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BONZ^TM Shackle Installation Instructions

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PLEASE READ all instructions all the way through BEFORE YOU START!

Safety First! Before you undertake any suspension modifications, remember that such mods may change your vehicle's handling characteristics and stability. Raising your vehicle's center of gravity with extended shackles, lifted springs, etc., may increase the likelihood of a rollover, especially at high speed or on uneven terrain. 

Hence, all A.O.R. products are designed and intended for off-road use only. It is entirely your responsibility to determine the fitness and suitability of this A.O.R. product for your application.  A.O.R. will accept no responsibilty for any unsafe condition, damage or personal injury arising from your use of this product.

A.O.R. products should only be installed by those knowledgeable and experienced with 4x4 suspensions. Your safety depends on it!

TOOLS NEEDED: Do not use air-impact tools for this installation! You'll need floor jack, jack stands, wheel chocks, 1 1/16" (27mm), 13/16" (21mm) and 7/8" (22mm) wrenches, rubber mallet.   

1. Park your truck on a hard, flat surface and apply the parking brake. Chock both sides of rear tires if you're working on the front or chock front tires if you're working on the rear.

Be sure truck can't roll.

2. Use floor jack under the axle to lift working end until both tires are 3-to-4 inches off the floor. It is not necessary to remove wheels and tires. Place jack stands under frame rails just behind spring hangers nearest truck's cab. Lower truck onto jack stands, but leave floor jack under axle--you'll use it to raise and lower axle during shackle installation.

Make sure jack stands hold truck securely.

3. Be sure axle is again supported by floor jack. Ubolt and remove old shackle bolts and shackles. Slowly release floor jack pressure until tires rest on floor or work surface.

4. Inspect shackle mounting places--including perches, frame mounts and bushings--for excessive wear or damage. Damaged or worn parts must be replaced with new ones or repaired to as-new condition before A.O.R. shackles are installed.

5. Install shackles into upper mounts--nut can be outboard or inboard. Apply nuts, but do not tighten all the way yet. NOTE: On front shackles, the bends are not in the middle of the shackles. Bends are offset to maximize frame clearance for extreme flex. Mount front shackles with the long ends in the frame. 

6. Use floor jack to raise axle until spring eyes and bushings fit into shackles. Insert bolts. You may want to apply grease to bolts to ease installation and reduce squeaking from poly bushings. Do not grease bolts for rubber bushings. You may need to tap bolts with a rubber mallet during installation. But do not force a bolt if it catches or there is excessive resistance. Use floor jack to realign holes correctly. Excessive hammering can ruin bushings and deform shackles.

7. Tighten nuts. However, do not overtighten nuts until bushings bulge or shackles bend. Overtightening can "freeze" your suspension and prevent it from cycling properly.

8. Recheck all bolts for proper tightness. Now you're done. Happy 'wheeling and thanks for choosing A.O.R. products!