Safety first: work on a level surface, chock wheels, support the chassis and axle on heavy-duty jackstands rated for the truck’s weight — never rely on a hydraulic jack alone. Wear eye protection and gloves.

Ordered procedure with theory (each action + why it’s done):

1) Diagnose and confirm fault
- Action: Visually inspect springs, bushings, shackles, U‑bolts, spring seats and frame. Lift load slightly to observe movement, listen for clunks, check ride height and axle centring.
- Theory: Leaf springs carry load, position the axle and control axle fore/aft movement. Failures are usually broken leaves, permanent sag (metal set), worn eye bushings or stretched/broken U‑bolts. Diagnosis isolates which element causes noise, looseness, misalignment or low ride.

2) Prepare the vehicle for removal
- Action: Drain load (remove payload), chock wheels, lift chassis with appropriate jacks and support axle and chassis independently on stands so the spring is unloaded or at a controlled preload as required.
- Theory: Leaf springs are under load; you must control axial and vertical forces to safely remove attaching hardware. Supporting axle and chassis prevents sudden shifts that can damage components or injure you.

3) Mark alignment and measure
- Action: Mark or measure spring and shackle positions, centre bolt relation to axle pad, and track axle centring relative to chassis before disassembly.
- Theory: Reusing or replacing springs must reproduce axle centring and correct pin/shackle alignment. Marks and measurements help restore geometry and detect frame or pad wear.

4) Remove preload and hardware in sequence
- Action: With axle supported, loosen and remove axle U‑bolts/nuts; remove spring-to-axle clamp/plate; remove shackle/anchor pin nuts; remove center bolt if replacing pack.
- Theory: U‑bolts clamp the spring to the axle and keep the centre of the spring under the axle pad. Removing U‑bolts releases clamping force so the pack can be extracted. Remove hardware in a controlled order to avoid letting parts drop.

5) Extract the spring pack
- Action: Slide the pack forward/back as needed, supporting the axle so it does not tilt; remove the spring from the front hanger eye and shackle.
- Theory: The pack must come out without bending the frame or damaging hanger eyes. Supporting axle preserves geometry.

6) Inspect related components
- Action: Inspect spring hangers, bushings, shackle pins, spring seats/pads, axle perch welds and frame for cracks or wear. Replace worn bushings, machined shackle pins, and corroded pads.
- Theory: Replacing only the spring while leaving worn hangers/bushings or deformed perches will recreate the fault quickly. Bushing wear creates play and clunks; worn perches prevent proper seating, causing misalignment.

7) Prepare replacement spring pack and hardware
- Action: Get the correct spring pack (matching dimension, leaf count, height and rate), new center bolt, new U‑bolts, new shackle pins/bushings and any required shims or spring seats. Clean and grease bushings where specified.
- Theory: Spring rate and length determine ride height and load distribution. New hardware (U‑bolts, center bolt) are critical: U‑bolts stretch and seat; reuse risks loosening. Bushings must allow rotation with minimal play.

8) Install new spring pack into hangers (dry fit)
- Action: Place spring into front hanger eye, rest on axle seat, align centre pin to axle pad, insert center bolt finger-tight; hang shackles and pin into rear or shackle mount.
- Theory: Correct orientation and centre pin alignment ensures axle is located laterally and longitudinally as designed. The center bolt holds leaves together and locates them on the axle pad.

9) Preload and tighten hardware to spec with axle supported correctly
- Action: Lower axle so spring supports designed portion of the load (spring under a small preload or full load depending on manufacturer instructions), then torque shackle/pin and U‑bolt nuts to Ford-specified values; torque center bolt if required. Tighten U‑bolts in a crisscross sequence evenly.
- Theory: Leaf spring stack compresses under load and settles. Tightening while spring is under the proper load aligns eyes and shackle angles, prevents pin binding, and ensures correct clamp force. Even U‑bolt torque keeps the pack seated and avoids induced stress.

10) Check and set axle alignment and pinion angle
- Action: Verify axle lateral centring, track width, and pinion angle; add shims at perches or adjust shackle length if necessary.
- Theory: The spring pack locates the axle and determines pinion angle. Misalignment causes driveline vibration, unequal tyre wear and handling issues. Shims or correct spring length restores geometry.

11) Re-grease and fit any straps/rebound devices and anti-rattle features
- Action: Install any spring straps, rebound straps, or bump stops and apply grease to specified bushing faces (if designed).
- Theory: Rebound straps limit extreme articulation and prevent pack separation; correct greasing reduces wear and noise.

12) Final torque check after settling
- Action: With vehicle on ground and normal load (or after short test drive), re-torque U‑bolts and shackle nuts to spec.
- Theory: The spring pack will settle slightly under static load and initial miles; re-torquing prevents loosening and maintains clamp force.

13) Road test and inspect
- Action: Drive under representative load conditions, listen for clunks, re-check torque and inspect for movement, sag, or misalignment.
- Theory: Dynamic loads reveal residual issues (binding, improper shimming, worn components) and confirm the repair restored correct function.

How the repair fixes common faults (theory)
- Broken leaf: Replaces the load-bearing element; restores load path and spring rate. A complete pack replacement restores original stack stiffness and ride height.
- Sag (permanent set): New spring pack restores free height and corrects axle sag and geometry, returning correct wheel travel and load distribution.
- Worn/damaged bushings or pins: Removing play and lateral/longitudinal movement. Proper bushings restore the designed pivot points; prevents clunks and uneven loading across leaves.
- Stretched/loose U‑bolts or damaged perches: New U‑bolts and repaired perches restore clamp force and pack seating, preventing the centre bolt and leaves from shifting under load.
- Misalignment/axle drift: Correct spring length, shims and shackle angles re-establish axle location fore/aft and lateral centring, fixing steering and tyre wear problems.

Key theoretical notes (essential concepts)
- Leaf springs are both springs and locating links. They transmit vertical load, locate the axle, and resist torque from acceleration/braking.
- The pack’s rate depends on leaf count, thickness and length — changing these changes ride height and stiffness.
- Bushings allow relative rotation; they wear rather than the pack itself in many cases. Tightening while loaded sets correct geometry.
- Clamping force (U‑bolts and center bolt) keeps the pack integrated; improper clamping leads to interleaf wear and noise.
- Always restore or maintain the original geometry; a correct-looking install that changes axle location or driveline angle will create new faults.

End.
rteeqp73

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