Does anyone have experience removing leafs from an Ironman 4x4 leaf pack?

So I messed up and ordered the Stage 2 foam cell pro kit with the 440lb constant load leaf pack. I figured since I load the truck with some serious weight while camping and hunting that I'd go with the heavy duty rear leaf springs. Boy was that a mistake! The ass end is jacked way up, the drive line is at a crazy angle causing a serious vibration, there is absolutely no give! It's literally like driving a forklift! I had to park it until I resolve this issue! I was told I could remove a couple of springs out of the pack to soften the ride and bring it down a bit. Has anyone else made this mistake? Has anyone else pulled any leafs from the pack? Should I pull leafs, or just eat the $600 and buy the right leaf springs?

 

Welcome to TW

 

There's no reason to eat the cost and buy new packs. If it's not possible or convenient to swap the whole packs with your distributor (e.g. restocking fees or shipping makes it cost prohibitive) then you can do it yourself, assuming you have the ability to install packs in the first place.

All you need parts-wise is a new spring center pin. Tools are minimal, a few big clamps, regular stuff like sockets.

Google for removing the 3rd leaf from OME Dakars or how to install an add-a-leaf, that should get you some idea of how you'd add or remove leafs from a spring pack. If you haven't installed the leafs it's much easier to do with the springs on the garage floor than installed on truck.

 

Thanks Dave, I did install them myself. I do know how to take a leaf pack apart. What I'm not sure of, is which 2 springs I should remove from the pack. There's a total of 8, 2 overload springs and 6 in the rest of the pack.

 

Thanks for the welcome! Excuse me as I figure out how to use the forum

 

I bought some cheap doormans a while back along with some rough country shocks. This is them in comparison to the Ironman 4x4 kit.

 

Gotcha. Leaf springs aren't rocket surgery. The top one and probably the second are the foundation, they hold the bushings and will have a full or partial wrap on the second. The next couple of full length and then they start to taper down in length. You can't remove ones with spring clips.

It wouldn't honestly surprise me if Ironman are made by the same factory as OME using the same formula of thickness and stack-up.

Either way, I'd probably just call Ironman and ask. They might be able to tell you which might be OK to remove.

 

OP how did the removal go? Did you remove 5&7 or just 7? Dealing with same issue.

 

So I had the issue as well, I did not install mine I had a shop do it. However yes the ass end was up in the air with the full leaf pack. Even loaded 1000lbs and it didn’t squat and the rear shocks were an inch from maxing out. So we removed I believe a total of 3 packs to bring the ass end down and make it work properly. Went off roaring yesterday and it’s amazing. Kept the other leafs for when I add the weight to the back end. I can get more info for whoever needs it.

 

to add on to this, we had to shorten the brackets, good things it’s a $10 part so when I go to add the leafs back with weight it’s a $10 part not $600 leaf packs.

 

this is extremely reassuring to hear. I am 3 weeks into the 440 constant load leafs on my nitro gas stage 2 set up. It’s borderline un-driveable in its current state. Even with 480 pounds of concrete in the bed for the week it did not make a bit of difference. I spoke to Ironman yesterday and they said it’s super common and to remove the 5th and 7th leafs. Would love to hear any more info you have to share on this. You mentioned you removed 3 on each side?

 

so if you spoke with Ironman I would go with what they advised. Also do it sooner than later. You can mess that rear part of the kit up quick with the way it is now. I said 3 yes but I believe it was just 2 and the tech spoke wrong. For sure do what Ironman says though they are an amazing company.

 

besides the rear end coming down did you feel a significant improvement in ride quality?

 

I actually didn’t even drive it with all the leafs installed deemed unsafe so had to immediately remove the other packs for ride quality and safety.

 

Got it. But your currently ride quality is good?

 

yes! I love it I went from stock and it is so much better!!!

 

These springs settle in too. My ride was pretty stiff starting out (even with 5/7 removed) and they've softend up some, but still provide ample support.

One thing to consider to those that are dismantling the pack, you might consider doing a bit of touchup to the springs.. I haven't had any squeak issues, but you'll notice how the PC was applied to it as a bundle instead of separately/individually.

Cheers to the good information in this thread.

 

So I made the same mistake lol, I’ll be removing a couple leaves in a day or 2. I was just wondering if you guys had to cut down the leaf pack center bolt or was it still able to fit up under the bump stop?

 

@mandog I just this tread and I’m currently experiencing the same thing. Did you remove the 5,and 7 leafs counting from top to bottom or Bottom to top?