Daemon4x4 - 4x4 & Off Road Technical Board

May i first of all say thanks to Pirate Storm and Clayton for their help in fitting the b/joint spacers.

This is the way Clayton,Pirate Storm and myself fitted 1.5" ball joint spacers to my truck yesterday.
1/ We first measured the distance from the wheel rim to the wheel arch.(make note of the gap).We then slackened off the torsion bars so the top wishbone can be moved later.
2/ Jack up the front and put axel stands under the front crossmember as you need the wishbones to hng loose.
3/ Undo the 4 nuts that hold the upper ball joint in place
4/ Undo the top nut on the shock absorber.
5/ Take off the outer track rod end to give extra movement on the lower wishbone later.
6/ We took of the brake hose also as i was fitting the extended braided hoeses but you will need to take the hose off of the caliper also so not to stretch and damage it.(Bend and tie the hose with a cable tie so not to lose too much brake fluid)
7/ With a 4" grinding disc you will need to grind the back lip of the wishbone down by about 10-15mm depending on what size spacers you are fitting.Keep checking every so often that the spacer will fit snug and flat on the inside of the wishbone.The amount that needs grinding off will probably depend on what size spacers you are fitting so please don't go by the amount that i have grinded off of mine.I would advise to grind a bit and then check the spacer will fit and continue to grind and so on.
8/ Once the spacer fits correctly then make sure that all the bolts will go thru the b/joint,spacer and wishbone ok before putting everything back together.If neccesary grind out more from the wishbone until everything fits ok.
9/ Start to put everything back together starting with the balljoint but dont do the bolts up tightuntil all 4 bolts are in place and do each bolt up so many turns each so to get the spacer to sit properly or you will end up snapping a bolt like Clayton did..Once the balljoint is all bolted up tight then start to put everything else back on.You will need to use a crowbar to lever up the upper wishbone enough to get the spacer and balljoint back under the wishbone.This is why we had to slacken of the torsion bars.
10/ If you have taken the brake hose off then you will need to bleed the brakes also.
11/ Repeat the above for the opposite side but be care not to let the hub drop as you take the t/r/end and shock off else you will split the inner cvboot like we did.
12/ Once both sides have been done and wheels put on take the truck for a spin to settle the suspension.
13/ I adjusted my torsion bars by 1.5" also as i have got 1" diff spacers fitted and the shafts are still looking ok and so not much of an angle on the cv's to cause excessive wear..

This will be a 2 man job

This is the way that we fitted the ball joint spacers so if anyone else fits them and finds an easier way then feel free to add to this write up.
Hope this is of some help .
here's a link to some pics of the installation of the spacers but they are not in any order tho
http://smg.photobucket.com/albums/v646/stormforce1067/ball%20joint%20spacers