THE NUTS & BOLTS Why MAXLOADER TM support springs? Additional 2500 3500-5000 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
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
BEFORE AFTER 4
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 100102 fits 1988-2002 Chevrolet C-10, K-10 trucks as well as 1988-2002 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 http://www.maxloader.us 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
2012 MAXLOADER APPLICATION CHART CHEVROLET 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCKS S-10 SANOMA 2X4 4X 4 1982-2003 200200 COLORADO YUKON 2X4 4 X4 2004-2010 200216 C1500 K 1500 1988-1998 200202 1500HD 2002-2006 200202 SILVERADO/SIERRA 2WD 4WD 1999-2012 200202 2500/3500 C & K W/OUT FAC.AUX 1988-2010 200204 210204 2500/3500 C & K W/ FAC.AUX 1988-2010 200206 210206 2500/3500 C& K W/OUT FAC AUX 2011-2012 200218 210218 2500/3500 C & K W/FAC AUX 2011-2012 200220 210220 230220 C3500 CAB & CHASSIS 2008-2010 210212 3500 CAB & CHASSIS 2011-2012 210226 230226 4500-6500 DURAMAX EYE BY SLIPER 2003-2009 230222 4500-6500 EYE BY EYE TAPER 2003-2009 230224 VANS G10,20,30 W/MULTI LEAF SPRING 1996-2011 200208 210218 G10,20,30 W/TAPERED LEAF SPRING 1996-2011 200210 210210 ASTRO VAN W/STEEL SPRING 1996-2005 200214 SUV BLAZER, TAHOE,YUKON W/LEAF SPG 1992-2008 200212 S10 BLAZER S15 JIMMY 1982-2004 200200 HUMMER 3 200214 DODGE 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCKS DAKOTA 2WD 1986-2004 201204 DAKOTA 4WD 1986-2004 201206 DAKOTA 2WD 2005-2011 201224 DAKOTA 4WD 2005-2011 201224 D100, 200 UNDER 7500 GVW 2WD 1994-2002 201208 W100, 200 UNDER 7500 GVW 4WD 1994-2002 201210 1500 2WD/ EXCEPT MEGA CAB 2003-2008 201226 1500 4WD/EXCEPT MEGA CAB 2003-2008 201228 D200, 300 OVER 7500 GVW 3" WIDE SPG 1994-2002 201212 211212 W200, 300 OVER 7500 GVW 3" WIDE SPG 1994-2002 201214 211214 D/W 200, 300 UNDER 9000 GVW 2003-2009 201216 211216 D/W 200,300 OVER 9000 GVW 2003-2009 201218 211218 2500/3500 2WD MEASURE U BOLT 2010-2012 201236 211236 2500/3500 4WD MEASURE U BOLT 2010-2012 201218 211218 D/W3500 CAB & CHASSIS 2009-2012 211232 231232 D/W4500,5000 CAB AND CHASSIS 2007-2012 211230 231230 VANS B100,200 1972-2002 201200 B300 1972-2002 201202 211101 SPRINTER 2500 2003-2008 201220 211220 SPRINTER 3500 2003-2008 211222 231222 6 If you do not find your particular vehicle, please call Maxloader for application.
FORD 2012 MAXLOADER APPLICATION CHART 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCK RANGER 2WD 1986-2003 202202 RANGER 4WD 1986-2003 202204 RANGER 2WD 2004-2011 202220 RANGER 4WD 2004-2011 202222 F150 2WD & HERITAGE 1980-2004 202206 F150 2WD 2004-2008 202208 F150 4WD & HERITAGE 1980-2004 202210 F150 4WD 2004-2008 202212 F150 2WD & 4WD 2009-2012 202228 F250,350 2WD 1984-2007 202214 212214 F250,350 4WD 1984-2007 202216 212216 F250,350 2WD W/4" AXLE 2008-2010 202218 212218 F250,350 4WD W//4"AXLE 2008-2010 202220 212220 F250,350 2WD / 4WD MEASURE U BOLTS 2011-2012 202238 212238 F350 CAB & CHASSIS 1999-2010 212232 232232 F350 CAB & CHASSIS 2011-2012 212246 232246 F450 PICK UP 2008-2010 212240 232240 F450 PICK UP 2011-2012 212248 232248 F450/550 CAB & CHASSIS 2008-2012 212242 232242 VAN E150 1980-2007 202206 E250/E350 1980-2011 202206 202216 E450 1996-2011 212228 232228 TRANSIT CONNECT 2010-2011 202244 SUV EXPLORER INCLUDING SPORT TRAC 1991-2006 202200 EXCURSION 2000-2006 202218 212218 ISUZU 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCKS NPR 212200 235200 MITSUBISI 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCKS FE125 216200 236200 FE140 216202 236202 NISSIAN 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCKS FRONTIER 2WD 1998-2004 204202 TITAN 4WD 2006-2008 204204 TITAN 4WD 2009-2011 204206 If you do not find your particular vehicle, please call Maxloader for application. 7
TOYOTA 2012 MAXLOADER APPLICATION CHART 2500# 3500# 5000# MODEL YEARS STD KIT HD KIT HDD TRUCKS T100 2WD 1993-1998 203204 T1OO 4WD 1993-1998 203206 TACOMA 2WD 1995-1998 203200 TACOMA 4WD 1995-1998 203220 TACOMA 2WD 1999-2004 203202 TACOMA 4WD 1999-2004 203222 TACOMA 2WD 2005-2008 203210 TACOMA 4WD 2005-2008 203208 TACOMA 2WD 2009-2011 203216 TACOMA 4WD 2009-2011 203218 TUNDRA 2WD 1999-2006 203224 TUNDRA 4WD 1999-2006 203212 TUNDRA 2WD 2007-2011 203226 TUNDRA 4WD 2007-2011 203214 MULTI FIT SPECIAL 5000# MULTI FIT KIT 2011-2012 230000 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.
www.maxloader.us 360-730-1247 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
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
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
(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: 67 84 ft pounds 1/2" square top U-bolt: 53 66 ft pounds 9/16 round top U-bolt: 93 116 ft pounds 9/16 square top U-bolt: 74 93 ft pounds 5/8 round top U-bolt: 157 197 ft pounds 5/8 square top U-bolt: 129 161 ft pounds 3/4 round top U-bolt: 264 330 ft pounds 3/4 square top U-bolt: 250 300 ft pounds VERY IMPORTANT!: After 200-500 miles of driving, re-torque U-Bolts. 12
WARRANTY www.maxloader.us 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. 360-730-1247 or warranty@maxloader.us 13
MADE IN THE USA FROM ALL U.S. MATERIALS www.maxloader.us 1-877 - MAX U OUT (1-877-629-8688)