Installing Icon AAL on the Stock 4 Leaf Pack

Hey guys, just trying to clarify some stuff when it comes to installing the Icon AAL.

From what I've read up on here, most people who install this on the 3 leaf pack don't run into any trouble as they bolt right up. They simply remove the overload, or keep it depending on preference, and then bolt up the AAL pack to the two factory leafs. But, when it comes to trucks running the 4 leaf TSB springs, you are required to cut away at least one of the factory spring pack clamps holding on the factory third (bottom) leaf and grind it all down smooth. I'm not referring to the overload leafs, I won't be running those on my application. Sound about right?

http://www.iconvehicledynamics.com/wp-content/uploads/2013/09/Icon_51100.pdf

Those are Icon's instructions and on the second page it looks like they're installed on a 4 leaf pack and they only had to cut away one stock clamp towards the rear to give clearance for the AAL pack.

Anyone have some experience with this or want to upload some pics of it installed?

Thanks!

 

i had the factory 4 leaf pack and yes i did have to remove the rear most bracket securing the factory leaf pack. There is one very large 'rivet' holding it on. grind off the head and use a flathead screw driver and hammer to give it a little motivation to come off. if you hold the AAL up to your leaf pack it's very clear what has to be removed. pretty easy. i used an angle grinder

 

Random Question for any one.
If you add the Icon 3 leaf progressive kit, do you need a mid or extended travel shock or is the standard travel ok.

 

Bump!

Thanks 2006J!

Anyone else have more insight? I've heard people say it's easier to do this with the leaf pack removed from the truck. Looks like I'll be diving into this over the weekend.

 

I was using standard travel 5100's and did just fine. It depends on your use though. If you want to get the most out of your setup, an extended travel shock, extended brake lines and extended bumps might be the way to go. I was mostly road use so I did fine with standard length 5100's.

I agree with 2006J, I had to remove the stock leaf pack retaining clips. Here's a picture of mine all lined up and you can see that the rear will contact. I ended up removing both the front and rear clips.

This is the only shot I have of them installed:

 

subd

 

Is the factory overload leaf the small bottom one?

 

Yes.

 

Thank you. I figured it out eventually. Just test drove it. Icon 2.0 Rear Shocks with icon aal, non tsb. I can definitely feel the difference. The Rear doesn't jump around on bumps, much smoother.

 

Did you have to remove the retaining clip from the overload? Do you have a pic of the front of the pack to see the clip?

 

I don't have any pictures because I no longer have the truck but I did not have to remove the retaining clip from the overload leaf (although I believe I've read that some people did remove this). I did not remove it because, if I recall correctly, there's a bracket that gets attached to the retainer for the brake line (e-brake cable).

 

I'm gonna measure it up tomorrow and see thanks

 

Did you install while on the truck or with the leaf pack off of the truck? It seems as if all of the instructions are with the leaf pack on the truck, but ive got some takeoff tsb springs that I figured Id add the aal to before installing. does it make more sense to do that or to put the new pack on, and then do the aal once its on?

Sorry to revive the old thread.

 

You can certainly install the AAL with the leaf pack on the truck. I was like you, I had a donor leaf pack and got the AAL installed off the truck and then just swapped complete leaf packs. Since you have a donor leaf pack, I would go that route. If you aren’t swapping leaf packs, I wouldn’t remove the leaf pack just install the AAL and reinstall. Getting the leaf packs off takes some finagling.

 

Awesome I needed the confirmation that it could be done off of the truck! Is it the same process? I wasnt sure if you needed to compress anything to install the aal and therefore need it on the truck. I appreciate the help

 

Yeah, it’s generally the same process except you can do it at chest height, on a work bench! You will need something to hold the leafs together so you can get the center pin tightened. I used hold rather than compress because it’s not something you need a lot of muscle to pull off, I used medium sized c-clamps. You’d need to do that if they were on the truck also.

 

ive got two beefy old c clamps that should do the job. thank you very much for the help

 

No problem, good luck with the install!

 

Having just dealt with this on Saturday, here are some tips... I think it's easier to do this out of the vehicle if you have to start cutting clips and such but that is your choice. Pre-soak fasteners with penetrating oil in advance. Jack stands and some kind of floor jack are required. You will have to raise and lower the rear axle a few times to get things in and out. Use caution! The springs are heavy. Spring clips and rivets can be cut off with a cut off wheel/ grinder but watch where the sparks go. Two C-Clamps help for disassembly/ reassembly. It is not a good idea to try to draw the springs up tight with only the center bolt. Note that there were thin angled shims under the factory springs so put them back in the right direction. The emergency brake cable brackets can be bent with two pliers to attach to the add a leaf clamp nut (I might have enlarged the hole when I first did this, I don't remember). I did not use/reuse the factory overload spring. My local Advance Auto had spring center bolts (two pack) in stock that fit perfectly. I was installing different older spring packs so I had to replace them as they were too short. You will need the cut off wheel to easily shorten new center bolts to allow the factory bump stop to fit but a hacksaw/sawzall would work. I removed 5100 shocks. Clean any sand and debris out of the allen wrench socket at the top of the 5100 shocks completely with a small pick and compressed air to avoid stripping that out. Wire brush the threads clean and use penetrating oil on the upper shock nut/ threads. Hand tools will get the whole job done but an impact helps with the U bolt nuts. You will need longer U bolts if they don't come in your add a leaf kit. After tightening u bolts and reassembling everything else, take a decent test drive over varying road conditions and then recheck tightness of the U bolts. They will probably be loose. I torqued mine to about 80 ft-lbs. I would recheck all involved fasteners after the test drive.

Good luck with the project.

I have an unloaded 1-1/2" of lift without the factory overload. I do not "off-road" so maximum travel, droop ect. are not factors for me.