Belltech 6400 Shackle Install on a 91 Ranger

[Kona]

Please scroll down four posts to find the much improved version

 

[mjonesjr]

Can you break your explanation down to steps? If so, I will have it put in the tech library.

 

[HndMeDnBroncoII]

if u have spare wrench u can bend it ninety degrees so u dont have to remove the box.
nice info though appreciate it

 

[Kona]

Can you break your explanation down to steps? If so, I will have it put in the tech library.

Just saw your response, give a a couple of days sir and steps you will have!

 

[Kona]

Here you go the document has the proper formatting lol

Gen II Ranger Belltech 6400 Shackle Install

Written By Kona

Difficulty: 5 out of 10

Time to install: Should take 1 hour without a torch, if you have to remove the box add a hour. My install took 7 1/2 hours due to charging batteries for my sawzall.

Disclaimer:
The Ranger Station.com, The Ranger Station.com Staff, nor the original poster are responsible for you doing this modification to your vehicle. By doing this modification and following this how-to you, the installer, take full responsibility if anything is damaged or messed up. If you have questions, feel free to PM the original poster or ask in the appropriate section of The Ranger Station.com forums.

I decided to write this article because I found the information on how to do this a little confusing. My install was a little troubled but should be typical of anyone in the rustbelt.

Equipment needed , 2 jack stands, 2 jacks , pry bar,21 and 22 mm sockets,T-55 Torx socket, PB Blaster, breaker bar (as large as possible) and 1/2 drive ratchet, car and helper, sawzall or torch.

1. I started a week or two ahead of when I wanted to do this by pressure washing out the shackle hanger pockets and then lubing the nuts and bolts every 2-3 days. I had a bit of luck as my springs had been replaced 3 years /25,000 kms ago and I had taken my box off for other repairs a few months ago.
2. I started the work by loosening the 4 shackle bolts (I thought)
3. Blocked the front tires, jack up the truck set the jack stands under the frame and took the wheels off.
4. I figured I would take the upper shackle bolts off 1st so I tackled the pass side first. Soon realized that the nut was turning... hmmn it's not supposed to do that? Checked and found the original nut and bolt had been replaced so the nut just turns. Oops, to get a wrench in there the box has to come off or you need a custom shortened wrench.
5. Optional: remove box ( 2 people required ) Remove 6 bolts with great difficulty and a breaker bar with T55 torx bit, disconnect the wiring harness plug to the taillights and the 3 small bolts holding the fuel filler neck in and lift and remove . Pictures in thread here. http://www.therangerstation.com/forums/showthread.php?t=31035
6. A few minutes later back at work, upper bolt removed lower loose, great, now to do the same on the driver’s side. Crap... broke the upper shackle bolt, hmm is that why the passenger side was replaced? So now we cut, tip here…. sawzalls work better if they do not need batteries (Corded or a torch) but if they do 1 hour chargers make it not a complete disaster just tedious. After a lot of hard work and a few blades we cut that sucker out of there and got a replacement bolt from our local auto parts store.
7. Stock shackle rear view

8. Front view

9. Install the new shackles, with no box to set a jack against to jack the spring ends down I had to use a pry bar under the frame to push the spring down, set the shackle in top end first (thought it would be easier ) ran the bolt and nut in and pried again to do the lower bolt ( yes I had a second person helping ) repeat on other side. Torque all spring bolts to 74-115 ft lbs.
10. Put the wheels back on, lower the truck torque the wheel nuts to 100 ft lbs
11. Optional , re-install the box, tightening the box bolts ( 2nd gen ) to 40-50 ft lbs. yes I know I will have to take the box off to get at the upper bolts again , I guess you could tack weld the nuts in but I did not have a welder.
Finished product
Belltech 6400

View from rear above, from front below

12. Got it all cleaned up and put tools away and went for a drive.

My impressions of the shackle lift are that I got a smoother ride and a little more flex, the lift on a two inch longer shackle seems to be 1" -1 1/2 " , very noticeable and I think well worth doing. They cost $65.00 Canadian plus two sawzall blades and a grade 8 bolt/nut pair. Since my install was troubled ,total time counting cleanup and waiting for my Black & Decker 1 hour battery charger to refresh 2 batteries was 7 1/2 hours. I think a torch or corded sawzall would have cut 2 or more hours out of that time.

 

[Kona]

I put the disclaimer and "written by" into the tech.doc and the general post

 

[LittleHorse]

so for a Bronco II this would mean I may have to remove the cab to get to that nut...that sucks. Anybody done this on a BII?

 

[Kona]

haHAHAHAH

 

[LittleHorse]

yeah...sounds like I should just dismiss this mod as a possibility. No WAY I'm going that far for 1.5" of lift. I'd rather spend $400 on new Skyjacker 4" lift springs.

 

[mjonesjr]

so for a Bronco II this would mean I may have to remove the cab to get to that nut...that sucks. Anybody done this on a BII?

I did it on my Bronco II. If you use a 1/2" drive ratchet and a pipe on the ratchet for a ratchet extension, it will break lose. I did the install on my BII in about 45 minutes.

 

[LittleHorse]

I did it on my Bronco II. If you use a 1/2" drive ratchet and a pipe on the ratchet for a ratchet extension, it will break lose. I did the install on my BII in about 45 minutes.

I looked at mine last night when I was replacing the gas tank and had that little plastic trim off between the body and the bumper so I could see - that nut on the other side of the shackle-to-frame bolt is easily accessible from the top with a wrench. Looks the Ranger guys are the ones who have it tough...with the bed blocking it.

 

[Crunchy]

Hey, I am doing this project soon. What size grade-8 bolts did you need, I would rather get them ahead of time instead of taking them off and then running to the store.

Also, I notice in this pic that the new shackle is wide than the old one by what, maybe a 1/4", and mine are the same, is this normal with the extra space between the shackle "forks"?

 

[Kona]

Got the bolts from Lordco auto parts , no idea how big bolts are , the spring bushing walked over its not the shackle width.

 

[ForOffRoadDriving]

the bolts should be 14mm, but 9/16" may fit.

 

[MountainMike]

It may cost a little more but I just got new nuts & bolts from work. We even had some of the nuts in stock but had to order the bolts from the Ford PDC in Edmonton.