Fexhull 60818

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Fexhull Air Suspension Kit 60818 Instruction Manual

For Ram 1500 and 1500 Classic Pickups (2009-2022)

1. Overview

This manual provides detailed instructions for the installation, operation, and maintenance of the Fexhull Air Suspension Kit 60818. This kit is designed to enhance the load-carrying capability and ride quality of your vehicle.

1.1 Product Compatibility

Vehicle: Ram 1500 and 1500 Classic Pickups
Model Years: 2009, 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018, 2019, 2020, 2021, 2022
OE Part Number: 60818

Figure 1.1: Compatibility and OE Number for Fexhull Air Suspension Kit 60818, showing a truck towing a trailer.

The Fexhull Air Suspension Kit 60818 is specifically engineered for the listed Ram 1500 and 1500 Classic models, ensuring proper fitment and performance. The kit integrates seamlessly into the existing suspension system to provide additional support when hauling or towing heavy loads.

2. Specifications

Feature	Specification
Minimum PSI	5 PSI
Maximum PSI	35 PSI
Load Leveling Capacity	Up to 7500 lbs
Distance Between Brackets	12.05 inches
Material	TPEE (Thermoplastic Polyester Elastomer)
Position	Rear

Figure 2.1: Key specifications of the Fexhull Air Suspension Kit 60818, including OE number, bracket distance, load capacity, PSI range, and material.

Air pressure specifications and bracket distance for the air springs — Figure 2.2: Visual representation of minimum (5 PSI) and maximum (30 PSI) air pressure, and the 12.05-inch distance between brackets.

3. Components List

The Fexhull Air Suspension Kit 60818 includes the following components:

Air springs (2)
Air lines
Brackets
Roll plates
Mounting hardware (nuts, washers, clamps, zip ties, air valves)

Components of the Fexhull Air Suspension Kit 60818 — Figure 3.1: All components included in the Fexhull Air Suspension Kit 60818, laid out for inspection.

Detailed view of Fexhull Air Suspension Kit components — Figure 3.2: Close-up views of individual components, including the top of an air bag, air line, various nuts and washers, and air valves with clamps.

4. Safety Information

Always wear appropriate personal protective equipment (PPE) during installation, including safety glasses and gloves.
Ensure the vehicle is securely supported on jack stands before working underneath. Never rely solely on a jack.
Do not exceed the Gross Vehicle Weight Rating (GVWR) of your vehicle. The air suspension kit increases load leveling capacity, not the vehicle's maximum weight capacity.
Maintain air pressure within the specified range of 5 PSI (minimum) to 35 PSI (maximum). Over-inflation or under-inflation can damage the air springs and affect vehicle handling.
Route air lines away from sharp edges, exhaust components, and moving parts to prevent damage.
If you are unsure about any step of the installation process, consult a qualified mechanic.

5. Setup and Installation

Proper installation is crucial for the performance and longevity of your air suspension kit. Follow these steps carefully.

5.1 Pre-Installation Steps

Park the vehicle on a level surface and engage the parking brake.
Raise the rear of the vehicle using a jack and support it securely with jack stands, ensuring the rear axle is fully suspended and the coil springs are extended.
Remove the rear wheels for easier access to the suspension components.

5.2 Air Spring Preparation

Deflate the air springs completely. You may need to compress them manually or use a vacuum to remove all air.
Carefully fold or roll the air springs to make them compact enough to fit inside the coil springs. You can use zip ties to temporarily hold them in a compressed state.

5.3 Installation into Coil Springs

Insert the compressed air spring into the top of the existing coil spring. Ensure it is seated correctly within the coil.
Once the air spring is in place, cut and remove any temporary zip ties. The air spring should expand to fill the coil.
Repeat for the other side.

Integrated design of the air spring within a coil spring — Figure 5.1: An air spring integrated within a vehicle's coil spring, demonstrating its installed position.

5.4 Air Line and Valve Installation

Attach the air lines to the air springs. Ensure a secure, airtight connection.
Route the air lines to a convenient location for the inflation valves, typically near the rear bumper or license plate. Avoid sharp bends, heat sources, and moving suspension components. Use the provided clamps and zip ties to secure the lines.
Install the inflation valves in the chosen location. Drill a small hole if necessary, ensuring it is clean and free of burrs. Secure the valves with the provided nuts and washers.
Connect the air lines to the inflation valves.

5.5 Post-Installation Checks

Reinstall the wheels and lower the vehicle.
Inflate the air springs to approximately 5-10 PSI.
Check all connections for air leaks using a soapy water solution. Bubbles indicate a leak. Tighten connections or re-seat lines as needed.
Ensure adequate clearance around the air springs and air lines throughout the full range of suspension travel.

6. Operating Instructions

The Fexhull Air Suspension Kit is designed to be adjustable to suit varying load conditions.

6.1 Inflation and Deflation

Inflation: Use a standard air compressor to inflate the air springs through the installed inflation valves. Monitor the pressure with a gauge.
Deflation: To reduce air pressure, press the center pin of the inflation valve.

6.2 Recommended Air Pressure

Minimum Pressure: Always maintain a minimum of 5 PSI in the air springs, even when unloaded, to prevent damage.
Maximum Pressure: Do not exceed 35 PSI. Over-inflation can lead to premature failure of the air springs.
Load Adjustment: Adjust the air pressure based on the load being carried. Increase pressure for heavier loads to maintain a level ride height and improve stability. Decrease pressure when the load is removed to restore ride comfort.

Benefits of the Fexhull Air Suspension Kit: improved ride quality and stability — Figure 6.1: Visual demonstration of how the air suspension kit improves vehicle leveling and addresses issues like rough ride, bottoming out, and trailer sway.

Visual comparison of vehicle leveling before and after installing the air suspension kit — Figure 6.2: A side-by-side comparison showing a truck with a sagging rear when loaded (BEFORE) and a level stance after the air suspension kit is engaged (AFTER).

7. Maintenance

Regular maintenance ensures optimal performance and extends the life of your Fexhull Air Suspension Kit.

Periodic Inspection: Regularly inspect the air springs, air lines, and connections for signs of wear, damage, or leaks. Check for cracks, abrasions, or loose fittings.
Cleanliness: Keep the air springs and surrounding areas free from dirt, debris, and corrosive materials.
Pressure Check: Check air pressure periodically, especially before and after hauling or towing. Adjust as necessary to maintain the recommended PSI range.
Roll Plates: The included roll plates protect the air springs from abrasion and enhance durability. Ensure they are properly positioned and free from damage.

8. Troubleshooting

This section addresses common issues you might encounter with your air suspension kit.

Problem	Possible Cause	Solution
Air springs lose pressure	Air leak in lines, connections, or valve; damaged air spring	Check all connections with soapy water for bubbles. Tighten fittings or replace damaged components. Inspect air springs for punctures or tears.
Vehicle remains low after inflation	Insufficient air pressure; air springs not fully inflated; excessive load	Increase air pressure to recommended levels (up to 35 PSI). Ensure air springs are fully expanded. Reduce vehicle load if it exceeds the kit's capacity or GVWR.
Rough ride or harsh handling	Over-inflated air springs	Reduce air pressure to within the recommended range (5-35 PSI). Adjust pressure based on load for optimal comfort.
Air lines pinched or damaged	Improper routing during installation	Inspect air line routing. Reroute lines away from moving parts, sharp edges, or areas where they can be pinched. Replace damaged lines.

9. Warranty and Support

Fexhull products are manufactured with over 20 years of professional experience, adhering to high standards of quality and efficiency.

For specific warranty details, please refer to the product packaging or contact Fexhull customer service.
For technical assistance or support, please reach out to the manufacturer directly.

Fexhull's commitment to professional experience and quality — Figure 9.1: Image representing Fexhull's manufacturing expertise and commitment to quality, with a mechanic working on a vehicle.

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