INSTALLATION INSTRUCTIONS ----1075 North Ave. Sanger, CA 93657-3539 toll free: 800-445-3767 web: www.belltechcorp.com---- 5001 AIRJACK AIR SPRING SUSPENSION SYSTEM C 1500 AND C-2500 Congratulations! You were selective enough to choose a BELLTECH PRODUCT. We have spent many hours developing our line of products so that you will receive maximum performance with minimum difficulty during installation. Note: Warning: Warning: Reminder: Note: Confirm that all of the hardware listed in the parts list is in the kit. Do not begin installation if any part is missing. Read the instructions thoroughly before beginning this installation. DO NOT work under a vehicle supported by only a jack. Place support stands securely under the vehicle in the manufacturer s specified locations unless otherwise instructed. DO NOT drive vehicle until all work has been completed and checked. Torque all hardware to values specified. Proper use of safety equipment and eye/face/hand protection is absolutely necessary when using these tools to perform procedures! It is very helpful to have an assistant available during installation. RECOMMENDED TOOLS: Properly rated floor jack, support stands, and wheel chocks Combination wrench set Torque wrench: 0-75 lb ft. range Ratcheting socket wrench and sockets sets Safety Glasses KIT INSTALLATION 1. Open the hardware kit and remove all of the contents. Refer to the part list (Page 3) to verify that all parts are present. 2. Park the vehicle on a smooth, level concrete or seasoned asphalt surface and activate the parking brake. Block the FRONT wheels of the vehicle with appropriate wheel chocks; making sure the vehicle s transmission is in 1 st gear (manual) or Park (automatic). 3. Using a properly rated floor jack, lift the rear wheels of the vehicle off the ground. Place support stands, rated for the vehicle s weight, and in the factory specified locations. Refer to the vehicle Owner s Manual. Prior to lowering the vehicle onto the stands, make sure the supports will securely contact the chassis. 4.! It is very important that the vehicle is properly supported during this installation to prevent personal injury and chassis damage! Make sure that the supports stands are properly placed prior to performing the following procedures. We DO NOT RECOMMEND using wheel ramps while performing this installation. 1
5. Slowly lower the vehicle onto the stands and, before placing the vehicle s entire weight on them, again check that they properly and securely contact the chassis as described above. Check for possible interference with any lines, wires, cables, or other easily damaged components. 6. Remove wheels from the truck. 7. IMPORTANT: Remove the wiring and the brake lines mounted to the inside of the frame rail. This operation will serve to prevent their damage during drilling, and to provide you with a hole with which to align the upper bracket template. This can be accomplished by unscrewing the bolts used to mount the nylon brackets to the inside of the frame rail (Photo 3) and the two bolts on the brake line bracket. 8. On stock vehicles, you must use the template supplied with this kit to mount the upper bracket. Following the directions printed on the template, align mounting hole A to the lower hole used to mount the brake line bracket (Photo 4). An extra pencil will fit perfectly in hole A to prevent the template from moving while you mark the holes with a punch. On the C-1500/C-2500 with a Belltech flip kit installed; remove the hardware consisting of the four hex head cap screws and nuts on the rear of the C-section. 9. Drill the ½ holes in the chassis. The use of a smaller bit size to drill pilot holes first will aid in this procedure. On trucks with a Belltech flip kit, drill through the four 7/16 boltholes with a ½ drill bit (Photo 5). 10. Mount the upper bracket to the chassis (or c-section on vehicles with a Belltech flip kit) with the hardware supplied (Photo 6). The button head Allen bolts are used in the bottom two holes on each side to provide clearance. The washers supplied are to be used on the inside of the frame rail only, do not use washers on the outside surface bracket. The hex head cap screws are used in the top two holes of the bracket. The ¼ airline hole can be drilled after the upper bracket is mounted. 11. Re-attach the brake lines and electrical wiring to their stock locations on the inside of the frame rail. 12. Install the 90 elbow fittings into the tops of the air springs. Position the fitting openings toward the frame. Compare to the upper brackets to ensure correct positioning. 13. Mount the air springs to the lower brackets using the 3/8 mounting bolts (Photo 7). Make sure that the studs on the top of the air spring are positioned correctly to slide into the upper bracket on each side of the truck (Photo 8). 14. Make sure the jack stands on the frame rails are stable. Support the center of the rear axle housing with the floor jack. 15. Loosen the U-bolts, one side at a time, enough to allow the front of the lower bracket to slide into place under the U-bolt retainer and over the spring center bolt. On vehicles with a Belltech flip kit, loosen the U-bolt nuts to the point where there is enough clearance between the axle saddle and the leaf spring over the spring center bolt (Photo 9). 16. Once the lower bracket is securely in place over the leaf spring and on the spring center bolt, re-torque the U-bolts. On vehicles with a Belltech flip kit, make sure the ears of the axle saddle are in place in the spring perch of the rear axle and the hole in the saddle is in place on the spring center bolt (Photo 10). Re-torque the U-bolts to 75-90Ft-lbs. 17. Using the floor jack, lift the rear axle up so the studs in the top of the air springs slide into the upper bracket. Attach the air spring to the upper bracket with the supplied nuts. Tighten the nuts securely (Photo 11). 2
18. Slide the airline through the ¼ hole in the upper bracket and into the fitting on the top of the air spring (Photo 12). Route the lines from each side toward the area in which the tee fitting will be located. Drill one small hole through the frame rail for each wire tie. Loop the wire tie through the hole, insert the airline and tighten wire tie to ensure mounting is secure (Photo 13). (Refer to Air Line Mounting Recommendations included in this kit). 19. Slide the air lines from the air springs into the tee fitting, then slide the third air line into the remaining tee fitting port. Route this line to the position on the truck where the air inlet fitting is to be mounted (Refer to Air Line Mounting Recommendations included in this kit). 20. Once the air inlet fitting is mounted to the truck, slide the air inlet into position in the air inlet fitting. 21. Put a slight amount of air into the air springs and check for leaks. This can be done by ear (sound) or with a soap and water solution on each air fitting looking for bubbles (Photo 14). 22. If no leaks are detected, re-check all the mounting hardware for tightness. NOTE: It is important to check and retighten the U-bolts after 100, 500, and 1000 miles. 23. Install the wheels and tires, lift the truck from the jack stands and remove them. Lower the vehicle to the ground. CAUTION: Never exceed manufacturer s maximum gross vehicle weight rating. AIR JACK AIR SPRING SUSPENSION SYSTEM Part Number 5001 Parts List QTY. PART NO. DESCRIPTION 2 5000-001 AIR SPRINGS 2 5001-010 UPPER AIR SPRING BRACKETS 8 110316 ½ X 13 BUTTON HEAD SOCKET BOLTS 8 110401 ½ X 13 STOVER LOCK NUTS 2 110258 HHCS 3/8 16 X ¾ 2 110625 FLAT WASHER A325 3/8 8 110660 ½ FLAT WASHERS 4 110674 FLANGE NUT 3/8 16 2 5096-015 MALE ELBOW ¼ 1 5096-017 SCHRADER VALVE 1 5096-020 T FITTING ¼ 6 9999-975 NYLON BLACK CABLE TIE 7 2 5001-005 LOWER AIR SPRING BRACKETS 3
WARNING: READ CAREFULLY BEFORE INSTALLATION 1) After installation, check clearances in all areas surrounding the Air Jack Air Springs including brackets, hardware and fittings. 2) If you are using an aftermarket wheel, the maximum backspacing is 5.5 inches. When installing the Air Jack system, bolt the wheels in place and insure that there is sufficient clearance between the tires and Air Jack Air Springs before operation. 3) On some wide aftermarket tires, snow chains and cables will interfere with the Air Jack Air Spring. Please test fit the chains or cables BEFORE entering an area where chains are recommended or required. If interference does occur, DO NOT use any chains or cables. Without adequate clearance, Air Spring failure will occur. 4) Although Air Jack Air Springs maintain a load capacity of 5000lbs. per pair, NEVER EXCEED THE MAXIMUM LOAD CAPACITY OF YOUR VEHICLE. Consult your owner s manual to find the maximum payload capacity of Gross Vehicle Weight Rating (GVW) of your specific make and model. 5) If you have any questions about the Air Jack Air Suspension System, contact a Belltech factory representative at (800) 445-3767. In California call (559) 875-0222. 4
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