Air Lift Performance MN-643 User's Manual
Contents
1. Tighten securely It will be necessary to drill two 1 2 holes through the driver side frame rail to completely attach this bracket NOTE It may be necessary to raise the chassis up to obtain clearance when drilling Using the mounted bracket as a template drill a hole through the front most hole in the bracket There is already an exisiting slot in the frame that will be enlarged Figure 3 Attach using one 1 2 bolt G two flat washers H and one nylock nut 1 Tighten securely Using the bracket as a template drill the remaining hole under the frame flange in between the two panhard rod mounts Figure 3 Attach using one 1 2 bolt G two flat washers H and one nylock nut I Tighten securely IV Attaching and Adjusting the Panhard Rod 1 Attach the panhard rod assembly C to the driver side frame bracket using one 9 16 bolt Y two flat washers H and one nylock nut T Leave loose at this time Lift or drop the rear of the frame so that it measures 31 from the floor to the top of the frame Measure the distance between the tire and the frame Pry the frame side to side so that the distance is equal on both sides Adjust the hyme joint and attach it to the passenger side beam assembly using a 3 4 bolt HH Place the bolt through one flat washer II through the flange a 1 2 wide spacer Z the hyme joint another 1 2 wide spacer Z the other flange on2. Figure 5 Leave the bottom loose at this time 5 At this time lightly oil and torque the axle bracket center bolt to 321 ft Ibs Gas Tank Cover VI Gas Tank Cover Figure 6 1 Install the cover back in place by using two 10mm bolts J under the frame on each side 2 Insert the two spacers L in the back between the gas tank mount and the gas tank cover Attach with two 10mm bolts J Tighten all bolts securely Figure 6 3 Install four 10mm nuts K onto the the previously installed bolts on the inside of the frame rail Tighten securely Technical Support 1 800 248 0892 4 Ext 2 VII Installing the Air Lines Air Line to 1 Choose a convenient location for mounting the inflation valves Bellows Popular locations for the inflation valve are the wheel well flanges the license plate recess in bumper under the gas cap access door or through license plate itself NOTE What ever the chosen location is make sure there is enough clearance around the inflation valves for an air chuck 2 Drill a 16 hole to install the inflation valves 3 Cut the air line assembly AA in two equal lengths CAUTION When cutting or trimming the air line use a hose Figure 7 cutter Air Lift P N 10530 a razor blade or a sharp knife A clean square cut will ensure against leaks Do not use wire cutters or scissors to cut the air line These tools may flatten or crimp the air line causing it to leak ar
3. Gross Vehicle Weight Rating GVWR as indicated by the vehicle manufacturer Although your air springs are rated at a maximum inflation pressure of 100 p s i The air pressure actually needed is dependant on your load and GVWR which may be less than 100 p s i Check your vehicle owners manual and do not exceed the maximum load listed for your vehicle Always add air to springs in small quantities checking the pressure frequently Air springs require less air volume than a tire and inflate quickly Should it become necessary to raise the vehicle by the frame make sure the system is at minimum pressure 10 p s i to reduce the tension on the suspension brake components Use of on board leveling systems do not require deflation or disconnection IMPORTANT Check and re torque all mounting hardware especially the beam U bolts after 100 and 3 000 miles Technical Support 1 800 248 0892 Ext 2 7 Thank you for purchasing Air Lift Products Mailing Address Street Address AIR LIFT COMPANY AIR LIFT COMPANY P O Box 80167 2727 Snow Rd Lansing MI 48908 0167 Lansing MI 48917 Local Phone 517 322 2144 Fax 517 322 0240 For Technical Assistance call 1 800 248 0892 The Choice of the Professional Installer Printed in the USA
4. U bolts M flat washers N and nuts O Figure 2a Torque to 22 mm flat washer and 128 ft Ibs 22 mm nyloc nut behind beam 4 For the driver side set the axle bracket TT onto the top of the axle Insert the bolts NN through the flat washers OO the 9 mm flat washer axle bracket and the stock spring retainer Fasten using flat washers OO and nyloc nuts PP Figure 2b 5 Tighten and evenly torque to 128 ft lbs 6 Set the beam assembly onto the axle bracket Insert the bolt 5 8 nyloc nut SE E QQ through one flat washer RR and through the front of the Axle Bracket beam assembly Fasten using a flat washer RR and a nyloc nut SS Figure 2b Leave loose at this time stock retainer Figure 2b NOTE Index the alignment pin into the spring perch hole before applying torque Technical Support 1 800 248 0892 2 Ext 2 Ill Attaching the Frame Brackets 1 Install the passenger side frame bracket D using the existing holes from the previously removed frame contact overload bracket Attach using four bolts G eight flatwashers H and four nylock nuts I Tighten securely NOTE Be sure the bracket flange is tight to the bottom frame flange Clamp tightly using a pair of vice grips Attach the driver side frame bracket E following the instructions in the previous step Install two 10mm bolts J above the rivet on the driver side frame rail See section step 5
5. MN 643 CROAL p 02511 OADIAMER _ Kit No 39205 ULTIMATE SUSPENSION UPGRADE by AIR LIFT Please read these instructions completely before proceeding with installation Parts List Item P N Description Quantity Item P N Description Quantity 26391 Driver Side Beam Assembly WF BB 10466 8 Zip Tie 6 26414 Passenger Side Beam Assembly 1 AY SQ 21230 Poly Cap 26380 Panhard Rod Assembly 07138 Upper Bracket Right 07137 Upper Bracket Left 58201 Bellows 17247 1 2 13 x 1 75 Bolt GD8 18485 1 2 Flat Washer 18460 1 2 13 Nylock Nut 17268 10mm Bolt GD8 8 18495 10mm Nylock Nut 13228 Spacer 10308 U Bolt 18509 Washer 65ID x 1 250D 18508 5 8 18 Nut 18451 3 4 16 Jam Nut 18484 1 2 20 Hex Nut GD8 18429 1 2 Lock Washer 21745 1 4 MNPT x 1 4 Tube Straight 18480 9 16 Nylock Nut 17219 9 16 12x 5 Bolt GD8 13034 Spacer 20086suw Air Line Assembly SBD 18405 5 6 Flat Washer SFE 21234 Rubber Washer FF 18411 5 16 Star Washer GG 21233 5 16 Hex Nut HH 17269 3 4 16 x 4 Bolt GD8 ll 18518 3 4 Flat Washer GD8 JJ 18470 3 4 16 Nylock Nut GD8 KK 18435 3 8 16 Nylock Nut LL 10195 Flat Washer 2 5 OD x 53 ID x 19 MM 17271 1 2 13 X 3 Hex Cap Screw NN 17307 5 8 18 x 6 5 Bolt OO 18509 1 25 OD Flat Washer PP 18536 5 8 Nyloc Nut QQ 17305 22mm Bolt RR 18535 22mm Flat Washer SS 18534 22mm Nyloc Nut TT 10513 Axle Bracket UU 17286 Centering Pin
6. W 10642 Spring Retainer WW 10445 Limiting Strap AA Ap A AWOANDANDHA N ANNNDN EN lt An9DOVOZErAC TONMGOoD gt D NO NOAANAANDNADOBRENH AA Read all maintenance guidelines on page 7 before operating the vehicle Technical Support 1 800 248 0892 Ext 2 DANGER Compressed air can cause injury and damage to the vehicle and parts if it is not handled properly For your safety do not try to inflate the air springs until they have been properly secured to the vehicle Ker halle I Getting Started Upper Bracket Remove Bolts 1 Elevate the rear of the vehicle and secure the frame with jack i stands 2 Remove both of the leaf springs NOTE Retain the front nuts and bolts to be reused 3 Remove the rear contact overload frame brackets from both sides Remove Gas Tank Cover of the frame rail Driver Side Only 4 Remove the bottom gas tank cover from the vehicle Figure 1 5 Remove the two bolts above the rivet on the driver side of the frame rail Figure 1 Passenger Side ll Attaching the Axle Beams 1 Attach the spring retainer VV to the passenger side beam using the centering pin UU Tighten securely Figure 2a 2 Install the passenger side beam assembly A to the front spring eye hanger using the supplied 16mm bolt KK flat washers LL and nyloc nut MM Leave loose at this time 3 Attach the passenger side beam assembly to the axle with
7. ate both rolling lobe air sleeves to 25 p s i and check for leaks refer to section IX 2 Tighten both bottom rolling lobe mounts securely at this time 3 The vehicle was set up for a rear top of frame height of 31 Do not deviate from this height 4 With the rear top of the frame at 31 torque both 16mm pivot bolts on the front of the beam to 110 ft Ibs 5 IMPORTANT Check and re torque all mounting hardware especially the beam U bolts after 100 and 3 000 miles Technical Support 1 800 248 0892 Ext 2 5 IX Checking for Leaks 1 Inflate the air spring to 25 p s i 2 Spray all connections and the inflation valves with a solution of s liquid dish soap and s water to check for leaks You should be able to spot leaks easily by looking for bubbles in the soapy water 3 After the test deflate the springs to the minimum pressure required to restore the Normal Ride Height but not less than 10 p s i 4 IMPORTANT Check the air pressure again after 24 hours A 2 to 4 p s i loss after initial installation is normal Retest for leaks if the loss is more than 5 Ibs X Fixing Leaks 1 If there is a problem with the swivel fitting then a Check the air line connection by deflating the spring and removing the line by pulling the collar against the fitting and pulling firmly on the air line Trim 1 off the end of the air line Be sure the cut is clean and square Reinsert the air line into the push to connect fitting
8. b Check the threaded connection by tightening the swivel fitting another 2 turn If it still leaks deflate the air spring remove the fitting and re coat the threads with thread sealant Reinstall by hand tightening as much as possible then use a wrench for an additional two turns 2 If there is a problem with the inflation valve then a Check the valve core by tightening it with a valve core tool b Check the air line connection by removing the air line from the barbed type fitting CAUTION Do not cut it off As this will usually nick the barb and render the fitting useless Cut air line off a few inches in front of the fitting and use a pair of pliers or vise grips to pull twist the air line off the fitting 3 Ifthe preceding steps have not resolved the problem call Air Lift Technical Service at 1 800 248 0892 for assistance XI Troubleshooting Guide Problems maintaining air pressure without on board compressor 1 Leak test the air line connections and threaded connection of the elbow into the air spring See Section X to repair 2 Leak test the inflation valve for leaks at the air line connection or dirt or debris in the valve core See Section X to repair 3 Inspect air lines to be sure it is not pinched Tie straps may be too tight Loosen or replace strap Replace leaking components 4 Inspect air line for holes and cracks Replace as needed 5 A kink or fold in the air line Reroute as needed You have now tested fo
9. e flat washer Il and one nylock nut JJ Tighten securely Turn the hyme joint so as to stay on the ball section throughout the travel of the suspension Tighten the jam nut securely Figure 4 Tighten the 9 16 panhard bolt and nut that was previously installed on the driver side bracket in step one Technical Support 1 800 248 0892 Ext 2 1 2 Bolts Drill 1 2 Hole 10mm Bolts N 1 2 Hole Driver Side Shown Figure 3 Flat Washer Flat Washer Jam Nut Spacer o View Passenger Side Figure 4 prlvenside Shown V _ Installing the Rolling Lobe Air Sleeves 1 Install the fitting S into the large top stud of the rolling lobe air sleeve Tighten the fitting finger tight plus 1 2 turns being careful to tighten on the metal hex nut only NOTE It may be necessary to raise the chassis to provide adequate space to install the air sleeves 2 Insert the studs of both rolling lobe air sleeves into the bottom mounting hole of the beam assemblies on both sides of the vehicle Attach finger tight using a 1 2 lock washer R and nut Q Figure 5 3 Lower the frame down while guiding both studs on top of the rolling lobe air sleeves through the holes in the upper mounting bracket 4 Attach the air sleeves using a 3 4 jam nut P on the large stud Use a lock washer R and 1 2 nut Q on the smaller stud Tighten the top mounts securely
10. ound the O ring seal inside the elbow fitting 4 Place a 1e6 nut GG and a star washer FF on the air valve Leave enough of the inflation valve in front of the nut to extend through the hole and have room for the rubber washer EE flat washer DD and 16 nut GG and cap CC There should be enough valve exposed after installation approximately 2 to easily apply a pressure gauge or an air chuck Figure 7 5 Push the inflation valve through the hole and use the rubber washer EE flat washer DD and another 16 nut GG to secure it in place Tighten the nuts to secure the assembly in place Figure 7 6 Route the air line along the frame to the air fitting on the air spring Keep at least 6 of clearance between the air line and heat sources such as the exhaust pipes muffler or catalytic converter Avoid sharp bends and edges Use the plastic tie straps BB to secure the air line to fixed non moving points along the chassis Be sure that the tie straps are tight but do not pinch the air line Leave at least 2 of slack to allow for any movement that might pull on the air line 7 Cut off air line leaving approximately 12 of extra air line A clean square cut will ensure against leaks Insert the air line into the air fitting This is a push to connect fitting Simply push the air line into the straight fitting until it bottoms out 16 of air line should be in the fitting VIII Final Adjustments 1 Infl
11. r all of the most probable leak conditions that can be easily fixed At this point the problem is most likely a failed air spring either a factory defect or an operating problem Please call Air Lift at 1 800 248 0892 for assistance or a replacement air spring Technical Support 1 800 248 0892 6 Ext 2 XII Maintenance and Operations Minimum Air Pressure Maximum Air Pressure 100 p s i Failure to maintain correct minimum pressure or pressure proportional to load bottoming out over extension or rubbing against another component will void the warranty By following these steps vehicle owners will obtain the longest life and best results from their air springs 1 2 Check the air pressure weekly Always maintain Normal Ride Height Never inflate beyond 100 p s i If you develop an air leak in the system use a soapy water solution to check all air line connections and the inflation valve core before deflating and removing the air spring see page 6 When increasing load always adjust the air pressure to maintain the Normal Ride Height Increase or decrease pressure from the system as necessary to attain Normal Ride Height for optimal ride and handling Remember that loads carried behind the axle including tongue loads require more leveling force pressure than those carried directly over the axle IMPORTANT For your safety and to prevent possible damage to your vehicle do not exceed maximum
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