How To ...

[reckless]

Hi everyone, Its been almost 1 year now i am trying to rebuild My Cj.
leaf Springs 1.5'' , front shackle , Shackle length Bot to bolt (3.5'') -- over all length is 5"....,back shackle mounts are extended almost 3'' out side the frame.29.1'' radial tires. Diesel Engine 3000cc B2 (Coaster) , Steering Box from toyota. I have no idea about the specs of differentials and trasfer case. Its 4 speed fwd.

Problems:
Bumpy ride , wanders alot , left turn is smoother than the rite one. Front is very noisy . Vibration when u start slowing down speed.(Need advice on pinion angle as well). I am not comfortable while driving its bit scary in short. I have attached few pics . i want you guys to keenly observe the pics and guide me.

It is bit hard to find wrangler leaf springs over here . i was planning to go for 2.5'' to 3 '' wide leafs . 0.5'' futher extension of shackles over all 4'' bolt to bolt.
I NEED YOUR EXPERTIESE.

 

[BusaDave9]

You have home made shackles made from angle iron. I don't know where the steering gearbox is from but it's not a jeep. I have never seen such a big weight on a drive shaft. Is that needed to balance it?
I would start by replacing the shackles and bushings. If you want to replace the springs do it now too.
It looks like you need a CV joint at the rear of the TCase. That's too much of an angle and although I cant tell from your picture it looks like the rear diff is almost pointing to the TCase. Check out this link:
http://www.jeep-cj.com/forums/f2/high-pinion-angle-keeping-pinion-bearings-lubed-7529/#post64224

 

[reckless]

Hey Busa Thankx for your reply. I have some wht idea that my rear shaft is causing vibration. Rear Drive Shaft was rebuild . i broke the original one while driving at 90 MPH i guess due to bad pinion angle. I wanted the newer one to be more solid .What do you suggest droping down the trasfer case about an 1'' will solve the problem or not . Actually i have placed SHIMS under Rear axel.
Mr Sajan worked on extending the rear leaf mount .. and preaches were not installed at the rite angle . So i used shims.
Steering Box is not frm Jeep. Its from Toyota FJ cruiser again fitting has been customized.
I have attached few details pics in the gallery. Kindly check them out,

 

[reckless]

What is the Stock Shackle length of CJ5 ??
2.5'' lift means adding up another 2.5 to stock ??

 

[BusaDave9]

I took a look at your gallery.

​

Nice CJ5 ! We can't get doors like that around here. Do you have 2 gas tanks?
Sorry to get off track.
A CJ shackle is 3 inched long. If you get a shackle that is 2 inches longer it only lifts the jeep about 1 inch because you are only lifting one end of the spring.
Yes, it may help the drive shaft to lower the TCase. You want to keep both U Joints at about the same angle so you may not need shims at the rear axle.

It looks like you may have too much angle at your TCase so you might be better of with a CV joint but then you need your axle pinion gear to point to your TCase.

 

[reckless]

i am at work rite now will let you know the length of the rear drive shaft.. i think its too short will not be able to manage to install CV..
Note : CV Shaft will be fabricated locally..
The Doors they are pretty cheap they were around US$70.00 including locks , handle , hinges all the necessary hardware.
My jeep looks gr8 frm a distance but from inside its bit screwed up . i am ready to spend few bugs outta my savings but i just need to be sure where do i need to spend. and its only suspension and steering... a little work on brakes as well..

Brake Padle is very spongy and sensitive as well. ultimately it hits the floor. My mechanic says it is due to the double valve servo system.. i am not satisfied with his answer . if you can guide me it would be of gr8 help.
i will be traveling to another city 400 miles away to get my rig some what comfortable. People over there are good in jeep thingy coz they cater the customers UP North . Jeeps are the best machienes for our Notheren area.
Will be planning a Journy to Fairy Medows Near to Naga Parbet ( Killer mountain ) as soon as i am done with my Rig. the whole plans gona take 2 months . then in winters i'll be busy Hunting.

 

[reckless]

Okey so we are done with drive shaft .
what about the wandering problem , due to short wheel base , i have to go for wider springs in any case. I cannot afford to change the front differential / axel.so i was thinking of just wider springs , 31' tires , and back wheel spacers.
wht is the optimum shackle length ( bolt to Bolt ).? This rig was orignally shackle reversal i moved the shckles to front.
I use this jeep for Hunthing as well . But i want it comfy on the carpet road as well.
i know the pros n cons of shackle reversal .
You are more experienced so wht confrigations you suggest ? i want it to be true off road Rig at the same time my daily use vehicle .

 

[BusaDave9]

No need to replace the front axle. Here is an excellent article to help with your steering.
http://www.jeep-cj.com/forums/f19/troubleshooting-correcting-your-steering-4106/
I have driven a CJ3a that had a terrible wander. When the jeep was sitting still and you turn the steering wheel side to side it would actually move the axle to the side before turning the wheel. That was caused by bad bushings and shackles. You may have the same problem. It is hard saying for sure so first check out the link above.

Check your front bushings. The stock shackles are 3 inches long. The front shackles and bushings are very important to the stability of a Jeep.

 

[Sasquach]

Brake Padle is very spongy and sensitive as well. ultimately it hits the floor. My mechanic says it is due to the double valve servo system.. i am not satisfied with his answer . if you can guide me it would be of gr8 help.
i will be traveling to another city 400 miles away to get my rig some what comfortable. People over there are good in jeep thingy coz they cater the customers UP North . Jeeps are the best machienes for our Notheren area.
Will be planning a Journy to Fairy Medows Near to Naga Parbet ( Killer mountain ) as soon as i am done with my Rig. the whole plans gona take 2 months . then in winters i'll be busy Hunting.[/QUOTE]

That sounds more than a bit scary! , the brake thing that is.
Spongy and ultimately hits the floor sounds like air in the system and a good fluid flush/bleeding would help there, the sensitive part for me says they need to come apart for a look at the drums/shoes and or rotors and pads.
Your mechanics double valve servo answer is hog wash(noncense).

 

[reckless]

Hey Busa can you help me to identify few thing. here is the image of T case



rear axel





FRONT AXEL

 

[BusaDave9]

I don't go by the numbers stamped on the casing but I can try to look them up.
It looks like you have a Dana 20 TCase. They look similar to a Dana 300 I usually tell the difference by how the shift levers are attached. A picture from the front of the TCase should verify it's a Dana 20 .

The rear end looks like an AMC Model 20. It has a very round differential cover. Like this:

 

[reckless]

Hi all,
i need Your opinion on few things, Rear Drive shaft Length is aproxx 15'' / Front Drive Shaft length is 31.5'' aproxx.
1) the way draglink is connected to tie rod.
2) Steering arm
3) Rear Shackle
4) Front Differential angel / identifications of Differentials / Transfer Case

 

[reckless]

What is the stock height of leaf spring as shown is fig.?
What should be the optimum height with 4''(bolt to bolt) shackles provided shackle length is balanced with inner steering knuckle.?
Wht should be the optimum width of leaf mine is aproxx 1.5''.?
How many Leafs should be there ?
Length of leaf springs eye to eye ?

 

[reckless]

Just wanted to remind .. this Rig will be mostly used for hunting / off road... Means i'll be traveling on high ways to reach the spots and off road . so after giving all the specs and pictures i want you guyz to give me good directions as i'll be starting this project shortly.
wht modifications i should go for ..?
you have answered this question few times b4 as well but the reason behind asking these little things is that i have to fabricate each and everything .. nothing is available as such in the market ..
e.g i'll look for some 2nd hand leaf springs meeting my demand and close to the specs you folks would give + if i could find bushings and some accessories frm some auto shop

which springs will be best ? shocks , tires , brakes.. drive shaft etc..... All the Little details.
need some guide regarding sway bar as well... what should be the right agnle to install..
Thankx

 

[BusaDave9]

Your front drive shaft is one inch shorter than mine but don't change yours unless you find out it's not right.
My rear drive shaft is 16.5 inches sitting still. I bought a CV joint to handle the drive shaft angle.
OEM springs are 2.5 inches wide but I am more concerned about your shackles and bushings. I would replace them with ones made for a CJ. I think you have too much movement there.
I am sure you have a Dana 30 front axle and an AMC20 Rear end.

 

[reckless]

I am working on the shackles thingy..Your are abolutly rite.. , leafs , shackles, bushing mouts are really screwed up .. so Dana 30 and AMC20 are some what considerable what rating will you give???
Dude i am hunting down the stuff...
what should be the thickness of leaf ?? or kindly give me few specs of YJ leaf springs .

Suggestion needed :
1 . I have alot of weight in the front , i have installed B2 engine
TOYOTA LAND CRUISER Data Library i was thinking to go for 2.5'' wide leafsprings ( 5 leafs )
2 . same specs in the rear but with 4 leafs.
3 . Some one told me about Rear Axel line is bit Foward ????--- I need some explanation / advise on this as well.
4 ) brakes , wheel bearing as u told me b4 i need to replace

Like you said i am also bit more concerened about the suspension .

 

[reckless]

Hey Busa i asked you alot of things b4 as well .. in thread #12 and #13 will be looking foward for something in detail

 

[Buuushman]

As for your differentials, there is a code stamped on the rear diff housing- as long as the diffs are still stock, the stamp will tell you what ratio you have, also if it is open or a Limited slip. There should also be a tag on the front diff.

Bush

Narrow Track AMC20 Code Gear Ratio Diff Type AA 2.73 Open DD 2.73 Trac-Lok BB 3.31 Open CC 3.31 Trac-Lok A 3.54 Open N 3.54 Trac-Lok GG 3.73 Open Q 3.73 Trac-Lok L 4.10 Open M 4.10 Trac-Lok Wide Track AMC20 Code Gear Ratio Diff Type D 2.73 Open DD 2.73 Trac-Lok B 3.31 Open BB 3.31 Trac-Lok A 3.54 Open AA 3.54 Trac-Lok H 3.73 Open HH 3.73 Trac-Lok C 4.10 Open CC 4.10 Trac-Lok

 

[BusaDave9]

I really don't want to measure my springs because the important measurement is the distance between the 2 mounts on the frame that the spring and shackle mount to. When weight is on the springs the shackles should be bowed outword slightly. If they are too vertical they could buckle when weight comes off the jeep as you drive.
Soft springs may measure longer before you mount them.
Firm springs may measure as long as the frame mounts and then when weight is on the jeep they may bow out slightly longer than the mounts on the frame.

Here is an approximate method to measure how much lift is in a set of springs but this is when there is weight on the jeep. Remember a lower jeep is more stable.

Your steering linkage does look different than most CJs in the US. Here we have the drag link and the tie rod both connected to the right steering knuckle. Your steering linkages are common on many other vehicles and it may be different because your jeep has right hand drive.

If your tie rod ends are in good shape I don't think they are the problem.
If I were to guess I think your wander is caused by the shackles and bushings. I once drove a flat-fender that had so much wander that it was dangerous to drive over 35 mph. When I stopped and moved the steering wheel side to side the front axle actually moved side to side before the wheels would start to turn. All the free play was in the shackles and bushings.
You could get shackles like this:

They help prevent flex. But let me add they shouldn't be necessary. OEM shackles work fine.
Also do not use shackles that are too long. Stock shackles are 3 inches.
Make sure you have good bushings. Polyurethane bushings have very little flex.

 

[reckless]

wht about the rear axel line bit foward???