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: info@mountainoffroad.com 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.
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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 Page 2
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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