2008 & Newer Ford F-350 Chassis Cab 4-Link Rear Installation Instructions

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1 KLM Highway 92 - Oskaloosa, IA phone: fax: & Newer Ford F-350 Chassis Cab 4-Link Rear Installation Instructions

2 Installation 1. Before doing anything, measure the pinion angle and write the angle down. This is important because you will need to put the axle back to this measurement after the installation. Also, take a measurement from the front of the axle to a location on each side of the frame. Write these measurements here. Pinion angle. Right side Left side NOTE: All the bolts in this kit use a flat washer on each side of the bolt. 2. Jack up the rear of the frame so that most of the tension is off the leaf springs. Place a set of jack stands under the frame, block the tires so the axle won t move and place a jack stand under the pinion so it doesn t rotate. Disconnect the emergency brake cables. There is one on top of the leaf springs, 3 brackets on the side of the frame and one crimp on clamp just behind the cab. Remove the leaf springs, front overload pads, and bump stops. The best way to remove the riveted pads is to use a torch to cut the rivet heads off. Make sure that there are no fuel lines, brake lines, or wiring that can be damaged while cutting the rivets off. Remove the rubber bumper off overload pad and cut the rivets with torch Punch out the rivets after the bumper overload pad is off Use a pair of vise grips to unclamp the crimped e brake cable Use a cut off wheel or sawzall to remove the bracket on the exhaust 3. Use a cut off wheel to remove the rubber vibration isolator on the exhaust pipe. This has been approved by ford and will not void any warranty.

3 4. Use a 7/8 drill bit or a die grind to open up the hole in the factory leaf spring perch to 7/8. It is just a about 1 /32 too small. Open the inside one to 1 to 1 1/16 THE OUTER HOLE IN THE LEAF SPRING PERCH NEEDS TO BE OPENED UP TO 7/8. THE INNER HOLE IN THE LEAF SPRING PERCH NEEDS TO BE OPENED UP TO 1-1 1/16. Remove the bump stop and drill hole out to 1/2

4 5. Remove the shocks and sway bar. Locate the new sway bar and bushing kit. Install using the factory bolts and red Loctite. Torque the factory bolts to 50 ft./lbs. 6. Use a rivet buster to remove the inner front rivets in the cross member located in front of the fuel tank. ON- LY REMOVE THE FRONT ONE. You will use this hole when mounting the upper air bag mounts in step 12 & 13. Drill this hole out to 1/2. Remove this rivet on each side

5 7. Locate the front trailing mounts (part # DS and PS). These mount to the frame and fit around the front leaf spring perch. Place the mount against the frame and use the 7/8 x 9 1/2 bolt to hold the mount in place. This will locate the mounting bracket in proper position. Use the 5/8 x 1 1/2 bolts to fasten the mount to the bottom of the frame. Go ahead and snug these two bolts. Next, fasten the top of the mount to the frame with the two 1/2 x 1 1/2. The lower three bolts will have to be drilled out slightly with a 7/16 drill bit. After you drill out these holes, use three 7/16 x 1 1/2 bolts to fasten in place. The last hole you will need to drill is the front lower hole. Drill it out to 1/2 and fasten in place with the 1/2 x 1 1/2 bolt. Once you have all the holes drilled and bolts started, torque the 7/16 to 65 lb/ft, 1/2 to 85 lb/ft and the 5/8 bolts to 150 lb/ ft. Drill 1/2 Drill three 7/16 holes

6 Fasten the forward air bag in place before installing the lower bag mount on axle Slide the four 3/4x9 1/2 bolts down through the lower air bag mount before mounting the forward air bag 8. Locate the lower bag mounts (part # DS and PS) and two 5323 air bags. First, slide the four 3/4x9 1/2 bolts down through the lower bag mount. Next, fasten the forward air bag (closest to the trailing arm mount) in place with the 1/2x4 bolt, flat washer and lock nut. (make sure the large port is facing the rear of the bracket). Torque the 1/2 bolt to 30 ft./lbs. Place the lower bag mounts on top of the leaf spring perch and fasten to the axle using the lower axle clamps (part # 15646). You will not torque any of the bolts until the axle cross member is installed in the next step. (just snug the bolts for now). Loosen the brake line mounting tab while you drop the bolts down over the axle. Reattach once the bolts are in place

7 9. Locate the pan hard bar lower mount (axle cross member) (part # 50617). The tall part goes on the drivers side. Connect the cross member to the lower air bag mounts with the four 5/8x2 1/2 bolts and the two 9/16x2 1/2 bolts. Once all the bolts are started, go back and tighten the 3/4x9 1/2 bolts to 175 ft./lbs., the 5/8 bolts to 150 ft./lbs. and the 9/16 to 125 ft./lbs. 9/16x2 1/2 bolt Passenger side shown in picture 10. Locate the other two 5323 air bags. Connect them to the lower air bag mounting brackets with the 1/2x4 bolts. These are the rear bags. Orientate the bag so the air port is facing the front. Torque the 1/2 bolt to 30 ft/ lbs. Inner dual has been removed in this picture

8 11. Locate the fuel tank cross member brackets. It consists of 3 pieces. Install using the picture below. Do not tighten the bolts going through the side of the frame as the upper bag mounts will be needed in the installation of the upper bag plates in step 12.

9 12. Locate the upper bag mounts (part # DS and PS). Install the driver s side mount first (part # ) Place the bag mount against the frame and over the airbags and fasten to the bottom of the frame using the two1/2 x 2 bolts (make sure the bolts go from bottom up). Use two 5/8 x 2 bolts to fasten the air bag mount to the side of the frame. Fasten the top of the air bags to the air bag mount using the 1/2 and 3/4 nuts and lock washers. Tighten these nuts to 35 lb./ft. Go ahead and tighten all the bolts. (torque 3/4 bolts to 175 ft./lbs.). 1/2x2 bolt goes where factory rivet in cross member was 1/2x2 bolt make sure the bolt goes bottom up or it will hit the air bag bottom bracket when the air is dumped out 13. Locate the passenger s side upper bag mount (part # ) and the pan hard bar mount (part # 50862). The 5/8 x 2 bolt is used to fasten the upper bag mount to the side of the frame and the pan hard bar mount (part # 50862) on the inside of the frame. Use the 1/2 x 2 1/2 bolt to fasten the pan hard bar mount and bag mount to the bottom of the frame. Next, use the 1/2 x 2 bolt in the bottom rear hole and use the 5/8 x 2 bolt in the rear hole in the side of the frame. Lastly, use the 1/2 and 3/4 nuts and lock washers to fasten the top of the bags to the upper bag mounts. Go ahead and torque all the bolts to the same specs as the other side. Don t forget to tighten the 1/2 bolts in the bottom of the bags to 35 lb/ft.

10 14. Locate the trailing arms (part # 10016). The front of the upper trailing arm goes into the original leaf spring perch. Use the 7/8 x 9 1/2 bolt to fasten in place. Make sure to use the 9/16 thick spacer (part # 15597) to line up the trailing arm, placing the spacer on the outside of the trailing arm. 15. Fasten the front of the lower trailing arms into the front trailing arm mount using the 7/8 x 5 1/2 bolts. On the other end of the trailing arm, use the 7/8 x 5 bolts. Make sure that the 7/8 x 5 bolt is inserted inside out. Do not tighten the 7/8 bolts until after step 18. Then torque the 7/8 bolts to 275 ft/lbs. 9/16 thick spacer goes in between cast knuckle and factory leaf spring perch

11 16. Locate the pan hard bar (part # 50715). Fasten into place with the 5/8 x 4 1/2 and 5/8x4 bolts. The 5/8x4 1/2 bolt goes on the axle cross member. Make sure to put one spacer on each side of the pan hard bar. Put the bolt in from the front of the truck facing towards the rear. Torque the 5/8 bolts to 75 ft/lbs. Place spacer on each side of pan hard bar 17. Now that the air suspension system is installed, its time to square up the axle and set the pinion to the factory location. Jack up the frame of the truck so that the distance between the upper and lower air bags are 8.5. Using the angle measured in step one, adjust the trailing arms to get the pinion set. Next, measure the from the front of the rear axle housing to the front axle. Adjust the trailing arms accordingly to get each side within 1/8. Once the axles are parallel, check your pinion angle to make sure it is correct. There is a video on YouTube that explains this step. Search for the Kelderman Manufacturing channel. 18. Reinstall the emergency brake cables. Use the OEM bracket on the leaf spring perch. 19. Now while the air bags are at the 8.5 range, go ahead and tighten the 7/8 trailing arm bolts to 275 ft./lbs. Go back and make sure all the bolts in the kit are torqued to the correct specs.

12 20. Insert the 3/8 fittings in the top of the four air bags. Tighten them finger tight then one full turn. Locate the Hadley height control ride height sensor (electronic system) and use the 1/4 x 1 1/4 bolts to fasten to the sensor mount. Snug the bolts but do not tighten yet. Next locate the plastic collar with the ball stud and linkage. Fasten the collar on the on the top trailing arm about 1 away from the threads on the bar (the end that attaches to the lower air bag mount). Locate the black linkage and fasten the two together. NOTE: you may fine tune the sensor placement in the top slotted hole. Just remember to tighten the 1/4 bolts once calibration and final adjustments are made. 20. Locate the compressor box. Mount the box where the engineers indicate. Use the wiring diagram provided at the end of the instruction packet to wire up the system. 21. Locate the air tank. Mount find an area on the frame to mount it. Make sure the drain plug is facing straight down. Just as with the 22. Now it is time to do the front kit. Us e the front kit instructions. Once the front kit is on and the front sensors are installed, wire up the Hadley system and use the instructions provided for that.

13

14 Kelderman Air Suspension Systems Installation Check List 1. Check to make brake lines and air lines are securely mounted. 2. Check air bags, air lines, and fittings for leaks using a soapy water solution. 3. Check for air leaks inside the air kit box 4. Make sure that the top rear trailing arm bolt heads are facing inside and the threads face outside. Make sure the c-flange bolt threads for the upper air spring bracket face upward. 5. Record trailing arm measurements: between the knuckles: Drivers side top: In. Drivers side bottom: In. Passenger side top: In. Passenger side bottom: In. These measurements will insure the pan hard bar is centered in the channel and the the wheel base is the same on both sides. 9. Record air bag measurements: Drivers side front: Note: The rear bag may Drivers side back: measure differently than the Passenger side front: front without weight added. Passenger side back: Setting the bag heights: First, position your jack stands so the the bags are approximatly 8 1/4" tall with no air in the bags. When air is finally supplied, the bag heights should be: F Series: 8 1/4-8 1/2", metal to metal-do not include upper and lower steel plates. The Hadley sensors are mounted to the suspension using a hole for the bottom bolt and a slotted hole for the top bolt. For a starting course adjustment setting, turn the body of the sensor or height control In. In. In. In.

15 Kelderman Air Suspension Systems Installation Check List value so the at the bolt is positioned in the center of the slotted hole. Position the split collars on the trailing arms so that the linkage rod stands verticle or slanted slightly inward. This should allow the valve arm to be positioned fairly level. A slight change may be needed at the slotted hole. When the installation is complete and the system is powered up, the bags heights can be fine tuned by loosening the bolt on the valve arm which will allow the valve arm to be moved up or down to achieve the proper bag height. NOTE: The Hadley electronic system will require you to go into sensor set up mode to make this adjustment. Refer the the Hadley manual. 10. When installing the Hadley system, the preferred method is to connect directly to the OEM signals. If relays are selected for the connections, refer to the Hadley manual for IMPORTANT SAFEGUARDS. Failure to do so can result in future issues. Also, fill in the installation check list in the back of the Hadley manual. 11. All the bolts should be torqued and paint mark applied: Fastner Nut/Bolt LB/FT Torqued? Front trailing arm mounts 1/2" UNF Nuts 85 Front trailing arm mounts 5/8" UNF Nuts 150 Front trailing arm mounts 7/16" UNF Nuts 50 Lower bag mounts 3/4" UNF Nuts 175 Axle clamp 3/4" UNF Nuts 250 Upper bag mounts 1/2" UNF Nuts 85 Upper bag mounts 5/8" UNF Nuts 150 Cross member brace 3/4" UNF Nuts 175 Air bags 1/2" UNC Nuts 35 Air bags 1/2" UNC Bolts 35 Air bags 3/4" UNF Nuts 35 Pan hard bar 5/8" UNF Nuts 75 Pan hard bar U-Bolt 1/2" UNF Nuts 85 Pan hard bar mount 1/2" UNF Nuts 85 Pan hard bar mount (lower) 5/8" UNF Nuts 150 Trailing arms (pinch bolts) 5/8" UNC Nuts 150 Trailing arms 7/8" UNF Nuts 275 D bushing (factory OEM) 12 mm Bolts 75 Paint mark? 12. Move the suspension through it's entire range of motion by inflating and deflating the air bags. Check for interference with:

16 Kelderman Air Suspension Systems Installation Check List Pan hard bar (tracking rod) Axle Air bags Exhaust Brake lines/brake caliper Fuel lines Frame 13. Make sure all bolts passing through the bottom C-flange have threads pointing upwards. 14. Test drive paying special attention to vibrations and vehicle handling. If vehicle pulls to the left or right, or vibration occurs, recheck wheelbase measurements and driveline angles. NOTE: This document is for the purpose of assuring the final builder that the installation was performed in a precise and professional manner. This document should be signed by the appropriate people and delivered to the final builder for quality control purposes. Installer's Signature Inspector's Signature Final builder's receipt of this document Date: Date: Date: Vehicle Vin # Suspension Kit Serial # Air Control Kit Serial # When this document is used for training purposes, please provide the signatures below. Kelderman Trainer: Date: Technician name: Date:

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