82-01 Chevy S-10/ GMC Sonoma Front Kit Part No B

Transcription

1 Chevy S-10/ GMC Sonoma Front Kit Part No B MN-481 (02105) ECN 3549 Please read these instructions completely before proceeding with installation Left Side Upper Shock Mount Right Side Upper Shock Mount Upper Bracket P/N Left P/N Right Shock Absorber Roll Plates Lower Bracket Air Spring Offset Side Shock Absorber Wheel Engine Parts Included for Installation: Item Description Qty. A Upper Shock Mount (Left) 1 B Upper Shock Mount (Right) 1 C Shock Absorbers 2 D Upper Bracket 2 E Lower Bracket 2 F Air Spring 2 G Roll Plate 4 H Shock Mounting Pin 4 I Jounce Bumper 2 J 3 /8"-24 x 7 /8" Bolt 8 K 3 /8" Flat Washer SAE 8 L 3 /8" Lock Washer 8 Item Description Qty. M 3 /8"-16 x 1.5 Type 1 Tapper 6 N 1 /8" x 1.75 Cotter Pin 2 O 5 /8"-11 x 6.5 Stud 2 P 5 /8"-11 Nylock Nut 2 Q 5 /8" Flat Washer 2 R Vinyl Hose 1' S 1 /2" Straight Air Fitting 2 T Tie Strap 12 U Valve Caps 1 V 5 /16" Flat Washer 1 W Rubber Washer 1 X Star Washer 1 Item Description Qty. Y 5 /16" Hex Nut 2 Z 3 /8" NPTF x 1 /4" Connector 1 AA Male Branch Tee 1 BB 1 /4" Nylon Tube 5' CC 1 /2" Nylon Tube 10' DD Inflation Valve 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 the sway bar links from each lower control arm. 4. Remove the shock absorbers. II. Removing the Coil Spring NOTE: Work on one side at a time. 1. Starting on the driver s side, place a floor jack securely under the lower control arm. Using the jack, elevate the control arm so that the spring is slightly loaded. 2. Install the spring compressor and tighten as required to lift the coil off the control arm seat. NOTE: Use extreme caution. Follow spring compressor directions and safety guidelines. 3. Loosen the lower ball joint retaining nut, but do not remove the nut. After loosening, run the nut up the shank of the ball joint until there is approximately 1 /2 " of thread showing between the nut and it s mating surface on the spindle. 4. Using a ball joint separator (pickle fork), separate the ball joint from the spindle. Remove the ball joint nut. 5. Lift the spindle/disc brake assembly up and secure. Lower the control arm, using the jack, so that the ball joint pin is separated from the spindle. Tighten the spring compressor, as necessary, to create enough freeplay to accomplish this step. 6. Push the lower control arm down, and remove the coil spring. Remove the spring compressor from the coil spring. NOTE: Use extreme caution. Follow directions and safety guidelines. III. Installing the Jounce Bumper 1. Locate a site for a 5 /8 " diameter hole 1 1 /2 " to the inside of the spindle stop plate, on the rear face of the lower control arm. Drill the hole and mount the lower shock pin (Figure 1). 2 Figure /2 " 2. Remove the stock jounce bumper. Install the replacement jounce bumper (I) into the OEM jounce bumper hole. NOTE: Do not tighten the jounce bumper until final assembly.

3 IV. Assembling the Air Spring 1. Set roll plates (G) on the top and the bottom of the air springs (F). 2. Install the 1 /2" straight fitting (S) to the air spring assembly. Tighten finger-tight plus 1 1 /2 turns. 3. Attach the upper bracket (D) to the air spring assembly. Attach using two bolts (J), two lock washers (L), and two flat washers (K). Tighten securely. 4. Attach the 5 /8" x 6.5 full thread stud (O) into the upper bracket (Figure 2). 5. Orient the lower bracket (E) so that the offset slots are towards the outside (wheel side) of the assembly (Figure 3). Orient the upper bracket/air spring assembly so that the air fitting is towards the inside, the engine side (Figure 4). Loosely attach the lower bracket and roll plate to the air spring assembly using two bolts (J), two lock washers (L), and two flat washers (K). Figure 2 Long Tab V. Installing the Bellow Assembly 1. From the underside of the truck, locate and drill a 9 /16" or larger diameter air line clearance hole in the roof of the coil spring tower. Ensure that this hole is drilled inside the ring of the OEM coil spring locating fingers. Deburr the hole. 2. Cut the 1 /2" nylon tube (CC) into two equal lengths. 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. Do not use wire cutters or scissors to cut the air line. These tools may flatten or crimp the air line, causing it to leak around the O-ring seal inside the elbow fitting. 3. Insert the hose into the fitting on the air spring. Make sure that the hose goes in all the way. This is a self locking fitting. A click can be heard/felt when seated. When fully seated the hose should be in approximately 9 /16". 4. Lift the air spring/mount assembly into the coil spring tower. Place a floor jack under the lower control arm. Raise the lower control arm, with the floor jack, to provide support to the bottom of the assembly. Ensure that the assembly is rotated so that the lower spring mount sits in the lower control arm properly (Figure 5). NOTE: Air line/fitting towards the engine side, deepest tab on the lower mount towards the engine side). Note orientation of roll plate and air spring. Figure 3 ENGINE Figure 4 Figure 5 Long Tab 3

4 5. Position the assembly up and into the spring tower, ensuring that the all-thread is inserted through the OEM upper shock hole. NOTE: Ensure that the OEM coil spring locating fingers, on the roof of the coil spring tower, slide inside the upper air spring mount. 6. Make sure that there are no sharp points where the hose may rub causing it to fail. Figure 6 7. Raise the lower control arm until the arm is level with the floor. Lift and drop the spindle assembly onto the lower ball joint; install the ball joint nut (Figure 6). 8. From the bottom of the control arm, tighten the lower air spring mounting bolts using a 9 /16" box end wrench. VI. Installing the Shock Absorber Figure 7 Passenger Side Forward 1. Insert the shock pins (H) supplied into the top and bottom of the spring eye. Install bottom shock pin in A-arm. (Figure 7). 2. Install upper shock pin (H) into the top shock bracket (A or B) using flat washer and nut included in shock pin hardware. Tighten nut securely. The flat edge of the bracket faces the rear of the pickup and will angle in towards the fenderwell (Figure 8) Rotate the shock assembly up until the upper shock bracket rests against the frame. Use a scribe and mark the three mounting holes on the face of the frame (Figure 8). Lower Control Arm Figure 8 4. It may be necessary to dent the fender liner slightly with a ballpeen hammer or a rubber mallet in order to provide additional clearance for the upper shock mount in the location shown in Figure 9. May need to dent this location slightly 5. Drill a 5 /16" hole through the frame at the upper hole location. See Figure 8. NOTE: Orient the drill so that the hole location, on the inside of the frame, is on the flat land just behind and towards the top of the control arm mounting structure. 4 Figure 9

5 6. Install one 3 /8" self tapper (M). Tighten securely. Do not overtighten. 7. Drill two 5 /16 " holes at the lower hole locations. Vehicle body or bumper Air Line to Bellows 8. Install two 3 /8 " self-tapping screws (M) in the lower shock mount holes. Tighten securely. Do not overtighten. Refer back to Figure 8. Flat Washer Valve Cap Rubber Washer Hex Nut Figure Leave sway bar loose until the passenger s side has been completed. VII. Reattaching Components Hex Nut Star Washer 2. Attach brake line to upper control arm, if removed. 3. Repeat entire installation procedures for the passenger s side. 4. Attach sway bar links and tighten securely. 5. Tighten all bolts, nuts, and install all required Cotter pins. VIII. Routing the Air Lines CAUTION: When cutting or trimming the air line, use a hose cutter (Air Lift P/N 10533), a razor blade, or a sharp knife. A clean, square cut will ensure against leaks (Figure 10). Do not use wire cutters or scissors to cut the air line. These will likely flatten or crimp the air line, causing it to leak around the O-ring seal inside the fitting (Figure 10). 1. Install the inflation valve (DD) to the end of the 1 /4" nylon tube (BB). Soak the end of the nylon hose in hot tap water to ease installation of inflation valve. 2. Choose a convenient location for mounting the inflation valve. Popular locations for the inflation valve are: a. The wheel well flanges. b. License plate recess in bumper. c. Through license plate itself. 3. Drill a 5 /16 " hole to install the inflation valve. 4. Place a 5 /16 " nut (Y) and a star washer (X) 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 (W), flat washer (V), 5 /16 " nut (Y), and cap (U). There should be enough valve exposed after installation - approximately 1 /2 " - to easily apply a pressure gauge or an air chuck (Figure 10). 5. Push the inflation valve through the hole and use the rubber washer (W), flat washer (V), and another 5 / 16 " nut (Y) to secure it in place. Tighten the nuts to secure the assembly in place (Figure 10). 5

6 6. Connect the male branch tee (AA) to the 3 /8" NPTF x 1 /4" connector (Z). 7. Route the air line along the frame to the male branch tee assembly. Install the 1 /2" lines into each end of the tee. 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. Use the plastic tie straps (T) 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. 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. 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. IX. Before Operating 1. Inflate the installed system to 80 p.s.i. and move suspension through full range of motion to check for interference or rub. 2. 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. If custom wheels and tires are used, then be sure to note tire to fender well clearance. Space jounce bumper for additional clearance. 4. Tighten and visually inspect all hardware after 100 miles. 5. Our BadBoy control kit is highly recommended for this kit. 6. Continue by reading the remaining information in this manual, including the Maintenance and Operation section. 6

7 X. Fixing Leaks 1. 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. 2. If there is a problem with the swivel fitting, 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. 3. If the preceding steps have not resolved the problem, call Air Lift Technical Service at for assistance. XI. 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 X 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 X 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. 7

8 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. Remember that loads carried behind the axle (including tongue loads) require more leveling force (pressure) than those carried directly over the axle. 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. Thank you for purchasing Air Lift Products 8 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 The Choice of the Professional Installer Printed in the USA