This only pertains to the heavy duty shackle kits (like Prothanes HD kit) that use shackle plates thicker than 1/4".

When using a kit like the Prothane Heavy duty Polyurethane shackle kit, on the first generation Mustangs, the left shackle can be a PITA if not done in the correct order. there is not enough room to insert the bolt after the bushings, and sleeve are in place.

So the tip is this:
lube (inside and out) and install the bushing closest to the gas tank. Lube another bushing on the outside, and the sleeve. Slide the bolt through the shackle. Slide the sleeve from the non-lipped side of the bushing until it is flush with the lip. Slide the sleeve with the bushing on it over the bolt. Now take that assembly and put the whole thing up into the steel sleeve.

If you want both the upper and lower bolt facing the same way, install the lower bolt before putting the shackle assembled above in place. And if you are real ****, and want all the bolts oriented the same way, follow this procedure in mirror image for the passenger side shackle.

In the future if you ever need to pull it back apart to lubricate it, Push the sleeve out towards the left side of the car. Then remove the bushing closest to the gas tank. Push the sleeve back through towards the gas tank, all the way out of the other bushing. Then push the other bushing out. It will come out with the bolt still inside, and you'll have enough room to get the whole thing out.

[IMG]local://upfiles/16598/F06A919A21F141379D73CEC47F6CE5C5.jpg[/IMG]

 

Went though this with stock shackles and poly bushings. Man what a pain. I would have never got it unless I got out the WD40. I really don't like WD but it was the only way to get the thing together.

 

Prothane gives you this real sticky synthetic grease. Worked great! With the whole assembly up in place, I was able to put a flat bar against the inner body, and push it into place using the side of a 5lb sledge as a "pry bar". Took less than 10 minutes... once I figured out the trick.

Scott