leaf pack help URGENT!

[Even]

I'm trying to get my new RE 4.5 leafs in right now and i have a dilemma. One of the bushings (the other is fine) is too small for the stock size bolts to go through. The side closest to the front obviously has to utilize the stock size because the bolt is welded inside the uniframe and you can't just use a different size bolt.

Ok, so i tried using a different size bolt for the shackle mount side which then puts the center pins too far back and nothing lines up right.

Is it possible that they pressed a smaller bushing in by mistake? Should i just punch the bushings out of my rustys packs and re-use them?

[XJFez]

I'm not sure if i remember perfectly which is horrible b/c i JUST installed my 3.5" packs about 2 weeks ago, but there is a metal sleeve inside the bushing that the bolt goes through right? If so read on.....how far off are you in size? I'm thinking if its close, and it were my problem....id put the pack in a vice, grab a punch of the correct size and just hammer it in...twist it around w/ some vice grips and hope that it spreads the metal sleeve enough to get the bolt through....thats the only thing i can come up w/ at the moment...also, depending on how far off it is, maybe drill part of the sleeve out? I dont recommend that though. Good luck, i'm sure someone else will chime in.

[Even]

Yea there is a metal sleeve but it's off by quite a bit. I thought about drilling it out slightly but i'm not so sure about that. The punch idea i don't think will work either.

I just tried punching the metal sleeve out but that seems like a lost cause with the tools i have right now.

[XJFez]

Hmmm...did you measure the O.D. of the bushing? Is it the same as the one on ur other leaf pack? And measure the I.D. of the leaf pack that wraps around the bushing, i guess if its the same as the other pack, swap the bushings if it needs to be done ASAP.

[crosbike]

The metal bushing is bonded to the rubber so you cant just push that out.

[Even]

They definetly pressed the wrong size in by mistake btw, the bolt will slide through the other 3 bushings perfectly

Also the bushing doesn't flinch when beaten by a BFH in a vice, just so ya know

[crosbike]

lame. call them up and bitch. you get my pm?

[Even]

yea i got it, check will be in da mailbox tommorow

[XJFez]

you might have more luck "pressing" it out instead...have anything to give that a try?

[Even]

I don't really have anything i can think of that would press it out. I'm thinking my only option is to drill it slightly larger.

The sleeve isn't a complete circle, the ends just wrap around and touch eachother. I tried using a punch to hammer it in and open it up but the punch only goes so far, and as soon as i pull it out the rubber pushing closes it back up smaller.

Bitching tommorow and sending it back to get a new bushing isn't really an option for me, i can't be taking up my mothers garage bay for 1-2 weeks.

[Pat]

reamer? or a drill press

[Even]

I'm just drilling it out with a normal drill bit, i tried to use the drill press but it's almost impossible to get the whole leaf pack up in the air while keeping the bushing perfectly straight.

I figured i would have it rolling by now but i guess not

[DrThunder]

You may get fucked when trying to drill that. If/when that bit decides to grab very hard it will rip the sleeve from the bushing and pretty much ruin the thing. The heat from drilling won't help the situation either.

[Jeepbonehead]

what is the O.D. of the bolt i have a bunch of the sleeves from random shit, you could press out the sleeve and put in a new one

[XJFez]

wow, i'm bent man, i feel like there is something stupid we must be missing....do you have maybe a C-clamp or something you can torque down on it to push the whole bushing out? is it so far off that if you were to just pound the bolt through w/ a hammer it would strip the threads clean?