P1200010.JPG
5806 hits | 73.19 KB | Posted: 1/21/07
Remove the lug-nut wrench from under the hood of your Excursion. We'll use the end with the rubber tip to remove the beauty cap on the front wheel.
(Posted in: V-Code Leaf Spring Installation)

P1200011.JPG
5721 hits | 73.71 KB | Posted: 1/21/07
Pry off the lug nut wheel cover.
(Posted in: V-Code Leaf Spring Installation)

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5679 hits | 70.01 KB | Posted: 1/21/07
(Posted in: V-Code Leaf Spring Installation)

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5976 hits | 57.79 KB | Posted: 1/21/07
Before jacking up the front end, I measured the height from the ground to the top of the wheel well. You may want to do this too so you can compare the height after you install the V-Codes.

Stock Excursion leaf springs before the spring swap creat...
(Posted in: V-Code Leaf Spring Installation)

P1200021.JPG
7112 hits | 71.36 KB | Posted: 1/21/07
This install covers the passenger side leaf spring. When jacking up the passenger side, position your floor jack like I did in the above picture. If you're doing the driver's side, you can position the floor jack under the front differential.

[b]T...
(Posted in: V-Code Leaf Spring Installation)

P1200022.JPG
6197 hits | 80.22 KB | Posted: 1/21/07
Since we'll need to jack the truck up and lower the front end, I jacked the front end under the axle tube as high as my floor jack would go.

Using a 6-ton jack stand, position the jack stand under the frame rail behind the rear mount of the front ...
(Posted in: V-Code Leaf Spring Installation)

P1200023.JPG
5901 hits | 64.32 KB | Posted: 1/21/07
With the vehicle secured on jack stands and your floor jack still maxed out under the front axle, now it's time to remove the wheel.

[b]Tools needed:[/b]
21mm deep socket
1/2" impact wrench
(Posted in: V-Code Leaf Spring Installation)

P1200024.JPG
5900 hits | 79.95 KB | Posted: 1/21/07
With the wheel removed, we can now remove the lower shock bolt. We need to disconnect the shock so we don't over-extend it when we drop the front axle in a later step.

[b]Tools Needed:[/b]
You'll want air tools. This bolt will probably be very ru...
(Posted in: V-Code Leaf Spring Installation)

P1200028.JPG
6564 hits | 80.64 KB | Posted: 1/21/07
With the lower shock bolt removed, you can compress the shock as much as possible to get it out of your way for the rest of the project.

You may also lower the floor jack to the point where the leaf spring is not compressed and the floor jack is b...
(Posted in: V-Code Leaf Spring Installation)

P1200029.JPG
5805 hits | 61.4 KB | Posted: 1/21/07
With the shock disconnected, we can now remove the nuts on the u-bolts. My u-bolts actually turned out to be in great shape so I decided to reuse them (considering the dealer sold me the wrong ones in the first place).

[b]Tools Needed:[/b]
21mm d...
(Posted in: V-Code Leaf Spring Installation)

P1200032.JPG
5567 hits | 65.15 KB | Posted: 1/21/07
All 4 u-bolt nuts removed.
(Posted in: V-Code Leaf Spring Installation)

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5527 hits | 76.19 KB | Posted: 1/21/07
Slide the u-bolts out from the top. They pull out quite easily.
(Posted in: V-Code Leaf Spring Installation)

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5698 hits | 77.51 KB | Posted: 1/21/07
All 4 u-bolts removed. Notice the round mark on the bump-stop from the rubber stopper. This is from constant bottoming-out of the suspension!
(Posted in: V-Code Leaf Spring Installation)

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5600 hits | 82.01 KB | Posted: 1/21/07
Lift the bump-stop off of the leaf spring.
(Posted in: V-Code Leaf Spring Installation)

P1200036.JPG
5504 hits | 57.38 KB | Posted: 1/21/07
Here are the new u-bolts (left) and my original u-bolt (right). Notice how my original u-bolt is more of a "rounded square" than a square. Make sure to double-check your u-bolts with new u-bolts, if you buy them.
(Posted in: V-Code Leaf Spring Installation)

P1200041.JPG
5656 hits | 74.65 KB | Posted: 1/21/07
Unfortunately, the front leaf spring eye-bolts are not easy to get to, so you have to remove the corner bumper supports.

[b]Tools Needed:[/b]
13mm socket (for the bumper-support bracket bolts)
impact wrench
(Posted in: V-Code Leaf Spring Installation)

P1200042.JPG
5597 hits | 76.3 KB | Posted: 1/21/07
There are three 13mm bolts holding the bracket in place. Using an impact wrench makes easy work of the bottom two.
(Posted in: V-Code Leaf Spring Installation)

P1200043.JPG
5574 hits | 73.63 KB | Posted: 1/21/07
The top 13mm bolt for the bumper corner support bracket is in a tight spot. You'll have to resort to a 3/8" ratchet to access this one.

[b]Tools Needed:[/b]
13mm socket
3/8" ratchet
(Posted in: V-Code Leaf Spring Installation)

P1200044.JPG
5453 hits | 70.45 KB | Posted: 1/21/07
Next up, remove the nut from the rear eye-bolt of the leaf spring. Simply punch the bolt through the hole with a hammer. Make sure not to crush the threads. You may need to use a 3/8" extension (6 inches in length) to punch the bolt all the way throu...
(Posted in: V-Code Leaf Spring Installation)

P1200046.JPG
5387 hits | 80.58 KB | Posted: 1/21/07
Prepare to spend a lot of time on this step.

As you can see, I pulled out the Bernz-O-Matic propane torch for the step and headed up the nut bolt to make it a little easier to loosen this nut. Spend about 3-5 minutes doing this, got to the next st...
(Posted in: V-Code Leaf Spring Installation)

P1200048.JPG
5610 hits | 76.45 KB | Posted: 1/21/07
I couldn't fit my impact wrench in this space so I had to resort to using a 1/2" ratchet on the bolt head and a 1/2" breaker bar on the nut. On top of this, I had to use a 3-lb sledge hammer to hit against the 1/2" breaker bar to loosen the nut. I ev...
(Posted in: V-Code Leaf Spring Installation)

P1200050.JPG
5465 hits | 81.51 KB | Posted: 1/21/07
Success! Before you go pounding this bolt out, you'll need to remove a support bracket on the front of the radiator for the trans cooler. Please proceed to the next step -- this bolt will not be able to be removed until the support bracket is removed...
(Posted in: V-Code Leaf Spring Installation)

P1200051.JPG
5560 hits | 74.58 KB | Posted: 1/21/07
With the support bracket from the previous step out of the way, you can now punch the eye-bolt out from the front of the leaf spring. Use a hammer and a 6" extension for a 3/8" ratchet.

[b]Tools Needed:[/b]
6-inch extension for 3/8" ratchet
Hamm...
(Posted in: V-Code Leaf Spring Installation)

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5702 hits | 68.11 KB | Posted: 1/21/07
Before we drop the front axle, we must disconnect the way bar. If we don't, the sway bar will prevent the front axle from dropping all the way and separating from the leaf spring.

[b]Tools Needed:[/b]
13mm socket
1/2" impact wrench
(Posted in: V-Code Leaf Spring Installation)

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5521 hits | 66.61 KB | Posted: 1/21/07
With the sway bar disconnected from this side of the front axle, the axle can now have full range of motion.
(Posted in: V-Code Leaf Spring Installation)

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5563 hits | 75.81 KB | Posted: 1/21/07
Now it's time to lower your floor jack. Keep lowering it until the axle separates from the leaf spring. The leaf spring has a short stud that fits into a notch in the top of the axle. This should separate naturally by dropping the axle with the floor...
(Posted in: V-Code Leaf Spring Installation)

P1200059.JPG
5454 hits | 61.09 KB | Posted: 1/21/07
This photo is actually from the driver's side -- but it applies to the passenger side leaf spring eye-bolt as well. This bolt runs into a support bracket for the cooler that's mounted to the front of the radiator. See next step for removal.
(Posted in: V-Code Leaf Spring Installation)

P1200062.JPG
6429 hits | 80.36 KB | Posted: 1/21/07
The blocker beam on the front of the Excursion was blocking my ability to drop the leaf spring completely out from the front end. So, I removed the blocker beam. There are two brackets on each side (the very rusted brackets). The plastic front facia ...
(Posted in: V-Code Leaf Spring Installation)

P1200063.JPG
5657 hits | 74.01 KB | Posted: 1/21/07
Position 2 jack stands under the blocker beam so it doesn't crash to the ground when you unbolt it.

[b]Tools Needed:[/b]
(2) jack stands
(Posted in: V-Code Leaf Spring Installation)

P1200064.JPG
5873 hits | 74.69 KB | Posted: 1/21/07
Unbolt the nuts from the 3 bolts on each side of the blocker beam.

[b]Tools Needed:[/b]
21mm deep socket
1/2" impact wrench
(Posted in: V-Code Leaf Spring Installation)

P1200066.JPG
6128 hits | 80.07 KB | Posted: 1/21/07
With the 5 bolts removed from each side, you can separate the blocker beam and facia from the front bumper. The rusty bracket will still be keeping everything held together due to the long studs that are binding against the stud holes.
(Posted in: V-Code Leaf Spring Installation)

P1200067.JPG
5840 hits | 78.21 KB | Posted: 1/21/07
Lift the blocker beam bracket out of the holes in the blocker beam.
(Posted in: V-Code Leaf Spring Installation)

P1200072.JPG
5517 hits | 80.63 KB | Posted: 1/21/07
The coast is finally clear to remove the leaf spring. You can use your 3-lb hammer to knock it out of the spring hangers. The leaf spring is somewhat heavy and awkward. I found that rotating it like this in the picture and fishing it out provided the...
(Posted in: V-Code Leaf Spring Installation)

P1200073.JPG
5782 hits | 72.03 KB | Posted: 1/21/07
New leaf spring (left) and old leaf spring (right).
(Posted in: V-Code Leaf Spring Installation)

P1200074.JPG
5761 hits | 69.43 KB | Posted: 1/21/07
New leaf spring (bottom) and old leaf spring (top). There doesn't appear to be a significant difference when compared side-by-side (other than the fresh coat of paint). However, the old leaf springs have 175,000+ miles on them and are fatigued. The n...
(Posted in: V-Code Leaf Spring Installation)

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5470 hits | 74.17 KB | Posted: 1/21/07
The shackle won't initially line up with the leaf spring. No problem, proceed to the next step.
(Posted in: V-Code Leaf Spring Installation)

P1200077.JPG
5490 hits | 77.84 KB | Posted: 1/21/07
Jack the front axle back up with your floor jack. Hopefully the stud in the new leaf spring will align with the notch on the leaf spring perch. If not, you may need a second set of hands to raise/lower the jack while you use your body to lean into th...
(Posted in: V-Code Leaf Spring Installation)

P1200078.JPG
5417 hits | 79.8 KB | Posted: 1/21/07
Reinstall the bump-stop/u-bolt plate. The notch in the bump-stop lines up with the nut on top of the leaf spring.
(Posted in: V-Code Leaf Spring Installation)

P1200080.JPG
5727 hits | 76.08 KB | Posted: 1/21/07
Reinsert the eye bolt in the front of the leaf spring first (save the rear bolt for the next step for easier installation). The front spring mount is stationary while the rear spring shackle does pivot -- thus making it easier to install the rear eye...
(Posted in: V-Code Leaf Spring Installation)

P1200081.JPG
5441 hits | 69.34 KB | Posted: 1/21/07
Reinsert the rear bolt and tighten.

[b]Tools Needed:[/b]
24mm socket (nut)
21mm socket (bolt head)
1/2" ratchet or breaker bar
1/2" impact wrench
(Posted in: V-Code Leaf Spring Installation)

P1200082.JPG
5304 hits | 80.14 KB | Posted: 1/21/07
Reinstall the u-bolts and tighten with the new nuts (discard the old nuts). Hand-tighten at first, ensuring each nut is threaded evenly, then tighten with a breaker bar.

[b]Tools Needed:[/b]
21mm deep socket (nuts)
1/2" breaker bar or impact wre...
(Posted in: V-Code Leaf Spring Installation)

P1200083.JPG
5225 hits | 72.63 KB | Posted: 1/21/07
Re-attach shock with lower shock bolt.

[b]Tools Needed:[/b]
21mm socket (for bolt)
15mm socket (for nut)
1/2" ratchet
1/2" impact wrench
(Posted in: V-Code Leaf Spring Installation)

P1200085.JPG
5737 hits | 71.42 KB | Posted: 1/21/07
The completed install! There's actually room for spring travel again.

[b]Conclusion[/b]
This project was painfully drawn-out as I struggled with seized bolts and identifying the most efficient way to disassemble and reassemble. Once finished and ...
(Posted in: V-Code Leaf Spring Installation)

P1200089.JPG
5449 hits | 50.71 KB | Posted: 1/21/07
Fortunately for us, this bracket is simple to remove with a 3/8" ratchet and an 8mm socket. It's somewhat hidden behind the rubber radiator support strap -- just hold it aside with one hand while you use your ratchet on the bolt. Fish the bracket out...
(Posted in: V-Code Leaf Spring Installation)

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5439 hits | 67.18 KB | Posted: 1/21/07
I also wanted to show this bolt from the driver's side angle as well. You may run into the issue where the front driveshaft interferes with the bolt. Simply jack the floor jack up to create enough room for the bolt to clear the top of the driveshaft.
(Posted in: V-Code Leaf Spring Installation)