Installation Instructions

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Installation instructions

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IMPORTANT INFORMATION AND SAFETY PRECAUTIONS

This product will provide excellent service life when it has been properly installed and maintained.

Read the instructions carefully. Pay particular attention to the NOTE sections which contain helpful information to make the installation as easy as possible. Also pay close attention to the sections with the following warning symbol next to them:

Before starting the installation process verify the following:

1. Check the contents of the kit against the parts list shown on the label located on the outside of the kit box. If parts are missing, contact your local ATRO bushing distributor.
2. Make sure the Gross Axle Weight Rating (GAWR) of the front steering axle for the vehicle does not exceed 20,000 lbs.
3. Measure the leaf spring and hanger bracket widths and insure they match the ATRO leaf spring bushing length.
4. Measure the leaf spring eye diameter and frame hanger bracket eye diameter to insure that they match the outer diameter of the ATRO leaf spring bushing.

REQUIRED TOOLS

A special installation tool is required when installing an ATRO leaf spring shackle kit. To identify the required bushing installation tool, please refer to your ATRO catalog or to our website at www.atrobushing.com

Note: Failure to use the proper ATRO leaf spring bushing installation tool may damage the bushing assembly and VOID your warranty.

REMOVAL OF OLD COMPONENTS - FRONT OF FRONT SPRING EYE

1. Securely support the vehicle to remove the weight off of the front leaf springs
2. Remove the old front of front spring pin and spring eye bushing.

Note: It is not necessary to completely remove the leaf spring from the axle.

1. Remove all burrs and corrosion from the spring eye with a file, hone or wire brush and wipe clean.
2. Coat the inside of the spring eye and bracket bore, as well as the outside of the ATRO leaf spring bushings with white lithium grease or an anti-seize compound.
3. Align the ATRO leaf spring bushing with the spring eye. Using the proper installation tool (see required tools section) and an impact hammer or press (preferred), install the ATRO bushing into the spring eye. (See Figure 1)
4. Remove any contaminants, such as rust or dirt, which may have been deposited in the inner diameter of the bushing during installation.
5. Insert spring bolt through hanger bracket. (See Figure 2)
6. Torque spring bolt to the following specifications:
   • 3/4”-16 Grade 8 Cap Screw - 175 lbf-ft
   • M20x2.5 Grade10.9 Cap Screw - 175 lbf-ft
   • 1” - 14 Grade 8 Cap Screw - 195 lbf-ft
   • M24x3 Grade 10.9 Cap Screw - 195 lbf-ft

1. Insert hex cap screw through outer side bar, ATRO spring eye bushings, inner side bar and washer at the framehanger bracket.
2. Loosely thread locknut on cap screw. Do not tighten yet!
3. Align the outer side bar, ATRO spring eye bushing, inner side bar and washer at the spring eye end.
4. Insert hex cap screw and loosely thread on locknut.
5. Torque both 3/4”-16 Grade 8 Cap Screws to 175 lbf-ft.

Note: Do not use air tools to tighten the locking nuts. A torque wrench must be used to attain the required torque and prevent over-tightening.

FRONT END ALIGNMENT

After installing the ATRO leaf spring bushing it may be necessary to perform a front end alignment check for caster, camber and toe-in. Use the manufacturers’ guidelines and specifications for performing this task.

MAINTENANCE

The ATRO leaf spring bushings are self-lubricating and virtually maintenance free. The spring, hanger bracket, side bars, and ATRO leaf spring bushings should be visually inspected during every oil change. Also, the lock bolts should be re-torqued periodically to insure the integrity of the leaf spring bushings.

WARRANTY NOTICE

Follow the guidelines below to take full advantage of your ATRO spring eye bushing warranty. Failure to do so could void your warranty and may lead to premature failure, damages and/or injuries.

• DO NOT use alternate components and/or hardware in conjunction with ATRO spring eye bushings
• Always use matching ATRO components on both sides of the vehicle
• DO NOT exceed the 20,000lb GAWR
• Use proper installation tools and installation methods (see installation instructions)
• DO NOT expose ATRO spring eye bushings to excessive heat (i.e. welding or torch use)

ATRO Engineered Systems, Inc. can not be held responsible for any failure, damages or injuries that may result from not adhering to these guidelines.

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Installation instructions

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1. DISASSEMBLE THE SUSPENSION. RS20200, RS20201, RS20230

• Mark each swing arm to its position with the compensator beam (1, 2, 3, 4). This will ease the reassembly of the swing arms in the beams.
• Remove the trunnion shaft end caps and pull compensator. Discard the cast iron rings inside the trunnion castings. (RS20200 only).
• Remove the swing arm bolts. These bolts may be tack welded. Tack welds must be removed.
• Remove old springs and overload pads from the swing arms.
• Wire brush all beams and check for cracks. Grind out any cracks and re-weld, if not too severe. If cracks are major, replacement parts may be required.

2. TRUNNION SHAFT. RS20200

• Clean the trunnion shaft with a rotary wire brush and solvent to remove rust, dirt, grease, etc.
• The trunnion shaft may show wear in the bushing area. If the wear or grooves do not exceed 3/8” in depth and no cracks appear, the shaft can be reused. If the trunnion castings are not tight on the shaft the castings and shaft should be replaced.
• Check the fit of the trunnion shaft wear sleeve (Part # RS20212) on the shaft. Addi-tional grinding may be required to fit the sleeve over the shaft.
• If the sleeve slides over the shaft. Remove it and apply Loctite 620 to the trunnion shaft from the casting out to 7 1/2”. Push the sleeve against the casting tightly and let set until reassembly. If the sleeve does not slide over the trunnion shaft REMOVE sleeve from shaft end and apply heat to the sleeve ONLY (not the shaft) to expand it and then Install.

3. COMPENSATOR BEAM.

• Redrill the elastomer spring bolt holes located on the compensator beam to 11/16”. DO NOT REDRILL the bolt holes in the spring itself.
• Burn out the center bushing sleeve with a torch just enough to allow ATRO’s sleeve (Part # RS20214) to be inserted into burnt out area.
• With ATRO’s center bushing sleeve template (Part #RS10000) bolted to the compen¬sator beam through the two swing arm bushing threaded holes, place center bushing sleeve (Part # RS20214) over cylinder bolted to the center of the template (additional grinding of the burnt hole area may be required to fit center bushing sleeve). Tack weld sleeve in place, remove template, and finish welding around each side of sleeve and internal gussets. Use a cylinder hone tool inside the center bushing sleeve to remove any high spots due to
• Lubricate and press ATRO center bushing (Part # RS20216) into new center bushing sleeve. ATRO’s center bushing press-in tool should be used (Part #RS11000). Note: Stepped end of bushing fits into casting on trunnion shaft.
• Remove any weld splatter from top of inside web with a grinder to allow ease of swing arm assembly.

4. SWING ARM.

• Clamp the swing arm on a milling machine table squarely, using the flats of the end bushing bore hole (large hole). Bore the swing arm hole to a diameter of 3.120 - 3.125. The hole centerline should be parallel to the endbushing hole.
• Lubricate and press in swing arm bushings (Part # RS20230) using ATRO’s swing arm bushing press-in tool (Part #RS12000).
• Lubricate and press in end bushings (Part #EB38000 or EB38001.
• Bolt urethane spring (Part #RS20220) and overload spring (Part #RS20222).
• Minor alterations may be required to the overload spring to reassemble swing arm to compensator beam. Call ATRO office if problems occur, (800) 325-6114.

*Note: Urethane spring (Part #RS20220) is designed to replace either long or short rubber springs. If a short spring is replaced then the in-board spring guides on the swing arm and inside the compensator beam must be removed to allow the large spring to rest level.

5. REASSEMBLE SUSPENSION.

• Replace original thrust washers alongside the swing arm bushings. MATCH SWING ARMS TO THEIR ORIGINAL POSITION IN THE CORE (swing arms and beam marked with 1, 2, etc. from step one: Disassemble suspension.) Install swing arms with swing arm bolts into compensator beams. Do not tighten bolts at this time.
• Rotate swing arm into position inside the compensator beam.

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Installation instructions

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IMPORTANT INFORMATION AND SAFETY PRECAUTIONS

This product will provide excellent service life when it has been properly installed and maintained.

Read the instructions carefully. Pay particular attention to the NOTE sections which contain helpful information to make the installation as easy as possible. Also pay close attention to the sections with the following warning symbol next to them:

INSURE THE CORRECT KIT IS BEING INSTALLED

Before starting the installation process verify the following:

1. Check the contents of the kit against the parts list shown on the label located on the outside of the kit box. If parts are missing, contact your local ATRO bushing distributor.

warning: Do not replace any missing hardware with substitutes! Inferior components may cause premature or catastrophic failure.

2. Make sure the Gross Axle Weight Rating (GAWR) of the front steering axle for the vehicle does not exceed 20,000 lbs.
3. Measure the leaf spring and hanger bracket widths and insure they match the ATRO leaf spring bushing length.
4. Measure the leaf spring eye diameter and frame hanger bracket eye diameter to insure that they match the outer diameter of the ATRO leaf spring bushing.
5. Remove any contaminants, such as rust or dirt, which may have been deposited in the inner diameter of the bushing during installation.

WARNING

Always wear safety glasses and other necessary safety gear while performing the following procedures to prevent bodily injury.

Overheating the spring eye could weaken the spring resulting in a premature failure.

1. Securely support the vehicle to remove the weight off of the front leaf springs
2. Remove the old front of front psring pin and spring eye bushing.

Note: It is not necessary to completely remove the leaf spring from the axle.

REQUIRED TOOLS

A special bushing installation tool is required when installing an ATRO spring eye bushing. To identify the required bushing installation tool, please refer to your ATRO catalog or to our website at www.atrobushing.com.

Note: Be sure to use the proper ATRO leaf spring bushing installation tool. Use of the wrong tool may damage the bushing assembly and void your warranty.

ATRO LEAF SPRING BUSHING INSTALLATION - FRONT OF FRONT SPRING EYE

1. Remove all burrs and corrosion from the spring eye with a file, hone or wire brush and wipe clean.
2. Insert the correct bushing installation tool into the ATRO leaf spring bushing. (Refer to Figure 1)
3. Align ATRO leaf spring bushing with bore of spring eye.
4. Using the correct installation tool in conjunction with a press (preferred) or impact hammer, install the bushinginto the spring eye.
5. Remove any contaminants, such as rust or dirt, which may have been deposited in the inner diameter of thebushing during installation.
6. Install adapter collars into frame hanger bracket, aligning the groove in the adapter collar so that the lock bolt will slide through it. (Refer to Figure 2)
7. Note: Note all bushings require adapter collars. If adapter collars were not included in the kit, insure the diameter of the spring pin matches the spring pin bore of the hanger bracket.
8. Apply a small amount of lubricant such as grease or graphite lube to the spring pin to aid installation.
9. Align bore of spring eye bushing and shims (if included with bushing) with the spring pin holes in hanger bracket. (Refer to Figure 2)
10. Insert spring pin through adapter collar/hanger bracket, shims (if required), and spring eye bushing.
11. Note: It may be necessary to tap the spring pin in with a brass hammer or mallet during installation.
12. Insure grooves in adapter collars and spring pin are aligned so that the spring pin lock bolts will slide through them.
13. Install new spring pin lock bolts and torque to the following specifications:
    • 1/2”-20 Grade 8 Cap Screw - 110lbf-ft
    • 7/16” -20 Grade 8 Cap Screw - 70lbf-ft

Note: Do not use air tools to tighten locking nuts. A torque wrench must be used to attain the required torque and prevent over tightening.

REMOVAL OF OLD COMPONENTS - REAR OF FRONT SPRING EYE

1. Securely support the vehicle to remove the weight off of the front leaf springs.
2. Remove the old shackle assembly.

Note: It is not necessary to completely remove the leaf spring from the axle.

ATRO LEAF SPRING BUSHING INSTALLATION - REAR OF FRONT SPRING EYE & BRACKET

1. Remove all burrs and corrosion from the spring eye and bracket with a file, hone or wire brush and wipe clean.
2. Insert spring pin into bore of spring eye bushing.
3. insert spring pin/bushing assembly into isntallation tool. (Refer to Figure 3)
4. Align ATRO spring eye bushing with bore of frame hanger bracket.
5. Using the correct installation tool in conjunction with a press (preferred) or impact hammer, install the bushing into the frame hanger bracket.
6. If the hanger has been removed, reinstall following the manufacturers instructions.
7. Repeat steps 2-5 to isntall a spring pin/bushing assembly in a rear spring eye.

Side Bar Installation

1. Install adapter collars into side bars, aligning the groove in the adapter collar so that the lock bolt will slide through it. (Refer to Figure 4)
2. If shims were included in the bushing kit, install them on both ends of each spring pin.
3. Note: Not all bushings require shims. If shims were included in the bushing kit, they must be installed as described to prevent excessive lateral movement of the leaf spring.
4. Making sure the grooves in the spring pins and adapter collars are aligned so that the side bar lock bolts will slide through them, install the side bars on the ends of the pins protruding from the frame hanger bracket and the leaf spring. (Refer to Figure 4)
5. warning Inspect side bars for excessive wear. If necessary, replace side bars. Failure to do so could result in an accident, serious property damage and severe injury or death.
6. Install NEW side bar lock bolts and locking nuts. (Refer to Figure 4)
7. Tighten the side bar lock bolts and locking nuts. Torque to the following specifications:
   • 1/2"-20 Grade 8 Cap Screw - 110lbf-ft
   • 7/16"-20 Grade 8 Cap Screw - 70lbf-ft

Be sure that the adapter collars are properly aligned and installed. After tightening the side bar lock bolts, the pin and adaptercollars should be clamped firmly within the side bars. Failure to properly install the adapter collars will damage the bushing assembly and cause premature failure.

FRONT END ALIGNMENT

After installing the ATRO leaf spring bushing, it may be necessary to perform a front end alignment check for caster, camber and toe-in. Use the manufacturers’ guidelines and specifications for performing this task.

MAINTENANCE

The ATRO leaf spring bushings are self-lubricating and virtually maintenance free. The spring, hanger bracket, side bars, and ATRO leaf spring bushings should be visually inspected during every oil change. Also, the lock bolts should be re-torqued periodically to insure the integrity of the leaf spring bushings.

WARRANTY NOTICE

Follow the guidelines below to take full advantage of your ATRO spring eye bushing warranty. Failure to do so could void your warranty and may lead to premature failure, damages and/or injuries.

• DO NOT use alternate components and/or hardware in conjunction with ATRO spring eye bushings
• Always use matching ATRO components on both sides of the vehicle
• DO NOT exceed the 20,000lb GAWR
• Use proper installation tools and installation methods (see installation instructions)
• DO NOT expose ATRO spring eye bushings to excessive heat (i.e. welding or torch use)

ATRO Engineered Systems, Inc. can not be held responsible for any failure, damages or injuries that may result from not adhering to these guidelines.

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Installation instructions

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ATRO Parts TS96-22286, TS96-22600, TS96-22700

1. Remove old bushing(s) from rod eye.
   • Using the small diameter end of the ATRO PT96-52200 tool and a hydraulic press, apply pressure to the bushing as shown below. This will remove pressure from the retaining ring.
   • While maintaining pressure on the bushing, remove the retaining ring with snap ring pliers.
   • Release pressure from bushing and remove from rod eye.
2. Bushing Installation (Recommended Method)
   • Thoroughly clean inside of rod eye – remove any excess rust or debris.
   • Using a file or alternate method, remove any burrs and sharp edges from leading edge of rod eye.
   • Assemble the 2-piece ATRO# PT96-52200 installation tool and bushing as shown in the picture below. The support sleeve first slides over the press tool, then the press tool/support sleeve assembly is placed on top of the bushing.
     • NOTE: The purpose of the support sleeve is to prevent excessive bulging of the split steel outer sleeve during installation.
   • Using a hydraulic press, install bushing into rod eye until fully seated.
   • Install the retaining ring that was included with the new ATRO bushing.
3. Bushing Installation (Alternate Method)
   • Thoroughly clean inside of rod eye – remove any excess rust or debris.
   • Using a file or alternate method, remove any burrs and sharp edges from leading edge of rod eye.
   • Install a two piece, 3” shaft collar onto one end of the bushing outer sleeve as shown below. (Shaft collars can be purchased at hardware suppliers)
   • Tighten shaft collar to slightly pre-compress the bushings’ split outer sleeve.
   • Using a 2 15/16” OD piece of tube and hydraulic press, install bushing into rod eye until fully seated.
     • NOTE: There is no need to remove the shaft collar – the tube will pass through it during the pressing operation.
   • Install the retaining ring that was included with the new ATRO bushing.

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Installation instructions

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ATRO Part TH96-22200

Bushing Removal

1. Remove steel cap from rod eye by either grinding off the tack welds (older style) or prying off (newer, crimped style). (Fig. 001)
2. Remove the center bolt holding the plate on. (Fig. 002)
3. Remove grease boot from bottom of apex rod eye.
4. Thread an M20x1.5 bolt into the old apex bushing pivot ball until it bottoms against the top of the plates’ taper stud. Continue tightening the bolt until the plate separates from the pivot ball. (Fig. 003)
5. Remove the retaining ring, steel retaining washer, and plastic wedge washer from the rod eye.
6. Using the small end of the ATRO PT96-52300 tool, or a piece of tube/bar with the correct OD (approximately 2 3/16”), press the old apex bushing out. (Fig. 004)
7. Bushing Installation

Bushing Installation

1. Thoroughly clean inside of rod eye – remove any excess rust or debris.
2. Using a file or alternate method, remove any burrs and sharp edges from leading edge of rod eye.
3. Lubricate ID of rod eye and OD of TH96-22200 apex bushing with P-80, grease, or other lubricant.
4. Using ATRO install tool PT96-52300, press the new ATRO TH96-22200 apex bushing into rod eye until fully seated. A piece of tubing or large socket with an OD of 2 13/16” and an ID of 2 1/4” may be used as an alternative to the PT96-52300 tool.
5. Insert the supplied steel retaining washer on top of the apex bushing.
6. Install the supplied new retaining ring.
7. Clean any corrosion or contamination from the mount plate taper stud.
8. Insert mount plate taper stud into apex bushing.
9. Apply medium strength threadlocker to the bolt included with the ATRO apex bushing kit and thread into the taper stud. Torque bolt to 100 ft-lb.
10. Install metal dust cover onto top of V-Rod and stake in place using a punch or similar tool.

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