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"Shackled" 1996 K1500 6.5

Paveltolz

Доверяй, но проверяй
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Saratoga Springs, UT
Thought I would share yet another lesson learned from experience born of ignorance or complacency.

Issue. Driver's side shackle failed dynamically and split at the leaf spring on one side, apparently some time ago and then, over time, the other side failed as would be expected.

Background. I purchased the truck four years ago and it was apparent that it had been used for construction. Apparently the PO had hit something with the right front as it wouldn't take an alignment no matter what. To get a "lift" they also fully cranked the torsion bars and included an 'add-a-leaf' to ensure the ball joints self destructed.

I thought I did the right thing by replacing everything between the inside of the rims and raising it "correctly" with an El Rancho 3" Rough Country kit. The rear springs were shot, a couple were cracked so BDS 4" inch springs were added and connected up with the stock shackles. Unfortunately, this gave the rear end a jacked up effect instead of an even 3" lift on all four corners. Additionally, the Torsion bars had spun or rounded off inside their sockets so those were replaced with a set from a 2500. Surprisingly, the ride was quite good. Except for the constant right pull.

Three plus years of steering correction and finally one shop figured it out, pulled the front end out where it was supposed to be and after that I had to fight not to pull the truck into the left lane out of habit of correcting the right side pull.

Point. I hadn't paid any real attention to the rear suspension like one does with the front end.
Because of the front end damage, apparently the shackle(s) were subjected to too much lateral stesses instead of mainly just the vertical stresses it was designed to take. Like bending a coat hanger or any other piece of metal, eventually, it's going to let go.
So, since I hadn't conducted any rear suspension checks over the years, I set myself up for failure.
DSC01047.jpg

One side broke clean.
DSC01051.jpg

The other cracked, slowly tore "along the dotted line" and eventually let go...
DSC01053.jpg

You can see how the bolt hole is oval instead of round on the torn side and here is a closer shot of it.
DSC01055.jpg

With a little bit of attention, the occasional inspection, like when greasing the front end, I would have at least caught the break, certainly the tearing and saved myself the new dent/dimple in the bed of my truck.

Fortunately the other shackle appeared to be undamaged but I replaced them both with aftermarket units from Summit which ared designed to lower the truck a bit so now it rides level.:thumbsup:

Another series of steps down life's paths, the ones strewn mainly with pain.:hello:
 
Can you get a picture of the new ones installed? Right where the shackle on mine is, there is a C rail the bed sits on, so the lowering shackle brought the spring right up nearly touching the rail. I was wondering how well it wored on others.
 
Mine's a K1500 and the fitment was close only with the clearance up by the bed. Otherwise, I'd say it was perfect. I don't know but would things be a little different back there between the K1500 and C1500.

As for Pictures, here you go.
Driver's side.
You can see the smack mark made on the bed floor when the spring unloaded. :nonod:

DSC01058.jpg

DSC01057.jpg
Dont mind the cuts in the support. They'll be welded / filled later today. Had to cut the lower bolts and the blade bit and kicked back a couple of times. :eek:

Passenger side.
DSC01060.jpg
DSC01059.jpg
 
Yours actually look right, the taller shackles on mine messed up the angle on the shackle and brought it towards the front and before I put anything heavy on the back I am going to change it, because it seems like the bed support there will hit the spring when loaded. I have over the axle springs, and might be shorter than the 4x4

ShackleAngle.jpg
 
While you're inspecting things, In the first picture of the finished install, the bolts used are Grade 5 and not the Grade 8 that came on the truck. The Grade 8 will give you a lot longer and safer service. My .02
 
Good eye. Picked up the Grade 8 bolts etc today at Fasenal, will swap them this weekend after the air temp gets up above freezing.
 
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