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Old 03-12-2012, 07:47 AM   #1
brctitle's Avatar
Join Date: Jul 2011
Location: Arlington, VA
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New leaf springs, and associated issue

so I finally completed a two-months-long replacement project. Replaced the sagging stock leafs on my '95 4.0L with Pro-Comp, just about the cheapest kit I could find (college student budget). The Jeep stands tall and proud once more.
By the way, since the spring bolts fused to the sheaths inside all eight bushings, I had to cut through them. That was what took so long, since I'm working with a floor lift from Jiffy Lube that is only available Sundays after 4pm. I tried several times to cut the bolts with a sawzall, and it really isn't effective. A 3-inch pneumatic cut-off wheel costs twenty bucks with a ten-pack of blades and takes care of the job in minutes, instead of hours. Go with that, not a reciprocating saw.

So, here's the new issue:
Manual transmission. When I start moving, either forward or reverse, I hear a loud clunk from what sounds like the rear driveline, as soon as I engage the clutch. It also happens when I engine brake. It started happening immediately after I did the lift. Can anyone tell me what's going on, and how to fix it?
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Old 03-12-2012, 08:20 AM   #2
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Location: Asheville, NC
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When mine did that after installing my springs, I just hadn't torqued the u-bolts down enough. I went with a spec I read on here, though I don't remember what it was, and when I actually put a torque wrench on it, I was surprised how loose they were. Fixed the clunking for me.

'95 YJ 2.5L, 5-sp, 2.5" lift, 31" Pro Comp MT's

'62 Willys pickup Super Hurricane L6
Original, disassembled and in slow progress.
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Old 03-12-2012, 11:15 AM   #3
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Location: Spokane, WA
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Same symptoms happened to me when I installed my BDS springs. Turned out the center pin was too long and didn't allow the perch to fully seat. This allowed the axle to rock when under acceleration or braking.
Originally Posted by wmpiehl
Haha, just don't let Mitch teach you how to wheel, he is really scary
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Old 03-12-2012, 11:31 AM   #4
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Location: Arlington, VA
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Come to think of it, I did use air-impact to replace the u-bolt nuts, so they might be under-torqued. They were somewhat rusted, especially in front, so I didn't want to strip them. Maybe they need replacement. Should be fairly simple to check, though. Thanks! Will inform as I fix it.
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Old 03-12-2012, 12:14 PM   #5
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new hardware is always a good idea when lifting
how high did you lift it?
could be the old u-joints binding
what does your driveshaft angle look like?
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Old 03-12-2012, 01:43 PM   #6
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Location: Arlington, VA
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Tightened the u-bolts: front were nice and tight, but I'm amazed I didn't catch that the rear bolts were little more than hand-tight. I took it for a spin and the problem seems solved.
Timberwolf, I wasn't really aiming for much of a lift. The springs are set to add 2.5 inches all around. I guess the old springs were just sagging badly, because overall the rig seems about six inches taller.

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