THE NUTS & BOLTS. Why MAXLOADER TM support springs? Additional lb capacity *

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2 THE NUTS & BOLTS Why MAXLOADER TM support springs? Additional lb capacity * Maintenance Free Level Loads Better Handling and Control No Adjusting Needed No Clamping Bolts No Air Lines No Compressors No Parts to Rub Through or Fail Less Sway Less Axle Wrap Less Vehicle Maintenance Factory Ride when empty Easy do-it-yourself Installation Cost Effective Limited Lifetime Warranty** At MAXLOADER TM we believe the consumer does not have the time or money to invest in a system that will eventually fail. The goal of MAXLOADER TM is to provide a system that is cost effective and safe for the user. MAXLOADER TM is easy to install, reliable in all situations and will give a lifetime of use. The incredible design of the MAXLOADER TM system allows for support that is needed, when it is needed. Whether a standard or commercial application; MAXLOADER TM s are a cost effective and safe way to handle heavy loads. *DO NOT exceed manufacturers recommended GW ratings. See vehicle owner manual for guidelines. Ratings respective of standard and heavy duty models. **See dealer or our website for details 2

3 Why the Maxloader System? Unlike all other products the Maxloader System works with the Factory suspension not against it. Other products in the market place either pretension the leaf springs or lift the frame off the leaf springs thus changing the factory ride and not allowing the leaf springs to work the way they were intended. Maxloaders don t change the factory ride and once installed and the u-bolt are re-torqued after 500 miles there is never anything more your customer needs to do but load his vehicle. Why the Maxloader system instead of all others? First a little about leaf springs, having built and designed leaf springs for over 30 years affords us the knowledge and understanding of how a leaf spring works and what you can and can t do with a leaf spring and what you should and should not do with a leaf spring. 10 to 15% of a leaf spring s capacity is friction hence a multi leaf spring, means more leaves, more friction and more capacity. Leaf spring material is also a concave material, its higher on the edges than in the center, this is done so as the material is heated, arched, quenched and reheated it will hold its arch. This makes the top side of a leaf structural and the main leaf or top leaf of a spring should not be compromised outside the axle seat and u bolt plate. The standard leaf spring in today s vehicles is semi elliptical and is designed to work or deflect moving downward as they are loaded or stressed. I have given this brief summary of a leaf spring to help you better understand how the Maxloader system works and why it is the best on the market. Maxloaders are made so the customer does not need to do anything to make them work other than load their vehicle. They don t change the factory ride and they don t pre-load the suspension like other products. The Maxloader System is a no service, no worry system. It has no adjusting bolts, no air lines, no compressors, no rollers, no taking apart the factory spring. No changing the factory ride. The factory springs are allowed to work the way they were made to and then the Maxloaders go to work when they are needed. Because of their design they are very progressive. There is no need for them to be adjusted, they adjust themselves, as the factory spring deflects it contacts the Maxloader out near the eyes of the factory spring as more weight is applied the Maxloader then uses the bottom side of the bottom leaf of the factory leaf spring thus allowing the Maxloader to support the factory spring for its entire length. This gives the system a better supporting platform and not only allows it to help support weight but also cut down on sway and axle wrap. At the ends of the Maxloaders is a special designed polyurethane graphite impregnated pad that not only cuts down on any contact noise but also helps to dampen road shock as it travels through the leaf spring system. The unique design allows for easy installation by most back yard mechanics. There is no need for drilling, clamping, wiring or changing of any settings. The Maxloader System is designed with a hole in the top leaf to accept the factory center bolt head and a center bolt head in the bottom leaf to fit into the axle seat, this insures perfect alignment of the axle once the Maxloader System is installed. Every kit comes with a new set of u-bolts so if the suspension is not stock a current inside length of the existing u-bolts are needed. U-bolts should never be reused as the threads are pulled when torqued and they don t stay tight after that. Once the customer re-torques the u-bolts after 500 miles there is nothing more they need to do just use their vehicle with confidence knowing the Maxloader System will go to work for them when they need it. 3

4 BEFORE AFTER 4

5 2012 Vehicle Application Guide ORDERING POP/Retailer We ve made for an easy, complete, vehicle specific kit of MAXLOADER TM springs/u-bolt sets in one box. This makes it easier for the customer to pick the product they need right from the shelf. Shop/Installer For maximum stocking coverage the MAXLOADER TM Spring Support System has been designed to accommodate a maximum of vehicles with a minimum of parts. Example: MAXLOADER TM spring item number fits Chevrolet C-10, K-10 trucks as well as Chevrolet c-20/30, K-20/30 trucks. However, this array of trucks requires three different U-bolt sets based on their specific application. The cross platform design allows you to stock a single pair of MAXLOADER TM springs and 3 separate sets of U-bolts to cover this range of trucks. The alternative would be to stock 3 complete MAXLOADER TM spring/ubolt, vehicle specific kits. For more information on ordering a MAXLOADER TM Spring Support System or general product information/inquiries please contact your authorized MAXLOADER TM dealer, MAXLOADER TM account representative or visit us on the internet at All MAXLOADER TM springs are sold in pairs only. U-bolts are sold in sets of four only. Single unit items are not available. If needed, replacement polyurethane pads are available, contact MAXLOADER TM directly for this item. 5

6 2012 MAXLOADER APPLICATION CHART CHEVROLET 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCKS S-10 SANOMA 2X4 4X COLORADO YUKON 2X4 4 X C1500 K HD SILVERADO/SIERRA 2WD 4WD /3500 C & K W/OUT FAC.AUX /3500 C & K W/ FAC.AUX /3500 C& K W/OUT FAC AUX /3500 C & K W/FAC AUX C3500 CAB & CHASSIS CAB & CHASSIS DURAMAX EYE BY SLIPER EYE BY EYE TAPER VANS G10,20,30 W/MULTI LEAF SPRING G10,20,30 W/TAPERED LEAF SPRING ASTRO VAN W/STEEL SPRING SUV BLAZER, TAHOE,YUKON W/LEAF SPG S10 BLAZER S15 JIMMY HUMMER DODGE 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCKS DAKOTA 2WD DAKOTA 4WD DAKOTA 2WD DAKOTA 4WD D100, 200 UNDER 7500 GVW 2WD W100, 200 UNDER 7500 GVW 4WD WD/ EXCEPT MEGA CAB WD/EXCEPT MEGA CAB D200, 300 OVER 7500 GVW 3" WIDE SPG W200, 300 OVER 7500 GVW 3" WIDE SPG D/W 200, 300 UNDER 9000 GVW D/W 200,300 OVER 9000 GVW /3500 2WD MEASURE U BOLT /3500 4WD MEASURE U BOLT D/W3500 CAB & CHASSIS D/W4500,5000 CAB AND CHASSIS VANS B100, B SPRINTER SPRINTER If you do not find your particular vehicle, please call Maxloader for application.

7 FORD 2012 MAXLOADER APPLICATION CHART 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCK RANGER 2WD RANGER 4WD RANGER 2WD RANGER 4WD F150 2WD & HERITAGE F150 2WD F150 4WD & HERITAGE F150 4WD F150 2WD & 4WD F250,350 2WD F250,350 4WD F250,350 2WD W/4" AXLE F250,350 4WD W//4"AXLE F250,350 2WD / 4WD MEASURE U BOLTS F350 CAB & CHASSIS F350 CAB & CHASSIS F450 PICK UP F450 PICK UP F450/550 CAB & CHASSIS VAN E E250/E E TRANSIT CONNECT SUV EXPLORER INCLUDING SPORT TRAC EXCURSION ISUZU 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCKS NPR MITSUBISI 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCKS FE FE NISSIAN 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCKS FRONTIER 2WD TITAN 4WD TITAN 4WD If you do not find your particular vehicle, please call Maxloader for application. 7

8 TOYOTA 2012 MAXLOADER APPLICATION CHART 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCKS T100 2WD T1OO 4WD TACOMA 2WD TACOMA 4WD TACOMA 2WD TACOMA 4WD TACOMA 2WD TACOMA 4WD TACOMA 2WD TACOMA 4WD TUNDRA 2WD TUNDRA 4WD TUNDRA 2WD TUNDRA 4WD MULTI FIT SPECIAL 5000# MULTI FIT KIT C3500HD CAB & CHASSIS D450 / D550 CAB & CHASSIS MUST SPECIFY U BOLTS F350 / F450 / F550 CAB & CHASSIS 8 If you do not find your particular vehicle, please call Maxloader for application.

9 Basic Installation Guide WE RECOMMEND MAXLOADER BE INSTALLED BY A QUALIFIED AUTOMOTIVE MECHANIC DO NOT exceed GVW of vehicle. WARNING! Not securing your vehicle properly to prevent it from rolling forward or backward or falling off of the jack stands can lead to vehicle damage,personal injury or even death. Secure your vehicle properly before installation! 9

10 PREPARING THE VEHICLE FOR INSTALLATION: On a flat, level surface (concrete or paved area recommended) Block the front tires (FIG 1.) to eliminate any possible movement during installation. It is important to not have the emergency break on. Using a floor jack (FIG 2) rated to handle the vehicle weight, align under the rear end housing and raise the rear of the vehicle to a comfortable working height. Support the vehicle with jack stands (FIG 3) on the frame rails in a secure location just forward of the front leaf spring hanger. Caution: Do not use the bumper for support. Check the vehicle stability. If unstable reposition jack stands and recheck stability. Removal of rear wheels will make for an easier installation, but it is not necessary. 10

11 MAXLOADER INSTALLATION 1) Raise the rear axle using floor jacks to relieve the downward pressure of the axle. Be careful not to raise vehicle off of the jack stands. NOTE: In most cases it may be necessary to remove shock on bottom end (FIG 4) to allow axle to lower far enough for installation do this one at a time and re-hook after installation of each side is complete. 2) With the floor jack still in place remove the U-bolts (FIG 5) on one side. 3) Loosen U-bolt on the opposite side. This is done to allow you to move axle forward or backward to align center pin. 4) Lower the axle so that the axle separates from the leaf spring enough to slide the Maxloader spring between the main spring and the axle (FIG 6) Make sure the spring end with the OPEN CLIP goes towards the FRONT of the vehicle. 11

12 (Some kits come with a *Sleeve Kit See special note below) 1) Slide the Maxloader spring in until center pins of Maxloader spring set in the axle seat. 2) Raise the axle until center pins of main spring fit into the center holes of the Maxloader spring. 3) Follow the same procedure for the opposite side. 8) Install new U-bolts and snug up (FIG 7 & FIG 8). Do not torque until procedure is complete. 9) Raise vehicle to remove jack stands. 10) Lower vehicle to ground. 11) Test drive to make sure suspension has been re-assembled properly and there are no complications from an improper installation. *Special Note for Sleeve Kits: Some Maxloader kits come with a 3/4 hole in the top leaf and a 9/16 head on the bottom leaf. These kits are supplied with two sleeves for the top leaf to change the hole to 5/8 or 9/16 Install the appropriate sleeve if needed to insure a snug fit of the center bolt on your leaf spring. On the bottom leaf you are also supplied with two sleeves a 9/16 5/8 and a 9/16 3 /4. The bottom leaf will be a tight fit, so use a hammer to tap the sleeve in place. This is to insure the sleeve will not fall of during installation. If your kit does not come with the sleeve kits they are not need continue with your installation. AFTER INSTALLATION After the Maxloaders are installed - torque U-bolts to required specifications listed. Torque Specification 1/2 round top U-bolt: ft pounds 1/2" square top U-bolt: ft pounds 9/16 round top U-bolt: ft pounds 9/16 square top U-bolt: ft pounds 5/8 round top U-bolt: ft pounds 5/8 square top U-bolt: ft pounds 3/4 round top U-bolt: ft pounds 3/4 square top U-bolt: ft pounds VERY IMPORTANT!: After miles of driving, re-torque U-Bolts. 12

13 WARRANTY YOUR LIMITED LIFETIME WARRANTY MAXLOADER TM Spring Support Systems U-Bolts are made from a special alloy that allows cold forming without sacrificing torque or clamping strength. U-bolts are shipped with nuts fastened upon threads. This ensures that threads are protected during shipping and require removal by purchaser/mechanic before installation. For this reason, no warranty is expressed or implied for claim of cross threading or gaffing. Torque values for specific U-bolt materials must not be exceeded. MAXLOADER TM Spring Support Systems are guaranteed to be free of manufacturer s defects at time of shipment. Any defects found thereafter MUST be reported without delay to a) shipping and/or freight company; or b) Maxloader. MAXLOADER TM extends only the following warranties, and only to the distributor and the original retail purchaser. These warranties give specific legal rights except where prohibited by law. The laws of the state of Washington govern all warranties and all exclusions and limitations of warranties and remedies. EXCLUSIONS These warranties do not apply to any vehicle applications which have been changed in any manner that alters the OEM vehicle configurations. These warranties shall not apply to any product or part which is used for a purpose other than its intended design, or which has been repaired or altered in any way as to adversely affect its performance or reliability, nor shall these warranties apply to any product or part which has been subject to misuse, neglect, accident or wear indicative of normal use and service. CAUTION Confirm vehicle load capacities before any installation of the MAXLOADER TM Spring Support System. Adhere to all OEM specifications regarding weight limitations and GVW load limitations. Failure to adhere to these guidelines and exceeding the recommended limitations will void all warranties herein and may void your automobiles factory warranty. DO NOT install this product on any vehicle for which it is not intended and DO NOT install this product on vehicles with other suspension modifications. This product is intended to be installed on vehicles with unmodified suspension for aiding in handling and safe transportation of goods in payload or hauling capacities. Maxloader does not authorize other persons to make any warranty or to assume any liability in connection with its products. Except for warranties of title and the limited express warranties set forth above, Maxloader makes no warranties express or implied of any kind with respect to its products. In particular, Maxloader makes no implied warranty of merchantability and no implied warranty of fitness for any particular purpose. The laws of limitations of implied warranties may differ from state to state, so the above limitations may not apply in all cases. LIMITATIONS OF LIABILITY The Maxloader Co. shall not be liable for consequential, incidental, or special damages resulting from or in any manner related to any product, or to the design use or any liability to use this product. The sale and exclusive remedy for a defective product or part shall be the replacement thereof as provided above and in no event shall exceed the amount paid by the purchased excluding freight charges. The laws of limitation or remedies for consequential, incidental or special damages may vary from state to state, so the above limitations may not apply in all cases. WARRANTY CLAIMS Warranty considerations are at the sole discretions of the Maxloader Company. Product must be returned within 30 days of purchase. Purchase must provide valid proof of purchase in the form of a copy of the original invoice and shall pay all freight charges associated with the return of this product. THIS WARRANTY IS NON-TRANSFERABLE Direct any questions you may have about any provision of this warrant to our warranty claims office or warranty@maxloader.us 13

14 MADE IN THE USA FROM ALL U.S. MATERIALS MAX U OUT ( )