Cost of Leaf bushing replacement vs 05 swap - Page 2 - Ford Powerstroke Diesel Forum
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post #11 of 23 Old 01-23-2016, 10:32 AM Thread Starter
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I did the turning test this morning with the wife at the wheel. No movement at all in the forward or rear leaf bushings. Later today im going to build a gopro mount to be able to record under the truck while driving. I did find a twisted leaf bracket, the guy did mention that the sound is coming from the leafs moving up and down over the bracket and the clunk is from the leafs catching the top of the bracket. I will see if I can get a video of this happening, maybe this is the twist he was talking about. I took pics of the leafs just to see if your trained eyes can spot something odd, I dont do any suspension work so I couldnt tell what was normal or not.

Drivers side aft of axle. It is pouring rain so you will see some water drops in the pics. Just to the left of the water drop is the guide bracket that I found is twisted. EDIT- After I looked at this pic I noticed my sway bar looks like its bent, hanging lower on the passenger side. When it stops pouring outside I will go take a look at that too.


Drivers side forward of axle


Passenger side aft of axle


Passendger side forward of axle


Top and bottom view of the twisted bracket on the drivers aft axle



This bottom view of the spring looks like the springs are not aligned, the top spring is shifting outboard of the lower spring, I would assume that they should be perfectly aligned on top of eachother?

Last edited by shordinges; 01-23-2016 at 10:48 AM.
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post #12 of 23 Old 01-25-2016, 09:09 AM
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Gopro it!.

Can you see any shiny rub marks at the bracket?

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You will get some axle wrap with a heavy trailer, I can feel it when towing my gooseneck with some heavy equipment. My Deavers will wrap enough to make the tires rub the front of the rear fender well if I give it too much throttle on aceleration.
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post #13 of 23 Old 01-25-2016, 09:14 AM
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twisted springs LOL

150.00 = robbery

whack em back in to place
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post #14 of 23 Old 01-25-2016, 09:17 AM
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Those leaf springs and even the hanger setup does look messed up though....

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You will get some axle wrap with a heavy trailer, I can feel it when towing my gooseneck with some heavy equipment. My Deavers will wrap enough to make the tires rub the front of the rear fender well if I give it too much throttle on aceleration.
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post #15 of 23 Old 01-25-2016, 09:28 AM
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Those springs are bent. They are junk. You need all new springs.


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post #16 of 23 Old 01-25-2016, 09:49 AM
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See how the ends of the springs are touching. On your pic the eye has rotated and you have a big gap between the springs.
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post #17 of 23 Old 01-25-2016, 09:54 AM
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Cost of Leaf bushing replacement vs 05 swap

Triple post.
@layson I don't know why you have issues getting replacement bushings for rev tech. I've called them and they told me the part number and I called Napa and they had them in stock. Turns out mine weren't bad so I didn't pull them to check though.


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post #18 of 23 Old 01-29-2016, 08:02 PM Thread Starter
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thanks guys for the replies, I dont know enough about the leaf spring suspension to know what it is supposed to look like. After your pics and pointing out the eye its for sure beyond repair. I dropped the axle today and smacked everything to be aligned again and found some other things wrong and fixed them. But now i see what they are supposed to look like and they are toast. I did gopro it but I could not figure out what the rubbing was from.

When the wheels were off I found that both end axle seals are shot and just rolling around the shaft. So axle needs to be pulled apart and possibly rebuilt if water has been getting in there. New springs, unfortunately I have no idea what brand leveling kit was installed so I might have to start from scratch and buy a new kit. Debating again the swap since its all going to be replaced/rebuilt.

What do you guys think caused this? I use this pickup as a daily driver on paved roads, it rarely goes off road. I dont tow and any TRUCK use it gets is loading the RZR in the bed. The eyes have opened up about 1/4 of the way.

Procomp has spring sets for about 130 each but i need to figure out if the guy before me put in 2 inch, 4 inch, 6 inch...On my truck there are 6 layers but Procomp says the six layer front is a 6.5 inch lift which I really doubt. Any good way to find out?

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post #19 of 23 Old 01-29-2016, 09:51 PM
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Those seals are kinda normal for falling apart. I wouldn't worry about them tell you do ball joints.

How big of a rear block do you have?
From the look of the sway bar it doesn't look like it has extentions so it was most likely not a kit and it was pieced together or just a cheapo leveling kit.

The theory behind the bent leaf springs is. The shackle is too short and runs out of movement when the springs compress. So it has to go somewhere and it bends to springs.


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post #20 of 23 Old 01-30-2016, 12:36 AM
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Based on your pics it looks like the PO put in a eBay minipack kit. The minipacks are short leafs that go under your stock springs, mainly for looks, period. They're garbage and damage your already worn out stock springs further. Not to mention make the truck ride like crap. Leaf springs aren't supposed to have spaces between them lol.

If you still want the leveled stance then the bds or procomp kit will be what you need. They come will full leaf packs that are built for more then just looks, shocks, and the required hardware which is a must whenever changing springs. The kits run about $500 plus a few hours of install so it will probably cost about $1,000 all together. You'll also need an alignment after.

If you want to lower the truck then you can always buy stock springs and hardware which will save you maybe a hundred or two on parts. You'll also need to downsize your tire size if you have big tires on currently as stock can only run 33x11.50 as the biggest I believe.

Can't tell from your pics but you may also have the stock trackbar and your axle is uncentered putting a little bit more stress on the leaf mounts. If it is a minipack kit then chances are it didn't come with an adj. Trackbar or mounting brackets to center it properly.

My guess is, is those pops/noises you're hearing is most likely the stress being put on your springs during normal flex when driving. Since your stock springs consist of 2 springs and there is nothing under them on the ends to help support them, they're being put past their limit with the added pressure being put on from the middle with the spring pack/axle. The pro comp/bds leveling kits have full length leafs to support the ends of the top leafs making them stronger, smoother and longer lasting.

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Last edited by Horizon122; 01-30-2016 at 12:45 AM.
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