Mountain Off Road 7686-1 User Manual

MOUNTAIN OFF ROAD ENTERPRISES LLC.
P. O. BOX 690 DELTA, COLORADO 81416

970-625-0500

970-625-3747 fax
E-mail: [e-mail]
www.mountainoffroad.com

INSTALLATION INSTRUCTIONS FOR M.OR.E.™ SH ACKLE REVERS AL
SYSTEM S.R.S.™ 7686-1 Please read terms and Policies page 5.

This S.R.S.™ fits 1976-1986 Jeep® CJ5, CJ-7, CJ-8 vehicles with 2” wide front leaf springs. It mounts
the pivot (large eye) end of the leaf spring at the front of the frame and the shackle (small eye) end of
the spring swings from a tube/bushing that is welded in a hole that you must bore through the boxed
frame behind the axle. This method of shackle mounting is far superior to hanging the shackle off a
bracket from the bottom of the frame. M.O.R.E.'s method retains the caster angle as close to stock as
possible and allows for the most clearance under the Jeep®. This system will fit stock leaf springs or
MOST aftermarket leaf springs up to four inches of lift. Improved handling and ride quality will be no­ticed regardless of other modifications to the suspension system. The frame of your Jeep® must be
factory stock and straight. It WILL NOT FIT if it has been modified. Have it checked for trueness at a
frame shop BEFORE you begin. It has been designed to fit with a Warn or Ramsey winch mounting kit
and will work with stock and MOST aftermarket bumpers.

LEAF SPRINGS: The springs you use MUST have a center bolt that is "centered” in the spring stack.

Measure your leaf spring from large eye to center bolt, small eye to center bolt and write down these

measurements. They MUST be the within 3/8”. The reason for this is this kit has been designed to

lengthen the wheelbase of the Jeep® aprox. one inch. This way, the tire won't hit the back of the front
fender upon suspension compression. If your spring center bolt is off-set it will not lengthen the wheel­base as designed and tire to fender contact WILL OCCUR. Now, DO NOT PANIC if your springs don't
have a centered center bolt. This kit will still work just call us for further instructions on how to proceed.

PITMAN ARM: You may need to use a stock pitman arm. If a “dropped” arm is used there is a possi-

bility that the tie rod could contact the drag link upon suspension compression. This will depend on the
amount of lift, be sure and check for any interference!

DRIVE SHAFT: The front drive shaft will need to have longer travel slip-yoke installed. Due to the
action of the suspension movement the stock slip-yoke will not have enough length or movement. We
recommend calling the following drive line shop: Tom Wood’s Custom Drive Shafts, 877-497-4238.

TIRE SIZE: Stock leaf spring equipped Jeeps can use up to a 30” tall tire without fender contact. 2.5”
lift spring equipped Jeeps can use a 31" tall tire, or up to a 32” tall tire if the bump stop is lowered one
inch. 3.5” to 4” lift spring equipped Jeeps can run up to a 33” tall tire if the bump stop is lowered two

inches. If your running a tire larger then 33" tall, plan on lowering the bump stop (a bunch), installing a
body lift (minimum 1") and possibly trimming the fender.

7686-1
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M.0.R.E.™ # 7686-1 S.R.S.™ contains the following items:

Photo of contents on page 6 of this instruction sheet.

ITEM DESCRIPTION QTY. PART NUMBER

A BRACKET-DRIVERS SIDE 1 7686-DS

B BRACKET-PASSENGER SIDE 1 7686-PS

C FRAME SPACER PLATE 4 7686-FS

D SHACKLE PLATE 4 9040

E SHACKLE TUBE 2 7686-ST20

F BUSHING-SHACKLE 4 M02203

G BOLT-SHACKLE (1/2” x 4”) 4 13219

H NUT-SHACKLE (1/2" CRIMP-LOCK) 4 37268

I BOLT-BRACKET DS (7/16" x l-1/2”) 2 15159

J BOLT-BRACKET PS (7/16 x 1-1/4”) 2 15157

K BOLT-BRACKET (5/8" x 2") 2 15311

L NUT-BRACKET (5/8” CRIMP-LOCK) 4 37036

M NUT BOLT-BRACKET (5/8” x 4”) 2 13319

N BOLT-SPRING PIVOT (9/16 x 4.5”) 2 13271

0 NUT-SPRING (9/16 CRIMP-LOCK) 2 37270

P TUBE SPACER-FRAME 2 S107686

Q FLAT WASHER BRKT BOLT (7/16) 4 33084

R LOCK WASHER BRKT BOLT (7/16) 4 33624

S FLAT WASHER-PIVOT BOLT 4 33088

T FLAT WASHER-MOUNTING BOLT (5/8”) 8 33090

- INSTRUCTION SHEET 1 7686-1IS

Please familiarize yourself with all of the components in the kit. The instructions will refer to the item by
letter not description! Read all instructions carefully before work is started on your vehicle. In addition to
basic hand tools, the following specialty tools are needed to perform this installation: Arc Welder (M.I.G.
preferred), Cutting Torch (Oxy/Acetylene), Large hammer and chisel (air hammer preferred), Protractor,
15/16” Wrench & Socket, ½ Drive Torque Wrench, Drill (½ chuck), Hole Saw 1-¼“ dia., Floor jack, Jack
stands (several).

7686-1
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STEP 1: Remove the plastic front frame cover.

STEP 2: If your Jeep® is equipped with a winch, remove it’s mount plates from the side. Re-

move the side plates from the frame.

STEP 3: Remove the front bumper. Loosen but do not remove the two top bolts in the front
frame crossmember that attach the steering box mounts to the crossmember. See figure 1 & 2.

STEP 4: Raise and support the Jeep® with jack stands under each side of the frame behind
the front springs. With the front suspension un-loaded (wheels off the ground about 3”) remove
the tires/wheels. Remove the front shocks. Remove the front drive shaft. Place two more jack
stands under the axle housing outside the springs. Remove the front leaf springs. Remove the
stock front shackle brackets from under the frame just behind the front bumper. See figure 3.

STEP 5: Remove the rear spring brackets from the frame. The best way is to heat the rivet head
with a torch and use a air hammer and chisel bit to knock the head off. If a torch is not available,
a grinder can be used. Grind the one weld on the outside of the frame and use a hammer to
knock the bracket off the frame. Clean-up the excess slag with a grinder (Underneath and on
the side of the frame). Be careful, do not scar the frame rail. See figure 4a & b.

STEP 6: At the front of the frame, insert item “P” into the hole In the boxed frame. See figure 5.
This keeps the frame rails from collapsing when tightening the bolts. Bolt item “A” on the drivers
side frame using items "I", “R" & "Q". Thread the bolts into the same holes that the stock
shackle bracket was removed from. Do not tighten at this time. Bolt item “B" to the passenger
side frame rail using items "J”, "R" & “Q”. Do not tighten at this time. See figure 6.

STEP 7: If your Jeep is equipped with a winch, take it's side mount plates and insert them be-

tween the frame and the new spring brackets (items A&B). Insert items “C” between the winch
side plate and brackets (items A&B). If a winch is not being installed, use two of item “C” spac­ers on each side between the brackets and frame. See figure 7. Install item “M” through the rear
holes. Install item “K” in the front holes. Install items “L” on items “M” & “K”. Do not tighten at this
time. Tighten Items "I" & “J” installed in step 6 to 50 lbs. ft. torque. Tighten the two top bolts you

loosened in step 3 to 50 lbs. ft. torque. Install the front bumper and tighten its hardware using
hand wrenches. Install the winch mount plate to the side plates and torque the nuts to 50 lbs. ft.
torque. Now, torque items “K” & “M” to 110 lbs. ft. torque. See figure 8.

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