Air Spring Kit Installation Manual

Product Overview

This heavy-duty air suspension kit is designed to eliminate vehicle sag, sway, and bottoming out. It levels the truck's stance, providing added support for a smoother and safer ride.

* See application guide for proper fitment.

Important Information & Warnings

WARNING: This product can expose you to the chemical Hexavalent Chromate, which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov

IMPORTANT: This air suspension kit will not increase the GVWR (Gross Vehicle Weight Rating), as the GVWR is determined by the vehicle manufacturer. Do not exceed the maximum capacity listed by the vehicle manufacturer.

PLEASE NOTE: The air bag must have clearance between itself and the surrounding components to prevent any contact when the bag is inflated or compressed. Trimming off excess bolt length is also required to ensure no contact with the bag or other suspension components can be made once installed.

Safety Warnings!

• Serious personal injury or death may result from an air spring failure or accident due to improper installation or air spring pressure operation or maintenance. Please read and abide the instructions, safety recommendations, and maintenance suggestions throughout this manual.
• Inflating an unsecured air spring is dangerous. If it bursts, it could be hurled into the air with explosive force resulting in serious personal injury or death. Never inflate an air spring unless it is secured to the vehicle.
• Removing and replacing air springs can be dangerous. This is only a job for a qualified service professional. Never perform air spring service procedures without proper training, tools, and equipment.

Kit Contents and Required Tools

Kit Contents

Required Tools

• Hoist or Floor Jack
• Safety Stands
• Safety Glasses
• Torque Wrench
• Standard Combination Wrenches
• Ratchet
• Metric & Standard Sockets
• Hose Cutter (included) or Sharp Utility Knife
• Pipe Thread Sealant
• Spray Bottle with Dish Soap/Water
• Air Compressor/Compressed Air Source (to test/fill air springs)

Passenger Side Assembly Diagram

An exploded view diagram shows the assembly of the passenger side air spring system. Key components include the air spring (A), roll plate (B), upper bracket (D), lower bracket (E), relocation bracket (F), round U-bolt (G), square U-bolt (H), axle strap (I), countersunk bolts (J), flange bolt (K), nylock nuts (L), carriage bolts (M), and serrated flange nuts (N). Torque specifications are indicated for various fasteners, such as 27 N•m [20 ft-lbs] for bolts (J) and nuts (L), and 25 Nm [19 ft-lbs] for bolt (K) into the strike plate.

Before Starting the Installation

1. Ensure the application information is correct for the make, model, and year of the vehicle.
2. Check with the vehicle manufacturer regarding the rear wheel brake proportioning valve, as it may affect braking performance.
3. It is recommended to use a good quality anti-seize on all fasteners to reduce corrosion and facilitate removal.

PLEASE NOTE: This kit contains push-to-connect fittings. Using scissors or wire cutters to cut the nylon airline will distort the line and cause leaks. The airline must be cut off squarely with the provided hose cutter or a sharp utility knife.

Installation Steps

Step 1: Measure Stock Ride Height

Park the vehicle on a level surface. Measure the distance between the center of the wheel hub and the bottom of the fender well. Record this measurement for all four corners.

Step 2: Remove Rear Wheels

Place wheel chocks in front of and behind the front wheels. Raise the rear of the truck high enough to remove both rear wheels. Place two jack stands under the rear axle and lower the vehicle until the axle is supported by the jack stands. Remove the rear wheels.

Step 3: Remove the Jounce Bumper

The jounce bumper assembly consists of a retaining cup and a rubber bumper. Pry out the two jounce bumpers from their retaining cups using a pry bar or large screwdriver.

Step 4: Remove the ABS/Brake/E-Brake Brackets

Unclip the ABS wiring loom from the bracket holding it to the strike plate. Gently pull the wiring loom downwards away from the strike plate. Remove the M8 bolt (using a 13 mm socket) holding the bracket to the strike plate. Gently pull the bracket away and let it hang freely. Discard the bolt. Repeat for the opposite side.

Step 5: Assemble the Air Springs and Brackets

Assemble the air springs as shown in Figure 5A. Reference Figure 5B for correct mounting hole assembly. Set the roll plate (B) over the bottom of the air spring (A). Place the lower spring bracket (E) onto the air spring, aligning holes. Fasten using two 3/8" – 24 countersunk cap screws (J), torquing to 20 ft-lbs (27 N•m). Turn the assembly over and set the roll plate (B) on top of the air spring (A). Fasten the swivel fitting (R) into the top of the air spring. Use Teflon tape or thread sealant to prevent leaks. Finger tighten the fitting and then turn an additional 1.5 turns. Set the upper passenger spring bracket (D) onto the air spring, aligning holes. Fasten using two 3/8" – 24 countersunk cap screws (J), torquing to 20 ft-lbs (27 N•m). Repeat the process for the driver side assembly using the upper driver spring bracket (C) and alternate hole placement (see Figure 5B).

Step 6: Install the Air Spring Assemblies

It may be necessary to raise the truck frame slightly for clearance. Position the air spring assembly so the lower bracket rests on the jounce bumper strike plate and the upper bracket nests around the jounce bumper (shown in Figure 6). The air fitting should be positioned on the inboard side of the frame. Repeat for the opposite side.

Step 7: Install the ABS Relocation Bracket

Drop carriage bolts (M) into the slots on the lower bracket. Install the relocation bracket (F) on the rearward side of the bracket, ensuring no wiring lines are pinched between the lower bracket and loom bracket. Secure using a flange nut (N) but do not fully tighten yet. Repeat for the other side.

Step 8: Install the Axle Clamp Bar

Position the axle strap (I) on the axle, aligning its mounting holes with the carriage bolts (M) in the lower bracket. Secure the axle strap using a flat washer (O) and nylon locknut (L). Remove slack by threading nuts, but do not torque yet. Align the air spring by adjusting the lower bracket on the strike plate so its slots align with the strike plate holes. Torque the axle strap nuts (L) to 20 ft-lbs (27 N•m). Torque the relocation bracket flange nut (N) to 20 ft-lbs (27 N•m). Repeat for the opposite side.

Step 9: Secure the Upper Bracket

Install the square U-bolt (H) around the vehicle frame and through the upper bracket mounting holes, ensuring no lines or wires are pinched. Install a flat washer (O) and nylon locknut (L) on each end of the U-bolt (Figure 9A). Remove slack but do not torque yet. Install the round U-bolt (G) around the jounce bumper cup and through the side mounting slots in the upper bracket (Figure 9B). Install a flat washer (O) and nylon locknut (L) on each end of the U-bolt (Figure 9C). Torque the round U-bolt nuts (L) to 20 ft-lbs (27 N•m). Torque the square U-bolt nuts (L) to 20 ft-lbs (27 N•m). Trim excess length of round U-bolts to prevent interference with leaf springs. Repeat for the opposite side.

Step 10: Attach Brake/E-Brake Line Bracket

Attach the bracket removed in Step 4 to the air spring bracket using the M8 bolt (K) (Figure 10A). Torque bolt to 19 ft-lbs (25 N•m). Clip the ABS wiring loom into the slot on the relocation bracket (Figure 10B). Repeat for the opposite side.

Step 11: Install Heat Shield

Bend tabs on the heat shield (P) to create approximately 1/2" of dead space between the shield and the exhaust when attached. Attach the heat shield to the exhaust pipe on the passenger side using two ring clamps (Q) (Figure 11). Each hose clamp holds a tab against the exhaust pipe.

Step 12: Install Air Line

PLEASE NOTE: This kit contains push-to-connect fittings. Using scissors or wire cutters to cut the nylon airline will distort the line and cause leaks. The airline must be cut off squarely with the nylon hose cutter provided or a sharp utility knife.

Provided are two fill valves. Install them in a convenient location, such as in place of license plate fasteners or by drilling two 5/16" holes. Cut the air line assembly (S) into two equal lengths with the hose cutter. Route one air line to an air spring fitting. Moisten the end of the air line before inserting it into the fitting and push until it stops. Repeat for the other fill valve. Secure airlines using tie-straps (T), keeping them away from moving items and heat sources.

Install a 5/16" nut on the air valve. Ensure enough of the inflation valve extends through the hole. Install a flat washer and a 5/16" nut and cap (reference Figure 12 for assembly). Approximately 1/2" of the valve should be exposed for easy gauge or air chuck application.

If an in-cab inflation kit is being installed, follow the instructions provided with that kit.

Step 13: Check System for Leaks

Inflate both air springs to 90 psi. Use a mixture of dish soap and water on all air line connections to detect leaks. Large, expanding bubbles indicate a leak (as shown in Figure 13). Repair as necessary and retest.

Inflate air springs to a predetermined value and recheck pressure the following day. If pressure has been lost, an air leak is present and must be repaired and retested until no leaks exist.

After Completing the Installation

PLEASE REMEMBER:

• Install wheels and torque fasteners to manufacturer's specifications.
• Re-torque all fasteners after the first 500 miles of driving.
• For safe and proper operation, never operate the vehicle with less than 10 psi or over 100 psi in the air springs. Staying within these pressure limits ensures maximum air spring life. Failure to do so may result in a voided warranty.
• NOTE: Do not exceed maximum vehicle payload. Failure to do so may result in failure of the air suspension kit and/or damage to your vehicle.

Thank you for installing the air suspension kit.

Optional Accessories

Optional dual needle air gauges are available to monitor pressure in each spring from the vehicle cab. A full line of air compressors, air tanks, and solenoids are also available to work with and control your air spring system.

Operating Your Vehicle with Air Suspension

Air springs have minimum and maximum pressure requirements. Never operate the vehicle with less than 10 psi in an air spring and never inflate air springs over 100 psi, as this will damage them. Check air pressure daily for the first few days to ensure no leaks have developed. Air springs are designed to maintain the vehicle's stock ride height with a load. Do not use air springs to lift the vehicle without a load, as this will result in a harsh ride.

Servicing Your Vehicle with Air Suspension

When lifting the vehicle with a floor jack or hoist on the frame, never allow the air spring to limit the travel of the axle. Always try to jack the vehicle on the axle. Suspending the axle with the air spring limiting its travel will damage the air spring and void the warranty.

Warranty

The owner's warranty will be void if air springs are run with less than the minimum of 10 psi. See additional warranty for details.