ROAD MASTER ACTIVE SUSPENSION These Fitting Instructions must be read and followed step by step for the to II owing kits.

Transcription

1 ROAD MASTER ACTIVE SUSPENSION These Fitting Instructions must be read and followed step by step for the to II owing kits. Item# 4611-TD FOR 007- CURRENT TOYOTA TUNDRA IM PO RT T The Roadmaster Active Suspension kit must never be fitted while the vehicle is standing with the rear wheels on the ground. In this position the rear leaf springs will be under load and the Roadmaster coil spring settings cannot be achieved, resulting in the Roadmaster not working correctly. Always install with the rear axle and leaf springs hanging free. A. ALWAYS CHECK THE LEAF SPRINGS FOR ANY EXCESS WEA R, FATIGUE, CRACKED OR BROKEN BLADES OR WORN BUSHINGS - ESPECIALLY OLDERSPRINGS, THESE MUST BE REPLACED WHERE NECESSARY. B. IF THEVEHICLE THE ROADMASTER KITWILL BE INSTALLED ON, IS FITTED WITH OVERLOAD LEAF SPRINGS, LOCATED ABOVE THE LEAF SPRINGS, THE OVERLOAD LEAF SPRINGS MUST FIRST BE REMOVED BEF ORE THE KIT CAN BE INSTALLED. ANY DEVIATION FROM THESE INSTRUCTIONS WILL VOID THE WARRANTY. THIS KIT WILL NOT BE WARRANTIED IF INSTALLED ON ANY VEHICLE USED FOR RACING, SIMILAR ACTIVITIES OR FITTED TO VEHICLES WHERE THE REAR SUSPENSION HAS BEEN MODIFIED IN ANY WAY. COMPONENTS INCLUDED G J E --=- u.,o F ' (9) L M H ci:;:;;:==:.l. K D A E F B D Q C N A Cap Screw 14mm X 150mm J Tube 13mm x 65mm Roller K Tube 9mm x 65mm Axle Brackets 0 Tube 13mm x110mm Threaded Rod G Bolt 1mm x 90mm 14mm nut 10 H Bolt 8mm x 90m Eye Bracket p Bolt 1mm x 10mm Cup Bearing L Nuts 1mm nyloc Coil Spring M Nuts 8mm nyloc 4

2 PLEASE NOTE When installing this kit on a 007 to PRESENT Toyota Tundra the rear shocks are located very close to the leaf springs, the two axle connecting bracket assemblies as shown below, must be installed so that the brackets do not interfere with the shocks or other brackets on this pickup. 1" Diameter spacers on each side of the tube spacer 1" Diameter spacers on each side of the tube spacer NARROW HEAD OF BOLT THIS SIDE - ' INSTALLED ON THE DRIVERS SIDE LEAF SPRING j THIS SIDE BRACKET MUST ONLYBE INSTALLED ON THE PASSENGER SIDE LEAF SPRING Page

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4 6 6) If installing to vehicle on the ground, make sure the vehicle is well supported now remove the tow nuts from the rear shackle as shown in the illustrations NOTE: When fitting to a vehicle while using a lift, utilize a lift that lets the axle hang free. With the vehicle supported at the frame, simply remove the two nuts without remove the bolts. 7 7) Remove the one side (outside) of the shackle 8 8) Now position the eye bracket (C) over the eye of the leaf spring and replace the eye of the shackle that was removed and secure the two nuts. Repeat on the other side leaf spring. 9 9) Before resuming installation of kit, once again make sure rear of vehicle is well supported and both rear wheels are removed for convenience. Review page with illustration showing correct side for each bracket. This will avoid interference with the shocks or any brake lines or wiring (this should not be applicable on the majority of vehicles). Next place the one side kit (as shown in step 10) directly on top of the leaf springs, with the two arms of the bracket astride the leaf springs and two U bolts. Page 4

5 10 10)Next remove from the end hole in the Axle Connecting Brack et the nylon insert nut, tube spacer, bolt and two spacers washers (not shown in illustration 10). With these items removed set them aside. Note: This kit has two 1'' diameter spacer washers as illustrated. (Not Shown In Image 10) 11 11) With the axle bracket no astride the leaf spring, relocate the tube spacer long bolt and two spacer washers 1 1) Attach the nyloc nut and tighten. VERY IMPORTANT: The bolt with spacer must be located directly below the leaf spring as shown. Note: This kit has two 1'' diameter spacer washers as illustrated. (Not Shown in Image 1) 13 13) With both the axle connecting bracket and the eye bracket in place, tum the spring with one hand and hold the threaded rod with the other until the coil spring is supported. Page 5

6 HOW TO TENSION THE COIL SPRING. WITH THE REAR OF THE VEHICLE STILL SUPPORTED, THE LEAF SPRINGS STILL IN THEIR MAXIMUM ARCHED POSITION AND THE AXLE HANGING FREE 14 14) Position the two nuts on the threaded rod as shown. Then use a ratchet fitted with a 1 mm socket on the head of the cap screw, and a mm wrench on the lock nuts closest to the eye bracket at the end of the threaded rod. The two nuts come locked together when the kits are assembled at our factory. By holding the threaded rod stationary and turning the coil spring the gap between the coils will start opening ) We have included with this kit two small discs that are to be used as a gauge to adjust the tension setting of the variable rated tension coil springs. These can be adjusted to two different settings depending on the vehicle's requirement. For improved handling and 5% additional load carrying the correct adjustment between the coils is reached when the white disc (1mm thick) is used as a gauge and can just pass between the coils. For improved handling and 40% additional load carrying the correct adjustment is reached when the black disc (mm thick) is used as a gauge and can just pass between the coils. the additional load carrying as stated above can vary depending on the vehicle. 16. Finally, jam one of the two nuts located in the center of the threaded rod hard against the coil spring, then follow with the second nut and jam a the first ) With the one side now installed, check all the fasteners to See that they are secure. Now continue the installation on the opposite side. 18) Once the installation on both sides is complete, raise the rear of the vehicle, replace the wheels, remove the two jack stands, lower the vehicle and remove the wheel chocks. Once you have taken the vehicle for a spin, we are sure that you will immediately feel the improvement in handling. Should you require technical support please call us at or us at sales@activesuspension.com Page 6