Jeep CJ Shackle Reversal Kit- Affordable Flex

In a perfect world, all Jeep vehicles would come with a super-flexy suspension right from the factory. And though the world today is far from perfect, you can pick up a brand-new Wrangler JK, which, if properly equipped, will out-flex anything else in stock form. However, this was not always the case with Wranglers, particularly pre-'97 leaf-sprung YJs and CJs. Leaf-spring technology, even at its best, was less than impressive by today's standards. For those of you who own a Jeep on leaf springs, it is necessary to significantly alter your suspension system to have the benefits of ample articulation.

Let's talk about ride quality too. Every leaf-sprung Jeep ever made had a silly forward-mounted pivoting shackle arrangement for the front axle. Looking back, we're still wondering why the factory didn't wise up and put the shackle behind the axle, where it could react naturally as the suspension cycled going down the road. This trick is called a shackle reversal, and it enhances ride quality while offering vast improvements in durability over forward-mounted shackles. Simply put, reverse-mounted shackles are superior.

That is why we decided to show you an affordable way to convert a Jeep CJ-in our case a Scrambler-to the superior setup. Along the way, we decided to show off an affordable way to add lift and axle beef at the same time. No single setup is perfect-this one happens to emphasize trail performance, yet the same parts we used in this particular project can be set up to provide gains in street ability too. Follow along now as we super-size a Jeep for cheap.

This is the hot ticket for Jeep builders who want to run full-width axles under a CJ or YJ. This kit is twice as nice because you get a front bumper and a shackle reversal from one product. It's called the Full Width Axle Kit from Blue Torch Fab Works (BTF). The kit includes all the necessary hardware to convert a leaf-sprung Jeep over to a shackle reversal and full-width axles. Made from 3/16-inch sheet steel, the material is laser-cut by Blue Torch Fab Works and then CNC-formed into parts that get welded and finally finish-ground for good looks. The kit is sold for the low price of $529.99.

This Scrambler was completely...        read full caption This Scrambler was completely stock when we started the project. DC Customs owner Dustin Chernoh found it rusting away in a farmer's field in Northern California. Knowing a good thing when he sees it, Chernoh offered the farm owner $1,500, running or not. Lucky for him the farmer took the cash, and all Chernoh had to do was return to the location with a trailer to collect his prize.	Here is a closer look at the...        read full caption Here is a closer look at the brackets BTF builds for the rear of the front leaf-spring setup. This part is welded directly to the side of the frame in place of the original spring mounts. We were impressed with the quality of this part. Notice how the main portion of the bracket features interlocking slots that help reinforce the pivot-point gussets.	To start the installation...        read full caption To start the installation process, it is necessary to remove the factory front-axle spring mounts from each framerail. Once this process is complete, you can begin mocking up the BTF parts. This is how the BTF parts look once tack-welded in place on the front of the frame.
This photo shows the driver-side...        read full caption This photo shows the driver-side frame tie-in shortly after Chernoh welded it up.	Here you can see Chernoh starting...        read full caption Here you can see Chernoh starting the process of welding the BTF parts in place.	Again, this is the driver...        read full caption Again, this is the driver side of the Jeep, only this shot shows the rear shackle pivot point after it was welded to the frame.

What Else To Consider
To achieve what we've shown you here, you will also need to address the following:

Driveshafts
Even if you use the stock spring packs and axles, you're going to have to lengthen your existing driveshafts to make a shackle reversal work. In some short-wheelbase applications, this may require installing a slip-yoke eliminator at the transfer case.

Shocks And Mounts
In most cases the factory shocks and mounting locations will need to be addressed once the shackle reversal is complete. Sometimes you can get away with running a slightly longer shock up front, but if you plan to go full-width, shocks mounts will have to be altered.

Steering
Steering linkages, pitman arm, and possibly steering-box location may require re-engineering to work properly. In our case, we converted the front axle to high-steer to help minimize the angle of the drag link.

Brake Lines
Any time you lift a vehicle, the brake lines must be replaced with lines that will reach the brake caliper throughout the entire range of suspension travel.

Sway Bar
If you run a sway bar, it will likely need longer end links at the very least.

Axles
Depending on how tall you go and what axles you use, you may need to address pinion-angle issues. In our case, Dustin Chernoh ordered a pair of 6-degree steel shims to correct the front pinion-angle misalignment.

U-bolts
Chances are you will need to get a different set of U-bolts to bolt in the new axle/spring configuration.

This shot shows the passenger-side...        read full caption This shot shows the passenger-side Rubicon Express leaf spring with the suspension articulated. Notice the way the leaf pack flattens out and the boomerang shackle still has plenty of area to move. This arrangement is ideal because the shackle cannot become inverted on the trail.

Still a work in progress,...        read full caption Still a work in progress, this photo shows the way Chernoh set up the rear Rubicon Express YJ leaf springs. Ideally you would want to run a reinforced shackle mount because the factory units are prone to cracking. In this case, Chernoh plans to move the shackle pivot point up inside the framerails.

Chernoh used a set of YJ 1...        read full caption Chernoh used a set of YJ 1 1/2-inch Rubicon Express leaf springs for the project. The plan was to clear a 42-inch tire with an aftermarket fender and hood. Once the leaf springs were located in place, we took the rig outside and flexed it with a forklift to check tire clearance. Notice that the springs are mounted to the top of the axle assembly. This provides an additional 3-4 inches of ride height, depending on the axles used. These particular leaf springs run right around $660 for a set of four.