Broken leaf spring!

It's the truth that unloaded springs fatigue and break a LOT more than springs in a truck that is loaded (within limits) on a regular basis. Not everyone is gonna break a spring by running around unloaded it just causes the springs to wear faster and as a result they will break. Just my .02 but if a spring shop says it, wouldn't you listen? They would (should and by this account do) know what they are talking about.

 

I had a customer bring in his 2005 single cab Prerunner 6 lug into my shop with a "clunking" from the rear end. Upon immediate inspection, I noticed the passenger side middle leaf spring was cracked and broken.

The unloaded spring failure makes sense to me. This truck is incredibly light, and only had 40,000 miles put on it in 8 years. It was never used to haul anything, and it resulted in the leaf spring on the passenger side (lighter side, less human weight) to break.

We replaced them with a Deaver J66 pack and the customer could not be happier. Ended up also doing an Icon coilover set with Total Chaos UCA's and an Eaton TruTrac LSD in the rear. Put some nice Pro Comp black wheels on it too.

 

But if you had an adequate shock absorber, shouldn't that stop the spring from breaking? I think this is a combination of an inadequate shock paired with a really weak leaf spring.

 

Yup, same here. 2 OEM leafs broke (one each side) at different times and only when unloaded.

Spring shop told me the same thing, but didn't recommend me to put something in the back but to try avoid anything that looks like potholes (even small) when unloaded.

 

A spring shop told my old man there's nothing worse for leaf springs than driving on woods roads with no load in the back. Must be true if there's shops all over North America saying the same thing.

My truck must be some sort of exception since I work in the woods and still have the original springs. Although its probably not good that the front of the bottom leaves are starting to wear through the leaves above them.

 

Sounds right I guess but what about only changing one side??? Did this and seems fine

 

I work as a mechanic (til Monday when I start my office job) and just today I changed 2 broken leafs on a pickup that is run on back roads with no load in the bed ever. The shocks in my mind just take the wave out of the ride the springs alone would have.

Sound advice for sure, but should be done too for the sake of your tires

Do it. No problems doing just one IMO

 

Cool Thanks

 

I broke a leaf spring on both my first gens, one on driver side, and one on passenger side. The first one I broke, I heard it break, when I went over a speed bump too fast, and my bed was empty. Took it to a spring shop, and they told me the same thing, that they see more springs break with no load, than with a load. I didn't notice the exact moment when my 2nd one broke, but I rarely haul stuff, so I assume my bed was empty when that one broke too. And I know a couple other people that have broken springs on their first gens as well.

 

I would think a better shock would slow how quickly the suspension cycles, thus increasing the life of the spring. A stronger shock, when you hit a bump, can almost mimic a loaded bed.

 

I can see that happening...when my customer (above) came in, his U-bolts were completely loose. When I did my AAL 6 months ago, the U-bolts came off by hand.

 

So the issue of springs breaking due to no load came up in the third post of this thread, which took the original post a little astray, but not by much. I believe that spring shops who deal with these issues all of time may have some good insight into the no-load issue BUT I've never had it happen with other makes because of no-load conditions. It would seem that the junk steel that Toyota used for the leaf springs is the main problem and the no-load condition may be a factor that increases the failures.
One of the benefits of a forum is the ability to compare your experiences with others and share fixes as well as knowledge. I'd like to know if replacement springs fail less often when compared to factory springs.

 

From all the information I have been privy to indicates that the most common cause of spring breakage is loose U-bolts.

 

My uncle who has a Dodge RAM 1500 broke leafs when unloaded.

The more you wheel on uneven roads unloaded, the better chances your leafs will break.

Leafs on a unloaded truck will travel more than a loaded truck (higher distance of up and down), thus metal will fatigue faster.

 

I'm not maligning Toyota, in fact I think they have some great engineering and generally good materials. I'm skeptical that a lack of load is the SOLE cause of leaf springs breaking, particularly when this issue is so prevalent in Tacoma's. If it was a bad design the identical replacement springs would be breaking at an equal rate. (I don't know if they are, most people seem to replace the springs with stronger sets) I do think the amount of failure is due to a materials problem. I've seen other makes and models break springs but not nearly at the rate that Tacoma springs seem to fail and not simply because the trucks were empty. In my opinion - It's just bad steel and Toyota doesn't want to admit it.

 

So do you think that OME Dakars would break without a load in the bed from bumps?

 

Sure they would, because the " Spring Shop said they would ".

 

I guess it's under the truck tonight to ensure some U-bolts are secure.

 

So I replaced both springs ....now it sounds like and old truck squeaks and groans!!!!!!!
I've sprayed every place I can think of that would squeak..No luck

Any suggestions?

 

If everything is tight and nothing is broken - keep calm and carry on.
It's a truck with leaf springs, not a 600 class Mercedes limo.