059-867-00 – E-Z Flex® Suspension Kits for Double Eye Springs – Dexter

SEOCONTENT-START© Dexter Axle Company 7/17
www.dexteraxle.com 059-867-00 Rev. C
INSTALLATION INSTRUCTIONS
E-Z Flex® Suspension Kits for Double Eye Springs
K71-652-00 E-Z Flex® Complete Kit for Tandem Axles with 33″ Axle Spacing, 6000 Lb. Max Capacity
K71-653-00 E-Z Flex® Complete Kit for Tandem Axles with 35″ Axle Spacing, 8000 Lb. Max Capacity
K71-656-00 E-Z Flex® Complete Kit for Triple Axles with 33″ Axle Spacing, 6000 Lb. Max Capacity
K71-657-00 E-Z Flex® Complete Kit for Triple Axles with 35″ Axle Spacing, 8000 Lb. Max Capacity
Safety Precautions:
Before performing any maintenance or repair work
requiring the raising of the vehicle, make sure that
the vehicle is properly supported on lift stands of
sufficient capacity. Follow the vehicle manufacturer’s
recommendations for lifting and supporting the unit.
Do not lift with or place supports under any part of the
suspension system unless specifically directed to do so
during the disassembly and reassembly steps of these
instructions.
! CAUTION
Never rely on jacks alone to support the
vehicle. A vehicle that is not securely
supported may fall and cause severe injuries
or death.
! CAUTION
Safety glasses should be worn at all times
when assembling or disassembling axles
and their components. Failure to comply may
result in serious eye injury.
Disassembly:
! CAUTION
Axles and suspension components are
heavy and must be carefully handled to avoid
pinching, straining or crushing injuries to the
body.
1. When the vehicle is raised and supported with
the tires just clear of the ground, remove the
wheel/tire assemblies from their respective hubs.
2. Disconnect any electrical wires or hydraulic brake
lines from the axles.
3. Place small jacks under the equalizers. Gently lift
the weight of the assembly until the bolts can be
easily removed from the center frame hangers.
Lower the partially disconnected assembly
until the equalizers are clear of their respective
hangers.
4. Carefully remove the spring ends from their
respective hangers by supporting their weight
and removing the bolts.
5. Remove the shackle link assemblies that attach
the leaf spring ends to the equalizers.
6. Slide the axles out from underneath the vehicle.
Inspection:
1. Examine the bolt holes in the frame hangers.
Holes that have been elongated or worn larger
will not provide for a proper fit of the new bolts.
The splined section of the bolt, adjacent to the
bolt head is designed to create an interference fit
in the hanger and prevent bolt rotation.
! CAUTION
Loose fitting bolts can result in premature
wear and lead to eventual failure. Failure of
suspension components may cause loss
of vehicle control and result in an accident
involving personal property damage, serious
injury and/or death.
2. If the bolt holes in the hangers are worn, the
hangers should be replaced.
CAUTION
Contact the vehicle manufacturer for
specific instructions regarding the removal
of old hangers and installation of new
hangers. Improper cutting and welding of
these components can adversely affect the
structural integrity of the vehicle frame.
Spring Eye Bushing Replacement:
1. Remove the old bushings from the spring eyes,
driving them out with a suitable drift punch. Make
sure the spring eyes are clean and free from
-2-
© Dexter Axle Company 7/17
www.dexteraxle.com 059-867-00 Rev. C
excessive wear, burrs and sharp edges before
proceeding. Springs that have been damaged in
any way must be replaced.
2. Drive the new bronze bushings into the spring
eyes. The preferred method is to use a piloted
punch that closely fits the inside diameter of the
bushing. If a punch is not available, a ⁹⁄₁₆” bolt
can be substituted. Place the bushing squarely
against the spring eye, insert the punch (or
bolt) into the bushing and drive it into place by
firmly striking the punch (or bolt) with a suitable
hammer.
CAUTION
Striking the bronze bushing directly with a
hammer may deform the inside diameter and
prevent reassembly of the bolts.
REASSEMBLY
Tandem Axle Suspension:
Note: Some trailer designs or tire sizes may prevent
easy access to the grease fittings when assembled
in the suggested fashion. The user may choose to
assemble the spring attaching bolts and shackle link
assemblies from the opposite direction. This will place
the grease fittings on the inboard side of the frame,
or the standard ¹⁄₄”-28 straight grease fittings can be
removed and replaced with an angled fitting. These
fittings should be available at most automotive parts
store.
1. Slide the front and rear axles into position under
the frame hangers. Starting with the front axle, lift
the front ends of the springs and position them
between the legs of the front hangers with the
bolt holes aligned.
2. Insert the lubricated spring eye bolts through
the outside leg of the hanger, the spring eye and
start it through the inside leg of the hanger.
CAUTION
Note the specific radial orientation of the
grease holes in the illustrations. Failure
to orient the grease holes as shown may
restrict the free flow of lubricant and lead to
excessive wear.
3. Read and observe the following cautions before
driving the bolts into place.
CAUTION
DO NOT HAMMER directly on the grease
fitting. Striking the fitting will cause damage
and render it inoperable
CAUTION
Attempts to pull the bolt into place with an
impact wrench may strip the threads or cause
the bolt to spin and damage the hanger hole
and/or bolt spline.
4. Use a suitable hammer to drive the bolt into
place. To drive the bolts in, place a small piece
of pipe or steel tubing against the head of the
bolt. The tube should be approximately ³⁄₈” inside
diameter to encircle the grease fitting in the head
of the bolt. Strike the end of the tube squarely
and firmly. Avoid glancing blows.
5. Continue driving the bolts into the hangers until
the bolt heads are seated against the hanger
surface. Install the flanged locknut onto the bolt
threads with the flanged side of the nut toward
the hanger. Tighten the nuts to 30-50 Ft. Lbs.
The nut should be seated against the shouldered
bolt end.
6. Place the rear ends of the rear axles springs
between the legs of the rear hangers. Insert the
lubricated spring eye bolts through the outside
leg of the hanger, the spring eye and start it
through the inside leg of the hanger.
CAUTION
Note the specific radial orientation of the
grease holes in the illustrations. Failure
to orient the grease holes as shown may
restrict the free flow of lubricant and lead to
excessive wear.
7. Repeat steps #4 and 5.
8. Apply anti seize or equivalent to the inside of the
steel bushing of the equalizer.
9. Apply anti seize or equivalent to the outside of
the center pivot bolt.
10. Install the new E-Z Flex® equalizer by placing it
inside the center hanger, align the center hole of
the equalizer to the holes in the hanger.
-3-
© Dexter Axle Company 7/17
www.dexteraxle.com 059-867-00 Rev. C
CAUTION
If your center hanger has a welded
reinforcement tube, you must check for
adequate clearance of the grease zerks.
11. Insert the center pivot bolts through the hanger
hole and into the equalizer center hole.
12. Use a suitable hammer to drive the center pivot
bolts into the hanger until the bolt head is seated
against the hanger surface.
CAUTION
Attempts to pull the bolt into place with an
impact wrench may strip the threads or cause
the bolt to spin and damage the hanger hole
and/or bolt spline.
13. Install the lock nut and tighten to 65-75 Ft. Lbs.,
thereby pinching the protruding steel bushing
between the inside hanger side surfaces.
14. Attach the shackle link/bolt assemblies to the
equalizers and spring eyes. The axles must
be lifted into their normal operating position
with the spring eyes above the lower holes
in the equalizers. Insert the shackle link/bolt
subassembly into both the equalizer and spring
eye at the same time.
15. Slide the plain shackle links onto the bolt ends
that protrude through the springs and equalizers.
Install the flanged lock nuts onto the bolts and
tighten to 30-50 Ft. Lbs.
16. Check the suspension for freedom of movement
by lifting either of the axles. When one axle is
lifted, the other should move downward and
should return to its normal position when the
lifting force is released.
17. Lubricate all the grease fittings using a Lithium
complex grease, NLGI No. 2 such as Mobil Oil
Company Mobilgrease HP or equivalent. Pump
the grease in until it begins to show at the ends
of the bronze bushings. For best results, the
suspension should be lubricated every 3,000
miles.
18. Reinstall the tire/wheel assemblies, following the
instructions provided by the manufacturer.
REASSEMBLY
Triple Axle Suspension:
1. Slide the front, center and rear axles into position
under the frame hangers. Starting with the front
axle, lift the front ends of the springs until they
are positioned between the legs of the front
hangers and are aligned to the bolt holes.
2. Insert the lubricated spring eye bolts through
the outside leg of the hanger, the spring eye and
start it through the inside leg of the hanger.
CAUTION
Note the specific radial orientation of the
grease holes in the illustrations. Failure
to orient the grease holes as shown may
restrict the free flow of lubricant and lead to
excessive wear.
3. Read and observe the following cautions before
driving the bolts into place.
CAUTION
DO NOT HAMMER directly on the grease
fitting. Striking the fitting will cause damage
and render it inoperable.
CAUTION
Attempts to pull the bolt into place with an
impact wrench may strip the treads or cause
the bolt to spin and damage the hanger hole
and/or bolt spline.
4. Use a suitable hammer to drive the bolt into
place. To drive the bolts in, place a small piece of
pipe or steel tubing against the head of the bolt.
The tube should be approximately ³⁄₈” diameter
inside to encircle the grease fitting in the head of
the bolt. Strike the end of the tube squarely and
firmly. Avoid glancing blows.
5. Continue driving the bolts into the hangers until
the bolt heads are seated against the hanger
surface. Install the flanged locknut onto the bolt
threads with the flanged side of the nut toward
the hanger. Tighten the nuts to 30-50 Ft. Lbs.
The nut should be seated against the shouldered
bolt end.
6. Apply anti seize or equivalent to the inside of the
steel bushing of the equalizer, and to the outside
of the center pivot bolt.
7. Install the new front E-Z Flex® equalizer by
placing it inside the center hanger, align the
center hole of the equalizer to the holes in the
hanger and insert the center pivot bolt. The yoke
end of the equalizer must be toward the rear of
the vehicle.
-4-
© Dexter Axle Company 7/17
www.dexteraxle.com 059-867-00 Rev. C
8. Use a suitable hammer to drive the center pivot
bolts into the hanger until the bolt head is seated
against the hanger surface.
9. Install the lock nut and tighten to 65-75 Ft. Lbs.,
thereby pinching the protruding steel bushing
between the inside hanger side surfaces.
10. Continuing with the center axle, lift the front ends
of the springs until they are positioned in the yoke
ends of the front equalizers and are aligned to
the bolt holes. Insert the lubricated bolts through
the holes taking care to orient the grease holes
as previously noted. Assemble and tighten the
nuts to 30-50 Ft. Lbs. The nuts should be seated
against the shouldered bolt ends.
11. Refer to Tandem Reassembly instructions to
install rear E-Z Flex® equalizer.
12. Place the rear ends of the rear axles springs
between the legs of the rear hangers. Insert the
lubricated spring eye bolts through the outside
leg of the hanger, the spring eye and start it
through the inside leg of the hanger. Make sure
the grease holes are oriented as previously
noted. Assemble and tighten the nuts to
30‑50 Ft. Lbs. The nuts should be seated against
the shouldered bolt ends.
13. Attach the shackle link/bolt assemblies to the
equalizers and spring eyes. The axles must
be lifted into their normal operating position
with the spring eyes above the lower holes
in the equalizers. Insert the shackle link/bolt
subassembly into both the equalizer and spring
eye at the same time.
14. Slide the plain shackle links onto the bolt ends
that protrude through the springs and equalizers.
Install the flanged lock nuts onto the bolts and
tighten to 30‑50 Ft. Lbs.
15. Check the suspension for freedom of movement
by lifting any one of the axles. When one axle
is lifted, the others should move downward and
should return to their normal position when the
lifting force is released.
16. Lubricate all the grease fittings using a Lithium
complex soap grease, NLGI No. 2 such as Mobil
Oil Company Mobilgrease HP or equivalent.
Pump the grease in until it begins to show at the
ends of the bronze bushings. For best results,
the suspension should be lubricated every 3,000
miles.
17. Reinstall the tire/wheel assemblies, following the
instructions provided by the manufacturer.
-5-
© Dexter Axle Company 7/17
www.dexteraxle.com 059-867-00 Rev. C
E-Z Flex® Equalizer included
in K71-652-00 & K71-656-00
Hanger Identification:
If Static Bump Clearance is greater than 2.5″, a bump stop should be used to avoid overstressing of leaf springs.
Static Bump Clearance of less than 1.5″ may limit full suspension movement and result in possible damage to
the frame and/or axles when operating on some rough and uneven road surfaces. Tire clearance should always
be greater than bump clearance to help prevent tire contact to underbody surfaces in the event of a suspension
component failure.
Parts Identification:
Bronze Bushing
Shoulder Shackle Bolt
with Grease Fitting
Center Pivot Bolt
Flange Locknut
for Shackle Bolts
Hex Locknut for
Center Pivot Bolts
E-Z Flex® Equalizer included
in K71-653-00 & K71-657-00
Shackle Link Optional End Designs
Shackle Link Assembly
All of the above items are included in this kit.
E-Z Flex® Equalizer
included in K71-656-00
E-Z Flex® Equalizer
included in K71-657-00
-6-
© Dexter Axle Company 7/17
www.dexteraxle.com 059-867-00 Rev. C
Typical Tandem Axle Installation
Front
Bronze Bushings to be installed in spring eyes
prior to bolt and nut assembly attachment.
Shackle Link Assembly Equalizer Shoulder Shackle Bolts
Center Pivot Bolt
Axis of Grease Cross-Hole
Typical Triple Axle Installation
Front
Bronze Bushings to be installed in spring eyes
prior to bolt and nut assembly attachment.
Axis of Grease Cross-Hole
Shackle Link Assembly Triple
Equalizer
Tandem
Equalizer
Center Pivot Bolt Center Pivot Bolt
Shoulder Shackle Bolts
Axis of Grease Cross-Hole
Shackle Link
Assembly