Part # C-10 Level 2 Complete Air Suspension System

Transcription

1 350 S. St. Charles St. Jasper, In Ph Fax Part # C-10 Level 2 Complete Air Suspension System Front Components: Front CoolRide Kit Front Shock Kit Master Series Single Adjustable Front Lower StrongArms Front Upper StrongArms Rear Components: Rear StrongArm System Rear Shock Kit Master Series Single Adjustable Compressor System: gallon RidePro E3 Compressor Kit

2 Components: 350 S. St. Charles St. Jasper, In Ph Fax Part # C10 Front CoolRide Kit For Use w/ Lower StrongArms Front air springs 224c Upper air spring plate Medium bump stop 1.5 tall Aluminum bump stop extension Driver side bump stop plate Passenger side bump stop plate Hardware: /8 x 1 ¼ USS bolt Upper air spring plate to frame /8 x 3/4" USS bolt Air spring to lower control arm/ bump stop /8 lock washer Air spring to lower control arm/ bump stop /8 nyloc nuts /8 flat washers

3 Installation Instructions 1. Hold the upper plate to the cross member as shown in the picture to the left and clamp to frame. Using the plate as a template drill four 3/8 holes in the cross member. 2. Apply thread sealant to the air fitting and thread into the air spring. 3. Remove the upper plate from the frame and place onto the studs on the top of the air spring. The holes are lettered; slide the plate to position C moving the air spring to the front of the vehicle. Secure with 3/8 flat washers and Nylok nuts. Note: Airline must be routed at this time.

4 Note: It is acceptable to let the suspension bottom on the air spring. However, if your tire hits the inner fender well before the air spring bottoms out, this bump stop must be installed. 4. The bump stop plate will bolt to the outer two holes of the upper air spring plate. It will hang over the front side of the cross member. It is acceptable to trim the bump stop to achieve maximum drop without the tire rubbing the inner fender well. 5. The break line bracket may need to be tweaked to clear the hose. 6. Fasten the air spring to the lower control arm using a 3/8 x 3/4" bolt, lock washer and flat washer. 7. Check air spring clearance through full suspension travel. Allowing the air spring to rub will result in failure and is not a warrantable situation. 8. Ride height on this air spring is approximately 5 tall. The shock absorber should be at about 50-60% travel at this point. Depending on vehicle weight this will usually occur around psi.

5 Shock Assembly: Part # C-10 Master Series SA Front Shock Kit For Use w/ Lower StrongArms stroke Master Series single adjustable shock Compression bump stop Short Stud top bearing Snap ring for bearing 350 S. St. Charles St. Jasper, In Ph Fax Components: Stud top base Aluminum cap for Delrin ball Upper Delrin ball half Lower Delrin ball half Cantilever pin w/ hardware Aluminum bearing spacer I.D Aluminum spacer Driver side upper shock bracket bolt-on Passenger side upper shock bracket bolt-on Hardware: /8 x 1 ¼ USS bolt Upper shock bracket to frame /8 USS Nylok nut Upper shock bracket to frame /8 SAE flat washer Upper shock bracket to frame /8 SAE flat washer Cantilever pin /16 SAE jam nut Upper shock stud

6 Installation Instructions 1. Place the new upper shock mount against the frame, the tab in the front of the bracket will slide into the factory shock stud hole. Position the bracket so that the bottom of the bracket is parallel to the bottom of the frame. Using the bracket as a template, mark an drill four 3/8 holes in the frame rail. Secure the bracket to the frame using four 3/8 x 1 ¼ bolts, Nylok nuts and flat washers. 2. Attach the shock to the upper mount. See diagram on following page. Note: A notch must be made in the inner fender well just above the mount to allow clearance for the shock stud. 3. Attach the shock to the lower control arm using the cantilever pin supplied. See diagram on following page.

7 Upper Shock Stud Assembly Short Delrin stud top base Delrin ball lower half Delrin ball upper half Aluminum cap for Delrin ball /16 SAE jam nut Short Delrin stud top 2 7. Black adjustment knob 8. Detent clip 9. Screw 10. Washer 1. Cantilever Pin 2. 5/8 SAE Washer 3. Aluminum Bearing Spacer Bearing 5. Aluminum Bearing Spacer 6. Control arm tab 7. ½ Lock Washer 8. ½ SAE Nut Cantilever Pin Assembly

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9 350 S. St. Charles St. Jasper, In Ph Fax Part # C-10 Front Lower StrongArms For Use w/ CoolRide Components: Driver side lower arm Passenger side lower arm Lower ball joint Cross shaft Bushing kit includes two bushing per kit Washer, 3/4" (B) x 2 1/2" (D) x 1/8" (T), Zinc Plated ¾ SAE jam nut

10 Installation Instructions Note: These control arms were designed for use w/ the RideTech bolt-on shock kit & MuscleBar swaybar. The factory shocks and sway bar will not work. Note: These Strong Arms are used on trucks of model years Throughout these years 3 different ball joints used; some are very similar. Be sure to use the correct ball joint for the year spindle you are using. 1. Bolt the lower Strong Arm to the frame using the oem fasteners. Make sure to align the dowel in the frame with the hole in the cross shaft. 2. Slide the boot over the ball joint then fasten the lower ball joint to the spindle using the new castle nut and cotter pin supplied. 3. Fasten the air spring to the lower control arm using a 3/8 x 3/4" bolt supplied w/ the CoolRide kit. 4. Thread the grease zerk into the ball joint and grease. 5. With the suspensionn at mid travel, the cross shaft nuts can be tightened. 6. The truck must be realigned after installation. This lower arm was designed to add an extra 2 degree s of positive caster. A total caster setting of 3-4 degrees positive is attainable on most trucks.

11 350 S. St. Charles St. Jasper, In Ph Fax Part # C-10 Front Upper StrongArms Components: Driver side upper arm Passenger side upper arm Cross shaft Cross shaft kit 2 bushings per kit Upper ball joint Hardware: ¾ flat washer (2 diameter) Cross shaft ¾ SAE locking nut Cross shaft

12 Installation Instructions 1. Drop the ball joint down through the upper control arm plate. Fasten to the arm w/ the hardware supplied. 2. Fasten control arm to frame using the stock hardware. Reuse the alignment shims; however the truck must be realigned after installation. 3. Slide the ball joint boot over the stud, then insert stud through spindle. Secure w/ new castle nut and cotter pin supplied. 4. With the suspension at mid travel, the upper cross shaft nuts can be tightened. 5. Install Zerk fitting and grease ball joint.

13 Components: c air spring 350 S. St. Charles St. Jasper, In Ph Fax Part # Chevy C-10 Rear CoolRide Kit w/ StrongArms Driver side lower StrongArm Passenger side lower StrongArm Front StrongArm cross member Driver side C Notch Passenger side C Notch Upper shock bridge Lower shock bridge Panhard bar C-C 23 7/ Panhard bar rod end Rubber rod end pressed into panhard bar Panhard bar axle mount Panhard bar stud (Loc-tite to bracket w/ 5/8 x 1 bolt and flat washer) Panhard bar stud spacer /8 shock stud Medium bump stop 1.5 tall C-10 U-Bolt Poly bushing half (DAY2909 Cut Down to ) Bushing sleeve for StrongArms Polyurethane bushing for lower shock bridge Bushing sleeve for lower shock bridge Plastic plug for end of trailing arm Template for C-Notch Hardware Kit (See next page)

14 350 S. St. Charles St. Jasper, In Ph Fax Hardware Kit 1 5/8 x 2 ¾ SAE Gr.8 Bolt Panhard bar to frame 4 5/8 SAE Nyloc Jam Nut Panhard bar & lower shock bridge 2 5/8 x 4 SAE Gr.8 Bolt Lower shock bridge 4 5/8 x 1 ½ SAE Gr.8 Bolt C Notch to frame 4 5/8 SAE Nyloc Nut C Notch to frame 4 5/8 SAE Flat Washer C Notch to frame 10 7/16 x 1 USS Bolt Front crossmember to frame 20 7/16 SAE Flat Washer Front crossmember to frame 10 7/16 USS Nyloc Nut Front crossmember to frame 12 7/16 x 1 ¼ USS Bolt C Notch & upper shock bridge 12 7/16 x 1 USS Bolt C Notch & upper shock bridge 25 7/16 USS Nyloc Nut C Notch & upper shock bridge & panhard bar stud 48 7/16 SAE Flat Washer C Notch & upper shock bridge 2 3/8 x 3 USS Bolt Air spring to trailing arm 2 3/8 Lock Washer Air spring to trailing arm 6 3/8 SAE Flat Washer Air spring to trailing arm and to upper mount 4 3/8 USS Nyloc Jam Nut Air spring to upper mount 5 5/16 x 1 ¾ USS Bolt Panhard bar axle bracket to axle cover 5 5/16 Lock Washer Panhard bar axle bracket to axle cover 5 5/16 USS Flat Washer Panhard bar axle bracket to axle cover 2 ¾ X 4 SAE Gr.8 Bolt Trailing Arm to crossmember 2 ¾ SAE Gr.8 Nyloc Nut Trailing Arm to crossmember

15 ARR21800-LCA Installation Instructions 1. Raise the vehicle to a safe and comfortable working height. Let the rear suspension hang freely. 2. Remove the bed. 3. Raise the axle a couple inches and support it so that it cannot rotate. Remove the trailing arms, coil springs, shock absorbers, and panhard bar. Refer to the factory service manual for proper disassembly procedures. Note: This kit is designed for use with a 1-piece drive shaft. 4. The factory trailing arm frame cross member will be replaced with the tubular one supplied. To remove the factory cross member, the rivets must be removed. The easiest method is to chisel them off with an air hammer. Then use a hammer and punch to drive the rivets out. Note: On each side there is one rivet in front of the cross member and one behind that must also be removed for the new cross member. 5. Install the new cross member with the trailing arm flanges towards the rear. The cross member is bolted to the bottom side of the frame rails using 10-7/16 x 1 bolts, 10-7/16 Nylok nuts and 20-7/16 flat washers. It may be necessary to enlarge some of the holes with a 7/16 bit. Note: On short bed trucks you may have to raise the cab to remove the factory cross member.

16 6. The factroy upper shock cross member must also be removed to allow for the new upper shock cross member and C Notch. 7. On the driver side of the rear frame cross member; these two rivets must be removed before installing the C notch. 8. The lower rear rivet on this reinforcement plate must also be removed to mount the notch.

17 9. The C notch will be used as a template for notching the frame rail. Hold the C notch up to the outside of the frame with the holes in the notch aligning with the holes in the frame. 10. While holding the notch in place, trace the inside edge of the notch. Then scribe a second outline ¼ larger than the first to allow for the thickness of metal. 11. Drill a ½ hole at the two corners of the outline as shown in the picture. This will give you a round edge and reduce the possibility of stress fractures. 12. Cut along the outline with a sawzall, cut off wheel, or plasma cutter. Then grind all edges smooth. 13. Slide the notch over the frame. The holes in the top of the notch should align with the factory shock cross member holes. There are also two larger holes on the outside of the frame rail that will align with two holes in the frame. Insert 5/8 x 1 ½ bolt, Nylok nut and flat washer in each hole to secure the notch. Then use notch as a template to drill the rest of the holes with a 7/16 bit. 7/16 bolts, Nylok nuts and flat washers are supplied. Some holes will use a 1 bolts and some will use an 1 ¼.

18 14. The upper air spring plate is built into the notch. But the two inner 3/8 holes will need to be into the frame using the notch as a template. 15. A 1 x 1 portion of the frame must be removed for air fitting clearance. (Shown in the picture to the left). 16. Install the medium bump stops into the notch. A 3/8 Nylok nut and flat washer will secure it. This picture is shown with the short bump stop. Note: If you wish to lower the vehicle an additional 1 you can install a shorter bump stop, but this will require cutting the bed floor to allow clearance for the differential housing. (Also requires a shorter shock part# MON33033 & ½ lower studs.) Note: Check bed to differential housing clearance. A couple washers may be required between the bump stop and notch to provide adequate clearance. 17. The new upper shock bridge is bolted in place using 6-7/16 x 1 ¼ bolts, Nylok nuts and flat washers between the notches on the bottom side of the frame rail. Note: There are four holes on each side of the bridge; only 3 will be used.

19 18. The Stongarms are a direct replacement of the factory trailing arms an will bolt to the new tubular cross member using two 3/4 x 4 bolts, Nylok nuts and flat washers. These bushing are polyurethane and are already lubricated with lithium grease. Future lubrication can be done with any non-petroleum based lubricant. Note: There is a driver and passenger side arm. The tabs for the shock bridge will point towards the center of the vehicle. 19. Bolt the other end of the StrongArm to the axle using the new U-bolts supplied. 20. Apply thread sealant to a 90- degree air fitting and screw it into the top of the air spring. The threads are already coated with a thread sealant but we recommend additional sealant. 21. Secure the air spring to the notch using two 3/8 Nylok jam nuts and flat washers. 22. Fasten the bottom of the air spring to the StrongArm using one 3/8 x 3 bolt, flat washer and lock washer.

20 23. Install the 5/8 shock studs into the upper & lower shock bridge. 24. Install the lower shock bridge between the trailing arms using two 5/8 x 4 bolts and Nylok nuts. The shock tabs will point down. 25. The lower shock bridge will use the ½ shock studs. 26. Bolt the new shock absorbers to the upper and lower studs using the nuts and washers supplied. 27. To install the panhard bar remove 5 bolts from the right half of the axle cover. Place the panhard axle bracket over the cover and secure with 5/16 x 1 ¾ bolts, flat washers and lock washers. 28. Slide the heim end over the stud and then the spacer. Secure the assembly with a 5/8 Nylok jam nut. 29. The other end of the panhard bar will bolt into the factory mount with a 5/8 x 2 ¾ bolt and Nylok jam nut supplied. 30. The StongArms have a tab of the outside of each one for attaching the parking brake cable. Note: This system is designed for use with a 1-piece drive shaft. 30. Driving height on this air spring is approximately 5 tall. This may vary to driver preference. 31. Make sure that the air spring does not rub anything. Allowing this will cause air spring failure and is not a warrantable situation.

21 Components: 350 S. St. Charles St. Jasper, In Ph Fax Part # C-10 Rear Master Series SA Shock Kit For Use w/ Lower StrongArms stoke Master Series single adjustable shock Internal bump stop eyelet with adjustment knob I.D. bearing Bearing snap ring Aluminum bearing spacers I.D.

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23 350 S. St. Charles St. Jasper, In Ph Fax Part # Series RidePro E3 Compressor System Components: Thomas 327 Compressor way RidePro air valve assembly gallon aluminum tank Air pressure sensor RidePro E3 ECU RidePro E3 Display x 3/8 Phillips pan head screw for display 1 Installation Guide Wiring: Display Harness Air valve wiring harness Air pressure sensor wiring harness Main power / compressor harness Fuse holder Amp fuse Airline & Fittings: /4 DOT airline - 30 ft. roll /4" npt x 1/4"tube elbow fitting for air springs /4" npt x 1/4" tube straight fitting for air valve and tank /8 npt female x 1/4" tube straight fitting for compressor /8 npt nipple (install between & compressor) /4"npt plug to plug extra tank port