Ford Ranger Rear Kit Part No

Transcription

1 EASYSTREET Ford Ranger Rear Kit Part No MN-487 (03202) ECN3773 Please read these instructions completely before proceeding with installation Item P/N Description Qty. A C-Section (Left) 1 B C-Section (Right) 1 C Lower Axle Bracket 2 D Upper Axle Plate 2 E Yoke Bracket 1 F Third Link Frame Bracket 1 G Brake Line Bracket 1 H Yoke Brake Line Bracket 1 I Lower Link (Left) 1 J Lower Link (Right) 1 K Panhard Rod 1 L Upper Link 1 M Air Spring 2 N Roll Plate 4 O Strut Rod Bushing Set 1 P Bump Stop Set 1 Q " Flat Washer, SAE 2 R /8" Flat Washer, USS 2 S /8"-9 Pin Jam Nut 4 T /16"-12 x 5" Bolt 3 U /16"-12 Nylock Nut 3 V /2"-13 x 1.5" Bolt (Zinc) 16 W /2"-13 x 5.5" Bolt (Zinc) 8 X /2"-13 Nylock Nut 24 Y /2" Flat Washer USS 46 Z /8"-24 x 1.25" Bolt 2 Hardware Item P/N Description Qty. AA /8"-24 x 1.5" Bolt 7 BB /8"-24 x 7 /8" Bolt 8 CC /8" Lock Washer 8 DD /8" Flat Washer, SAE 8 EE /8"-24 Nylock Nut 9 FF /8" Flat Washer SAE, Zinc 17 GG /8"-11 x 4" Bolt 1 HH /8"-11 Nylock Nut 2 II /8" Flat Washer, USA 2 JJ /8" Flat Washer 2 KK /16"-18 x 1.5" Hex Flange Bolt 7 LL /16"-18 x 1" Bolt 1 MM /16"-18 Nylock Nut 1 NN /16" Flat Washer 4 OO /16" Hex Nut 4 PP /16" Rubber Washer 2 QQ /16" Star Washer 2 RR Poly Cap 2 SS Short Strap 12 TT /8" Nylon Tube 20' UU 20086sub Air Line Assembly 1 VV /8" Straight Air Fitting 2 WW /8" Tube x 1 /4" NPT Straight 4 XX /4" NPTF x 1 /4" Tube Straight 2 YY /8" Male Branch Tee 1 1

2 IMPORTANT: Always keep safety in mind when working on your vehicle. I. Preparing the Vehicle 1. Elevate the truck and place the frame securely on jack stands. 2. Remove the wheels. 3. Disconnect and remove the sway bar. 4. Remove the shock absorbers. 5. Disconnect and remove the emergency brake cable from the frame so that it does not interfere with the installation. Figure 1 II. Trimming the Frame IMPORTANT: Before drilling any holes or cutting into the frame, be sure that all brake lines, gas lines, and electrical wires have been moved aside or relocated. 1. Remove the U-bolts, front and rear spring eye bolts. Save the front bolts as they will be used later. Remove both springs. 2. Remove jounce bumper and clear all lines away from the frame (Figure 1). 3. Remove the rivets holding the shock brackets onto the frame. Remove the shock brackets (Figure 2). Figure 2 4. Starting on the driver side, use the stock eye bolt that was previously removed and saved to install the left lower link into the front spring eye frame brackets. Do not tighten at this time. NOTE: The bellows bracket on the lower link is to the back of the shaft and the platform cantilevers to the outside of the vehicle. 5. Hold the left C-notch up against the frame. Line up the existing shock bracket holes to the holes corresponding on the C-notch. Use a block or have someone hold the lower link so that both bellows mounting surfaces are perpendicular and parallel to each other. 6. Using the cutout section of the bracket as a reference, mark the frame with a china marker or scribe. 7. Assemble the provided template at the end of this manual by matching up the corresponding numbers on each sheet. 8. Position the provided template against the frame and make the final cutting marks. CAUTION: Be sure that all lines (brake, electrical, hydraulic, etc.) have been moved or relocated on the inside of the frame rail before cutting, drilling, or grinding. 2

3 9. Be sure that the frame is supported forward and behind the area to be cut. 10. Using a grinder with a cutoff wheel, carefully cut the relief along the lines that were marked on the outside of the frame. NOTE: We used a plasma cutter to reduce removal time. 11. It may be necessary at this time to trim the bed cross member to provide clearance for the C-section. Figures 3 and 4 show the cutouts of both the bed cross member and frame. 12. Set the C-notch into place and trim, if necessary. The existing shock bracket holes in the frame should correspond with the holes in the C-notch. Grind or dress the frame to properly align. 13. Repeat steps 1-12 for the remaining side. Figure 3 III. Installing the Frame C-Section 1. Install bolt (V), two flat washers (Y), and nylock nut (X) through each existing shock bracket holes in the C-section. Tighten securely. 2. Drill all remaining large holes with a 1 /2" drill, using the holes in the C-section as a guide. 3. Insert the rest of the bolts (V), flat washers (Y), and nylock nuts (X) into the C-section (Figures 5 and 6). Tighten securely. Figure 4 4. Repeat steps 1-3 for remaining side. Figure 5 Figure 6 3

4 IV. Installing the Third Link Bracket 1. Clamp the third link bracket (F) onto the back of the frame cross member in front of the axle on the passenger side using two welding or C-clamps as noted (Figure 7). The bracket should be tight to the frame and cross member. 2. Center punch one hole in the cross member and drill a 3 /8" hole through it. Install one 3 /8" bolt (AA), two flat washers (FF), and nylock nut (EE). Leave loose at this time. 3. Center punch the one hole in the frame section and drill a 3 /8" hole. Install 3 /8" bolt (AA), two flat washers (FF), and nylock nut (EE). Tighten both securely. 4. Drill and install 3 /8" bolts through the remaining holes (Figure 8). Figure 7 V. Installing the Axle Retaining Plate and Axle Mount 1. Install bump stop set (P) on the top of the retaining plates (Figure 9). 2. Set the upper axle plate (D) on the spring perch with the center pin in the spring perch hole. NOTE: The jounce bumper will be to the inside of the vehicle. 3. Nest the lower axle bracket (C) around the axle with the fingers indexed into the spring perch (Figure 10). Figure 8 Jounce Bumper Retaining Plate (post down) Nylock Nut Figure 9 Figure 10 4

5 4. Insert 1 /2" bolts (W) and one flat washer (Y) through each top hole in the upper axle retainer bracket, and also through the lower bracket. Use one nylock nut (X) only and tighten each bolt evenly. NOTE: The flat edge of the lower bracket faces forward (Figure 11). 5. Repeat for the other side. Forward VI. Installing the Center Yoke 1. Remove the seven stock rear cover bolts, as shown in Figure Set the yoke bracket (E) against the cover on the housing and attach using seven bolts (KK). Use Locktite on these bolts (Figure 13). Figure Remove the bolt holding the brake line at the top of the axle (Figure 14). 4. Attach the bracket (H) to the axle using the bolt previously removed. NOTE: The cut out points to the passenger side. 5. Attach the stock junction to the bracket with a bolt (LL), two washers (NN), and nylock nut (MM) supplied. Figure 12 Figure 13 Figure 14 5

6 VII. Installing the Upper Link 1. Install two nuts (S) on the threaded end of the third link (L). Install one small ID washer (R) on the shaft along with one rubber bushing. Install one large washer (Q) onto the bushing. NOTE: The bushing with the male end goes on first (Figure 15). 2. Install the upper link into the link cross member mount (Figure 16). 3. Install the large ID washer, female rubber bushing, small ID washer, and two nuts onto the stud. The nuts on both outside ends of the bushing are lock nuts, leave loose at this time. 4. Set the bracket into the middle of the threaded portion by adjusting the inside nuts. Leave loose at this time. Figure Attach the other end of the upper link to the yoke bracket using one bolt (T), two washers (Y), and one nylock nut (U). Leave loose at this time (Figure 17). VIII. Installing the Panhard Rod 1. Attach the non-adjustable end of the panhard rod to the yoke bracket using two flat washers (JJ) and a nylock nut (HH). Leave loose at this time (Figure 18). 2. Attach the adjustable rod end of the panhard rod to the C-notch bracket with a 5 /8" bolt (GG), two flat washers (II), and nylock nut (HH). Do not tighten at this time. Figure 16 IX. Installing the Lower Links 1. Pull the lower links into position and attach to the axle mounts using bolt (T), two flat washers (Y), and nylock nut (U). Leave loose at this time. 2. Some adjusting of the axle housing may be needed in order to align properly. Figure 17 Figure 18 6

7 X. Installing the Brake Line Bracket 1. Attach the brake line bracket (G) suppled to the frame using bolt (Z), washer (FF), and nylock nut (EE). Refer to Figure Attach the stock bracket to the new bracket using bolt (Z), two flat washers (FF), and nylock nut (EE). Tighten securely. XI. Installing the Bellows 1. Set the roll plates (N) on the top and bottom of the air spring (M). 2. Set the air spring and roll plates in between the C-notch bracket and the lower link. Figure Align the inflation port on the air spring up the corresponding hole in the top of the C-notch mount. 4. Attach the air spring assembly to both the upper and lower brackets using four bolts (BB), four lock washers (CC), and four flat washers (DD). Tighten all the bolts securely (Figure 20). 5. Attach the straight fitting (VV) to the air spring. Tighten finger tight plus 1 1 /2 turns. 6. Repeat air spring installation for remaining side. XII. Routing the Air Lines NOTE: This system can be dual fill or single fill. 1. Cut the 1 /4" air line assembly (UU) into two equal parts. CAUTION: When cutting or trimming the air line, use a hose cutter (Air Lift P/N 10530), a razor blade, or a sharp knife. A clean, square cut will ensure against leaks. Using wire cutters or scissors to cut the air line will flatten or crimp the air line, causing it to leak around the O-ring seal inside the fitting. 2. Choose a convenient location for mounting the inflation valves. Popular locations for the inflation valve are: wheel well flanges, license plate recess in bumper, or through license plate itself. 3. Drill a 5 /16" hole to install the inflation valves. 4. Place a 5 /16" nut (OO) and a star washer (QQ) 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 (PP), flat washer (NN), and 5 /16" nut (OO) and cap (RR). There should be enough valve exposed after installation - approximately 1 /2" - to easily apply a pressure gauge or an air chuck (Figure 21). 5. Push the inflation valve through the hole and use the rubber washer (PP), flat washer (NN), and another 5 /16" nut (OO) to secure it in place. Tighten the nuts to secure the assembly in place (Figure 21). Valve Cap Flat Washer Figure 20 Vehicle body or bumper Rubber Washer Hex Nut Figure 21 Figure 22 Air Line to Bellows Hex Nut Star Washer 7

8 6. Route the air line along the frame to the tee (YY) for a single fill or both mounting hole locations for dual fill lines. Route the 3 /8" air line coming from the bellow assembly, or from the tee, along the frame to the reducer (WW) and into the 1 /4" air line with the inflation valve. 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. 7. Use the plastic tie straps (SS) 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. 8. Cut off air line leaving approximately 12" of extra air line and insert the air line into the air fitting. This is a push to connect fitting. Simply push the air line into the air fitting until it bottoms out ( 9 /16" of air line should be in the fitting). 9. Inflate to 30 p.s.i. and spray all connections and the inflation valves with a solution of 1 /5 liquid dish soap and 4 /5 water to check for leaks (Figure 22). Leaks should be spotted easily by looking for bubbles in the soapy water. 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 lbs. XIII. Adjusting the Pinion Angle 1. Measure the pinion angle and verify that the angle is equal to, but opposite from, the angle of the tailshaft of the tailshaft of the transmission (Figure 23). 2. Use the nuts on the upper link in order to adjust the pinion angle. After adjusting, tighten the outside nuts to lock both into position. Centerline B 3 Centerline C Centerline A Centerline D 3 Figure 23 8

9 XIV. Completing the Installation 1. Adjust the panhard rod length, as necessary, to center the rear axle between the frame rails. 2. Inspect the entire assembly and tighten all mounting hardware. 3. Install the shock absorbers. 4. Refer to Figures for finished installation shots. XV. Before Operating 1. Be sure to note the tire to fender, tire to fenderwell, or body to ground clearance. Space the jounce bumper for additional clearance. Figure Inflate and deflate system (do not exceed 100 p.s.i) to check for clearance or binding issues. With air springs deflated, check clearances on everything so as not to pinch brake lines, vent tubes, etc. Clear lines if necessary. 3. Tighten and visually inspect all hardware after 100 miles. 4. Our BigBore control kit is highly recommended for this product. 5. Please continue by reading the Maintenance and Operation section. Figure 25 Figure 26 Figure 27 9

10 XVI. Fixing Leaks 1. If there is a problem with any of the air fittings, 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. b. Check the threaded connection by tightening the swivel fitting another 1 /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. If the preceding steps have not resolved the problem, call Air Lift Technical Service at for assistance. XVII. 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 XVI 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 XVI for 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 for 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 for assistance or a replacement air spring. 10

11 XVIII. Maintenance and Operation: Minimum Pressure Maximum Pressure 5 p.s.i 100 p.s.i. Failure to maintain correct minimum pressure (or pressure proportional to load), bottoming out, overextension, or rubbing against another component will void the warranty. By following these steps, vehicle owners should obtain the longest life and best results from their air springs. 1. Check the air pressure in the air springs weekly. 2. Always maintain Ride Height. Never inflate beyond 100 p.s.i. 3. 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. 4. Always adjust the air pressure to maintain Ride Height. Increase or decrease pressure from the system as necessary to attain Ride Height for optimal ride and handling. 5. IMPORTANT: For your safety and to prevent possible damage to your vehicle, do not exceed Maximum 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. 6. Always add air to springs in small quantities, checking the pressure frequently. Air springs require less air volume than a tire and inflate quickly. 7. Should it become necessary to raise the vehicle by the frame or do any service work, make sure the system is at minimum pressure (5 p.s.i.) for safety and to reduce the tension on the suspension/brake components. Check that the front lower brackets nest properly in the lower A-arm when servicing is complete. Do this before operating the vehicle. 11

12 Installation Notes: Thank you for purchasing Air Lift Products Mailing Address: Street Address: AIR LIFT COMPANY AIR LIFT COMPANY P.O. Box Snow Rd. Lansing, MI Lansing, MI Local Phone: (517) Fax: (517) For Technical Assistance call EASYSTREET Printed in the USA The Choice of the Professional Installer