Trail-Gear AAL install issues

Hey guys,
I've run into an issue installing my trail gear add a leaf on my truck.
When I get the aal in place and lined up with the center pin, the front of the leaf is touching/rubbing the front clamp for the leaf pack. It's like my aal is too long and won't fit with the spring clamp up front.

It's the correct leaf apparently but there's no way this is going in. There's no clearance between the aal and spring clamp so once I put weight on it, it lengthens and pushes against the clamp.

I have the leaf oriented correctly, just hoping someone else may have run into this and has any ideas for me..

 

the answer your looking for is in the instructions. they want you to bend tabs out then bend back after installing.


edit. nvm in the instructions they aren't even using factory leafs.

 

Isn't the clamp rivited to the spring? I cut mine off with a chop saw. But mine didn't have the plastic slide pads.

 

It seems to be riveted. The instructions don't mention anything about those spring clamps either. I only have about 2 inches of spring on the end side of both clamps too..
Trail gear says I have the right one and was pretty much unable to answer my question. Just confused as to how I'm supposed to make this work without fully disassembling my leaf pack.

 

Same issue i had.

 

What brand add a leaf? Did you just put new clamps around the leaf pack further down on each end or what?

 

It was a fabtech. I cut 2inches off with a chopsaw. Then smoothed the edges with a bench grinder.

 

That's probably my best bet, shouldn't make a difference to height or stiffness I guess. I only need an inch or two as well it seems.
Pretty disappointed it's not a simple bolt on.. did you cut one inch from either side to keep it as even as possible or just two off the front?

 

Just 2 from the front.

 

Looks easy, I'll hold your beer!

 

That's it! I'll get the sawzall out tomorrow and make it fit, just feels wrong cutting up a new leaf

 

You won't cut that with a sawzall. It needs to be cut with an abrasive wheel. Taper the leaf like it is now if you can.

 

I had the same problem, though a different aal, different truck, but here was my solution:
https://www.tacomaworld.com/threads/wheelers-3-leaf-aal-issue-with-install.443667/
I would avoid cutting the aal personally. Seems easier just to remove the clip and maintain the full length aal.. I'm pretty happy with how mine turned out.

 

I don't think his AAL has clips like the ones in the link you posted.

 

It does not, I have the single leaf with no clips/retainers. Problem is, the clips are riveted and right near the end of the lowest leaf already. Doesn't give me much room..

 

Do you think an angle grinder with a cutting disc would do the trick? Really hoping I can make this work for this weekend.

 

Probably at least to flatten the end of the rivet out and then drill... might be the way I'd go about it - but my dremel would probably be the one that got the call for this job.

 

I meant for cutting an inch or so off my leaf. I really don't think moving the clamp is an option for me, not a lot of room to move it to.

 

Angle grinder will cut it.

 

Okay, you don't have any problems with yours by losing an inch or two off the front I guess? I have some cutting discs so looks like it's my only choice at this point.