ABAR Silverado HD AirBar (bridge)

Transcription

1 350 S. St. Charles St. Jasper, In Ph Fax on the internet: ABAR Silverado HD AirBar (bridge) 1 A285P-1 right c-notch 1 A285D-1 left c-notch 2 WW lower bars 2 TWW upper bars (c-c = ) 1 TW panhard bar (c-c ) 1 A294-1 lower axle bridge assembly 2 A047E-1 upper axle bracket (with.620 shcs installed) 1 A284-1 PH bar axle bracket 1 A296-1D upper bar frame mount (left side) 1 A296-1P upper bar frame mount (right side) 1 A289-1 upper bridge assembly 2 F2107 air springs 2 MON37029 shocks with 2 studs / 2 sleeves 2 ROD120 large rod ends 16 DAYMO2153 ½ poly bushing 8 A145 3/4 O.D. x 5/8 I.D. sleeves 1 ROD150 Kevlar lined hiem end 1 A156 carrier bearing relocater 1 ROD302 rubber bushing insert (installed into panhard bar end) 4 A345-1 ½ x 2 special T-bolt (for lower bridge to c-notch) 2 DAY2060 short bump stops 1 ABAR11100 Bolt Kit

2 350 S. St. Charles St. Jasper, In Ph Fax on the internet: ABAR11100 hardware list Note: Lower front bar end utilizes oem leaf spring bolt. 7 m8 x 40mm metric bolts panhard bar axle bracket 7 m8 flat washers panhard bar axle bracket 7 m8 lock washers panhard bar axle bracket 4 ½ x 1 uss bolts lower airspring 8 ½ lock washers lower airspring / upper bridge 2 ½ x 2 ½ uss bolts lower shock mounts 48 ½ x 1 ½ uss bolts upper bar frame mount, upper bridge & c-notch 92 ½ sae flat washers upper bar frame mount, lower airspring, c-notch & upper bridge 54 ½ nyloc nuts upper bar frame mount, shock, upper bridge & c-notch 1 5/8 x 1 ¾ sae (gr. 8) panhard bar to axle bracket 1 5/8 lock washer (gr. 8) panhard bar to axle bracket 1 5/8 x 5 ½ sae bolt (gr.8) panhard bar to bridge 6 5/8 x 4 sae bolts (gr. 8) air bar ends 6 5/8 thin nyloc jam nuts air bar ends 8 5/8 x 6 ½ sae bolts (gr. 8) lower bridge to axle 9 5/8 sae nyloc nuts (gr. 8) lower bridge to axle / panhard bar to bridge 17 5/8 sae flat washers (gr. 8) lower bridge to axle / panhard bar to axle bracket 9 3/8 x 1 uss bolts carrier bearing / upper airspring / e-brake cable 9 3/8 uss nyloc nuts carrier bearing / upper airspring / e-brake cable 14 3/8 sae flat washers carrier bearing / upper airspring / e-brake cable 1 5/16 x 1 ¼ uss bolt brake line retainer 2 5/16 uss flat washers brake line retainer 1 5/16 uss nyloc nut brake line retainer

3 350 S. St. Charles St. Jasper, In Ph Fax on the internet: ABAR GM 1 ton HD dually AirBar system 1. Remove bed for better access to the rear frame section. You will need at least four people to help with this. 2. Raise truck to a safe, comfortable working height. Support the truck by its frame slightly ahead of the front leafspring hangars. The jackstands will remain out of the way in that location. 3. Support the axle housing with another set of jackstands. 4. Remove leafsprings 5. Locate and mark location of cut for C notch installation. Use the C notch as a template. The REAR edge of the C notch should be 4 from the EDGE of the rear overload bracket. Double check that this places the C notch bumpstop hole inline with the oem bumpstop hole. This is VERY important because the entire Airbar system locates off these C notches. 6. Using the C notch as a template, scribe the outline of the cut onto the framerail.

4 7. Cut out the notch in the framerail. Cut only one framerail at a time. We prefer a sawzall, but a plasma cutter or a cutoff wheel will also work. We do NOT recommend a torch. NOTE: The fuel tank is very close to the drivers side frame rail use EXTREME care to protect the fuel tank from damage! 8. Install the C notch. Use the C notch as a template to drill the attachment hole in the framerail. Be sure to check for obstructions on the backside of the framerail to prevent damage. NOTE: Installing only one side at a time will ensure that no undue stress is placed on the rear frame section. This operation should be performed with the frame being supported AHEAD of the front leafspring hangars and with the leafsprings removed. This will ensure there is no weight hanging on the rear frame section. 9. Install and tighten all C notch attachment bolts except the lower rear bolts and the bumpstop area bolts as illustrated above. The lower rear area uses T bolts that will be installed with the inner C notch box/upper crossmember assembly. The bumpstop area bolts are threaded into the C notch itself. 10. Repeat steps 5 thru 9 on the other side of the truck. 11. After the C notches are installed the inner C notch / upper crossmember assembly can be installed. It is attached with 4 bolts along the upper lip of the C notch, the T bolts in the lower rear area of the C notch, and with the 2 bolts threaded into the C notch in the bumpstop area. All C notch and upper crossmember bolts can be final tightened and the bumpstops can be installed. Also note in the left hand picture that the tailpipe has been removed. A turndown or custom tailpipe should be installed to direct exhaust fumes from under the truck.

5 12. The oem bumpstop pad [NOT the leafspring pad on the left!] must be removed. The preferred method is to grind off the welds that attach the pad. This will allow full suspension travel. 13. You are now ready to the upper 4 link frame brackets. These brackets attach the upper bars to the frame and replace the oem overload brackets. At least 3 holes should align with the oem holes. Use the brackets as a template to drill the remaining holes. [Your bracket may not have the same bolt pattern as shown in the picture] 14. The lower axle crossmember is now ready to be installed. You will need at least one extra person to help hold the assembly in place while the attachment bolts are installed. Be sure that the tabs of the lower axle bracket fit securely into the bottom of the oem leafspring pad as shown in the picture above. The upper plate should locate into a locating hole in the oem springpad. Tighten the axle bracket bolts evenly on both sides. It is very important to use the grade 8 hardware that is supplied with the Airbar system to ensure a proper installation.

6 15. After the lower axle bracket crossmember is installed the 4 link bars can be installed. The lower [nonadjustable] bars will attach to the oem leafspring hangars. The upper [adjustable] bars will attach to the new upper bar frame brackets. The upper bars are adjusted at the factory to a xx.xx center to center distance. There should be no need to readjust these bars. 15. The spare tire must be removed and the mounting crossmember trimmed for airspring clearance as shown above. The driverside oem upper shock mount will also be removed in this process. A sawzall is the preferred method. Be sure there is plenty of clearance to the airspring when fully inflated. 16. Install the panhard bar axle bracket onto the rearend cover. Be sure to use the longer fasteners supplied with the system to ensure proper attachment. NOTE: This bracket may not be compatible with aftermarket rearend covers.

7 17. The panhard bar can now be installed. It is adjusted at the factory to a length of xx.xx. It should not require re-adjustment, but proper rearend centering should be double checked. The rubber bushed end will be attached to the fixed upper crossmember. The spherical rod end will be attached to the rear axle bracket. As you can see in the picture, clearances here are tight. Run the suspension through its full suspension travel to double check these clearances upon final assembly. 18. The airsprings can now [finally!] be installed. Run the suspension through its entire travel to ensure there is no contact with the airspring and any obstructions. The picture to the left gives an overall view of the installation and the routing of brakelines, wiring, and fuel lines. Double check clearances on these items upon final assembly. IMPORTANT!! The airspring can not rub on anything at anytime! Immediate failure may result!

8 19. Install the supplied shock absorbers onto the shock mounts on the C notch and the lower axle crossmember 20. The driveshaft carrier bearing will need to be relocated to optimize driveline angles at your new lower ride height. The oem carrier bearing bracket is sectioned as shown in the picture to the left. The new carrier bearing bracket is then bolted onto the remaining tabs. The carrier bearing mount is rotated 180 degrees and attached to the supplied bracket as shown in the picture on the right.

9 21. The bed supports will need to be trimmed before the bed can be reinstalled. There are 3 crossmembers that are affected as shown above. The 2 crossmembers that are directly over the axle housing will need to be removed completely for clearance. The front crossmember as shown above is only notched for C notch clearance. This is best accomplished with a cutoff wheels or sawzall to avoid damage to the inside of the bedfloor. [Don t accidentally cut through the bedfloor like we did!] 22. The bed floor lip must be notched for shock clearance. A 2 wide x 1 tall notch should be centered approx. 4 from the rear of the bedbrace as shown In the picture to the left. After the bed is re-installed, be sure to re-check all clearances for brakelines, wiring, fuel lines and air lines. Be sure to treat all trimmed areas on the frame and bed for rust prevention. Re- check airspring clearance Re-check panhard bar clearance Re-check shock travel to ensure the shocks do not bottom out when the truck is fully lowered. The shocks should capture the suspension travel before the airspring is fully extended. Ride height of the airsprings is approx On an empty truck this should be approx. 35psi. Fender height will be approx at ride height, both loaded and empty.