OTC Tools 5080A Leaf Spring Pin and Bushing Service Set (Truck Front)

1. Product Overview

The OTC 5080A Leaf Spring Pin and Bushing Service Set is designed for the efficient removal and installation of truck front spring eye bushing assemblies. This tool utilizes 10 tons of hydraulic force to perform these tasks quickly, often without requiring the removal of leaf spring hangers and spring assemblies from the vehicle. It is compatible with bushings having diameters from 1-1/4 inch to 1-7/8 inch and pin diameters from 7/8 inch to 1-1/8 inch, supporting popular Original Equipment (OE) and aftermarket components, including Horton pin and bushing assemblies.

Image 1.1: The OTC 5080A Leaf Spring Pin and Bushing Service Set, including the hydraulic ram, various adapters, and the protective carrying case.

2. Safety Information

WARNING: Always read and understand all instructions and safety warnings before operating this tool. Failure to do so may result in serious injury or property damage.

• Wear appropriate personal protective equipment (PPE), including safety glasses, gloves, and sturdy footwear.
• Ensure the vehicle is properly supported on jack stands or a lift before beginning any work.
• Never exceed the rated capacity of the tool (10 tons).
• Use only with a compatible hydraulic hand pump (sold separately) rated for up to 10,000 PSI.
• Inspect the tool and all components for damage or wear before each use. Do not use damaged equipment.
• Keep hands and other body parts clear of pinch points and moving components during operation.
• This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

3. Components Included

The OTC 5080A set includes the necessary accessories for servicing leaf spring pin and bushing assemblies. Please note that a hydraulic hand pump is required for operation and must be purchased separately.

• Hydraulic Ram Assembly
• Various Receiving Tubes and Adapters
• Pushing Adapters and Pins
• Storage Case

Refer to the main product image (Image 1.1) for a visual representation of the included components.

4. Setup

1. Prepare the Vehicle: Safely lift and support the truck, ensuring the leaf spring assembly requiring service is accessible and stable.
2. Select Adapters: Identify the correct receiving tube and pushing adapter/pin combination that matches the diameter of the bushing and pin to be serviced. The tool supports bushing diameters from 1-1/4 inch to 1-7/8 inch and pin diameters from 7/8 inch to 1-1/8 inch.
3. Connect Hydraulic Pump: Connect the hydraulic hose from a compatible 10,000 PSI hydraulic hand pump (not included) to the hydraulic ram assembly. Ensure all connections are secure and free of leaks.
4. Position the Tool: Assemble the selected adapters onto the hydraulic ram. Position the tool squarely against the leaf spring eye and the bushing/pin to be removed or installed. Ensure proper alignment to prevent damage to the tool or the vehicle components.

5. Operating Instructions

5.1. Bushing Removal

1. With the tool positioned and aligned, slowly actuate the hydraulic pump to apply pressure.
2. Observe the bushing as it is pressed out. Ensure it moves smoothly and without binding.
3. Continue applying pressure until the bushing is fully removed from the leaf spring eye.
4. Release the hydraulic pressure and carefully remove the tool.

5.2. Bushing Installation

1. Clean the leaf spring eye bore and the new bushing. Apply a suitable lubricant if recommended by the bushing manufacturer.
2. Position the new bushing into the leaf spring eye.
3. Re-assemble the tool with the appropriate adapters for installation, ensuring proper alignment with the new bushing and the leaf spring eye.
4. Slowly actuate the hydraulic pump to press the new bushing into place. Ensure it enters straight and without cocking.
5. Continue applying pressure until the bushing is fully seated. Do not over-press.
6. Release the hydraulic pressure and carefully remove the tool.

Image 5.1: Example of specialized service tools in use, demonstrating the type of application for the 5080A set.

6. Maintenance

• Cleaning: After each use, wipe down the tool components to remove dirt, grease, and hydraulic fluid.
• Inspection: Regularly inspect the hydraulic ram, hoses, and adapters for signs of wear, cracks, bends, or leaks. Pay close attention to seals and connection points.
• Lubrication: Keep moving parts lightly lubricated as needed.
• Storage: Store the tool in its protective carrying case in a clean, dry environment to prevent corrosion and damage.
• Hydraulic Fluid: Periodically check the hydraulic fluid level in your separate hydraulic pump and refill or replace according to the pump manufacturer's instructions.

7. Troubleshooting

• Loss of Hydraulic Pressure or Leaks:
  • Check all hydraulic connections for tightness.
  • Inspect the hydraulic hose and ram for visible damage or fluid leaks. If leaks are found, discontinue use and seek professional repair.
  • Ensure the hydraulic pump has sufficient fluid and is functioning correctly.
• Bushing Not Moving or Binding:
  • Verify that the correct adapters are being used for the specific bushing and pin size.
  • Ensure the tool is properly aligned and square with the component. Misalignment can cause binding.
  • Check for excessive corrosion or damage in the leaf spring eye bore that might impede bushing movement.
  • Confirm the hydraulic pump is delivering adequate pressure.
• Adapters Do Not Fit Specific Truck Models:
  • The 5080A set is designed for a range of common bushing and pin sizes. For certain specialized or larger truck models (e.g., some Freightliner Cascadia models with larger bushing ODs), custom adapters may be required or the tool may not be compatible. Consult vehicle service manuals or OTC support for specific applications.

8. Specifications

9. Warranty and Support

For warranty information, technical support, or to inquire about replacement parts and additional adapters, please contact OTC customer service directly. Refer to the official OTC website or product packaging for the most current contact details and warranty terms.

Manufacturer: OTC

Website: Visit the OTC Store on Amazon