. Now all you have to do is unbolt the u-bolts and lower the axle away from the leaf springs. With the axle loose unbolt the front leaf spring bolts and the rear bolts at the shackle. The front bolt may be rusted inside the spring eye or it may break the nut loose from the weld inside the frame. If it starts to come out but the stops, then it's probably stuck in the steel sleeve in the bushing. You'll have to cut the bolt to get it out. If you can't get it loose at all, and it suddenly breaks you've probably broken the captive nut inside the frame. The only way to go on from here is 1 of 2 ways. 1.) You could cut a small hole in the floor above the bolt so that you can use a wrench to hold the nut. 2.) You can use a hole saw and cut a hole on the inside of the frame rail so that you can stick a socket through and hold onto the nut. Either way you're in for some extra work.

Once you've gotten the old leaf packs out of the way you're halfway there. Now install the poly bushings that came with the BOR springs make sure you use plenty of the grease that's supplied with the bushings. Also along with the springs you'll need to install an axle shim. I found that a 6 or 8 degree shim should do the trick with the 6" leaf packs. When that's all done you're ready to bolt them in. Install is the reverse of the removal. Bolt the springs into the front spring pocket and to the rear shackle. Then raise the axle into place with the jack and bolt on the u-bolts. Bolt the shocks back on (which may be too short for the larger springs.)

Bolt the wheels back on and take the truck off the jackstands and you're ready to go!

The old rear springs (and axle)
The new leafs installed - axle shim is silver

 

Easily clearing 36's
From the rear

 

close up of the clearance


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