Leaf Spring Replacement (2500, 3500)

Leaf Spring Replacement (2500, 3500)

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

Note: Support the axle independently from the vehicle.

2. Support the rear axle to relieve the tension on the leaf springs.

Note: For the 3500 Cab chassis vehicles, the auxiliary fuel tank must be removed to service the left or right rear shackle bolts.

3. Remove the auxiliary fuel tank assembly, if needed. Refer to Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) Removal and ReplacementFuel Tank Replacement (15 Reg/Ext/Crew Cab w/34 Gal Tank) Removal and ReplacementFuel Tank Replacement (Cab/Chassis - Rear) Removal and ReplacementFuel Tank Replacement (Cab/Chassis - Front) Removal and ReplacementFuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) Removal and ReplacementFuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) Removal and ReplacementFuel Tank Replacement (15 Rec Cab With 26 Gal Tank) Removal and ReplacementFuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) Removal and Replacement




4. Remove and discard the rear spring U-bolt nuts (1) and the washers (2). Replace with NEW only.

5. Remove the rear spring anchor plate (3).




6. Remove and discard the rear spring U-bolts (1). Replace with NEW only.




7. Remove the rear spring front bolt (1).

8. Remove the rear shackle nut and bolt from the frame. Refer to Rear Spring Shackle Replacement (2500/3500 Series) Service and Repair




9. With the aide of an assistant, remove the leaf spring assembly (1) from the vehicle.

10. Remove the rear leaf spring shackle, if needed. Refer to Refer to Rear Spring Shackle Replacement (1500 Series) Service and RepairRear Spring Shackle Replacement (2500/3500 Series) Service and Repair

Installation Procedure

Note: DO NOT tighten the rear shckle to specifications, leave loose.

1. Install the rear leaf spring shackle, if needed. Refer to Refer to Rear Spring Shackle Replacement (1500 Series) Service and RepairRear Spring Shackle Replacement (2500/3500 Series) Service and Repair




2. With the aide of an assistant, position the rear leaf spring (1) in the vehicle.





Note: DO NOT tighten the rear spring front bolt or the rear shackle nut and bolt. Leave the bolts lose to allow the rear spring assembly to move.

3. Install the rear spring front bolt (1).

4. Install the rear spring shackle to frame bolt. Refer to Rear Spring Shackle Replacement (1500 Series) Service and RepairRear Spring Shackle Replacement (2500/3500 Series) Service and Repair.




5. Position the NEW U-bolts (1) on the rear axle assembly

6. Using a hydraulic jack stand, lift the rear axle assembly until the it comes in contact with the rear spring assembly.





Caution: Refer to Fastener Caution Fastener Caution.

7. Install the rear spring anchor plate (3), washers (2) and tighten the U-bolt nuts (1) in a crisscross pattern to:

* First Pass 100 Nm (74 lb ft).

* Final Pass addtional 180 degrees.




8. Tighten the rear spring front bolt to, 220 Nm (162 lb ft).

9. Tighten the rear spring shackle to frame bolt. Refer to Rear Spring Shackle Replacement (1500 Series) Service and RepairRear Spring Shackle Replacement (2500/3500 Series) Service and Repair.

10. Install the fuel tank assembly, if removed. Refer to Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) Removal and ReplacementFuel Tank Replacement (15 Reg/Ext/Crew Cab w/34 Gal Tank) Removal and ReplacementFuel Tank Replacement (Cab/Chassis - Rear) Removal and ReplacementFuel Tank Replacement (Cab/Chassis - Front) Removal and ReplacementFuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) Removal and ReplacementFuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) Removal and ReplacementFuel Tank Replacement (15 Rec Cab With 26 Gal Tank) Removal and ReplacementFuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) Removal and Replacement.

11. Remove the rear axle support.

12. Remove the safety stands.

13. Lower the vehicle.