Air Lift 59537 Installation guide

Air Lift
Brand
Air Lift
Model
59537
Type
Installation guide
Technical Support
1-800-248-0892
Ext. 2
MN-461
(021108)
ECR 7136
Please read these instructions completely before proceeding with installation
Air Spring Kit Parts List
Item Description Quantity
A Air Sleeves 2
B Upper Brackets 2
C Lower Brackets 2
D Jounce Bumper Spacer 2
E LowProleElbowFitting 2
E
G
F
D
K
J
Air Spring Attaching Hardware
Item Description Quantity
L
1
/2 “ x
7
/8 “ Hex Head Bolts 2
M
3
/4 “ Hex Jam Nut 2
N
1
/2”FlatWashers 2
L
N
M
AirLineAssemblyParts
List
Item Description Quantity
AA AirLineAssembly 1
BB Tie Strap 6
CC Valve Caps 2
DD
5
/16”FlatWasher 2
EE RubberWasher 2
FF SmallStarWasher 2
GG
5
/16” Hex Nut 4
HH Hose Clip 4
GG
AA
BB
A
B
I
C
CC EE FFDD
HH
II
H
Bracket Attaching Hardware
Item Description Quantity
F
3
/8 “-16 U-Bolts 2
G Clamp Bar 2
H
3
/8 “NylockNuts 6
I
3
/8 “FlatWashers 6
J
3
/8 “x1”WHST 6
K
3
/8 “ x 1” HHCS 2
Kit No. 59537
Technical Support
1-800-248-0892
Ext. 2
Tools Needed
IMPORTANT:Yourvehiclemaybeequippedwitharearbrakeproportioningvalve.Anytypeofloadassist
productcouldaffectbrakeperformance.Werecommendthatyoucheckwithyourdealerbeforeinstalling
thistypeofproduct.IfyourvehicleDOESNOThavearearbrakeproportioningvalveorisequippedwithan
anti-locktypebrakesystem,installationofaloadassistproductwillhaveNOEFFECTONBRAKESYSTEM
PERFORMANCE.
IMPORTANT: Failuretomaintaincorrectminimumpressure(orpressureproportionaltoload),bottoming
out,overextension,orrubbingagainstanothercomponentwillvoidthewarranty.
DANGER:Compressedaircancauseinjuryanddamagetothevehicleandpartsifitisnothandledproperly.
Foryoursafety,donottrytoinatetheairspringsuntiltheyhavebeenproperlysecuredtothevehicle.
Standardandmetricopenendorboxwrenches
Ratchet with
3
/8”,
1
/2”,&
9
/16” deep well sockets
5
/16”drillbit(verysharp)
7
/16”&
9
/16” Nut Drivers
HeavyDutyDrill
TorqueWrench
HoseCutter,RazorBlade,orSharpKnife
HoistorFloorJacks
SafetyStands
SafetyGlasses
AirCompressor,orCompressedAirSource
SprayBottlewithDishSoap/WaterSolution
I.GettingStarted
1.Determine the Normal Ride Height.The Normal Ride
Height is the distance between the bottom edge of the
wheel-well and the center of the hub with the vehicle
in the “as delivered” condition.Insomecases,Normal
RideHeightisnotperfectlylevel.
a. Removeunusualloadsandexamineyourvehiclefrom
thesidetoensureitisonalevelsurface(Figure1).
b. If necessary (in cases where your leaf springs are
saggingbadly),useajacktoraisetherearendsothat
the vehicle achieves the original “as delivered” ride
height.
2.Measurethedistancebetweenthecenterofthehuband
thebottomedgeofthewheelwell(Figure2).Thisisthe
NormalRideHeight.Enterthemeasurementbelow:
NORMAL
RIDEHEIGHT:__________inches
Figure 1
Figure 2
Technical Support
1-800-248-0892
Ext. 2
II.AssemblingtheAirSpringUnit
1.Install90degreeairswiveltting(E)tothetopoftheair
spring.Useanopenendwrenchbeingcarefultotighten
onthemetalhexnutonly.Tighten1and
1
/2turns(Figure
3).Donotovertighten.
NOTE: This fitting is precoated with sealant.
2.Set upper bracket (B) over the tting and thread post
(Figure4).Positiontheelbowtowardsthefrontorrearof
the vehicle depending on which direction will allow easier
accessfortheairline.
3.Threadnylonnut(M)ontothethreadpost,makingsure
thattheatsideisup(Figure5).
4.Tightenthenylonnut.Handtightissufcient.
IMPORTANT: Ensure that the bracket is tight and flat
to the roll plate on both sides.
5.Looselyattachthelowerbracket(E)tothebottomofthe
air spring with
1
/2”atwasher(N)and
1
/2” Hex Head Cap
Screw(L).SeeFigure6.
Figure 3
Figure 4
Figure 5
Figure 6
3/4" Nylon Nut
Air Spring
Upper Bracket
Nylon nut must be threaded
on the thread post with the
curved edge toward the
sleeve.
Technical Support
1-800-248-0892
Ext. 2
III.InstallingtheJounceSpacer
1.Forheavyloadusage,werecommendinstallingajounce
bumperstrikeplatespacer(D)underthestockstrikeplate
(Figure7).
2.Position the strike plate spacer (D) ush with the back
bottom edge of the stock strike plate and mark the
mountingholelocationusingapencilormarker(Figure
8).
3.Centerpunchanddrilla
3
/8”holeinthestockstrikeplate.
NOTE: In order to gain more accessibility for drilling
the mounting hole, it may be necessary to drop the
axle. Keep safety in mind and use safety stands if
needed.
4.Boltthestrikeplatespacertostockstrikeplateusinga
3
/8”
bolt(K),twowashers(I),andanylocknut(H).SeeFigure
10.Torqueto16ft-lbs.
IV.MountingtheLowerBracket
IMPORTANT: If the axle was dropped to install the jounce
strike plate spacer, it will be necessary to raise it back to
the normal ride height recorded on page 2.
1.Withthevehicleatnormalrideheight,withthehookendof
thelowerbracketoverthefactoryU-bolt,settheairspring
assemblyonthe leafspringforwardof theaxle(Figure
11).
2.SecurethelowerbrackettotheleafspringusingU-bolt
(F),clampbar(G),atwasher(I),andnylocknut(H).See
Figure12.Tightento16ft-lbs.
Figure 7
Figure 8
Figure 10
Figure 9
Figure 11
Jounce
Strike Plate
Technical Support
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Ext. 2
V.LocatingtheUpperBracket
1. Theupperbracketmustbeparallelandperpendiculartothe
lowerbracketasshownintheillustrationinFigure13.
2.Aligntheupperbracketsothattheshortlegoftheupper
brackettouchesthebottomoftheframerail(Figure14).
3.Usingtheupperbracketasatemplate,centerpunchone
hole(Figure15).AweldingclamporC-clampmayassist
inholdingtheupperbrackettotheframe.
NOTE: It is necessary to use at least three of the five
pre-drilled holes in the upper bracket for mounting.Any
combinationofthethreeispermissible.
4.CAUTION: Before drilling, be sure to check the back
side of the frame rail for brake lines, gas lines, or
electrical lines that may be in the way. It is necessary
to move any interfering lines prior to drilling.
5.Drillone
5
/16”holeandinstalloneWHST(J).SeeFigure
16.Tightento15ft-lbs.
IMPORTANT: Check again to make sure that the upper
and lower brackets are parallel and perpendicular to
each other (Figure 13).
6.Centerpunch and drill remaining two holes and install
theWHST(J).Again, torque to15ft-lbs.Donot over
tighten.
VI.InstallingtheOtherSide
1. Installtheminimum/maximumairpressuredecalinahighly
visiblelocation.
2.Repeatentireinstallationprocedureforremainingside.
3.ContinuewithsectionVII,InstallingtheAirLines.
Figure 12
Figure 13
Figure 15
Figure 14
Figure 16
Frame
Rail
Upper
Bracket
Fitthebottom
oftheupper
brackettightto
theframerail
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5
/16” Nut
RubberWasher
FlatWasher
5
/16” Nut
StarWasher
VehicleBodyor
Bumper
VII.InstallingtheAirLines
1.Chooseaconvenientlocation for mounting the ination
valves.Popularlocationsfortheinationvalveare:
a. Thewheelwellanges.
b. Licenseplaterecessinbumper.
c. Underthegascapaccessdoor.
d. Throughlicenseplateitself.
NOTE: What ever the chosen location is, make sure
there is enough clearance around the inflation valves
for an air chuck.
2.Drilla
5
/16 “holetoinstalltheinationvalves.
3.Cuttheairlineassembly(AA)intwoequallengths(Figure
17).
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.
(Figure 18a). 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 (Figure 18b).
4.Placea
5
/16 “nut(GG)andastarwasher(FF)ontheair
valve.Leaveenoughoftheinationvalveinfrontofthenut
toextendthroughtheholeandhaveroomfortherubber
washer (EE), at washer (DD), and
5
/16 “ nut (GG) and
cap(CC).Thereshouldbeenoughvalveexposedafter
installation-approximately
1
/2 “-toeasilyapplyapressure
gaugeoranairchuck(Figure19).
5.Push the ination valve through the hole and use the
rubberwasher(EE),atwasher(DD),andanother
5
/16 “
nut(GG)tosecureitinplace.Tightenthenutstosecure
theassemblyinplace(Figure20).
Figure 17
Figure 18a Figure 18b
Figure 19
Good cut – clean and
square
Badcut–attened
Figure 20
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6.Routetheairlinealongtheframetotheairttingontheair
spring.Keepatleast6”ofclearancebetweentheairline
andheatsources,suchastheexhaustpipes,mufer,or
catalyticconverter.Avoidsharpbendsandedges.Use
theplastictiestraps(BB)tosecuretheairlinetoxed,
non-movingpointsalongthechassis(Figure21).Besure
thatthetiestrapsaretight,butdonotpinchtheairline.
Wheretherearenoholestosecurethestrapsto,usethe
airlineclip(HH)andselftapper(II)tosecuretheairlineto
theframe(Figure22).Leaveatleast2”ofslacktoallow
foranymovementthatmightpullontheairline.
7.Cutoffairlineleavingapproximately12”ofextraairline.
Acleansquarecutwillensureagainstleaks.Insertthe
airlineintotheairtting.Thisisapushtoconnecttting.
Simplypushtheairlineintothe90°swivelttinguntilit
bottomsout(
9
/16”ofairlineshouldbeinthetting).
Figure 21
Figure 22
Figure 23
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Ext. 2
VIII.AligningtheAirSprings
1.IMPORTANT:Withthebottomoftheairspringstillloose,
inatetheairspringtoapproximately10p.s.i.Usethe
slottedadjustmentinthelowerbrackettocorrectlyalign
theairspringbetweentheupperandlowerbracket.This
canbeaccomplishedbytappingitinboardoroutboardfor
properalignment.Thereshouldbeasymmetricalcushion
of air around the base of the air spring when correctly
positioned.Figure24representsamisalignedairspring.
Figure25showsaproperlyalignedairspring.
2.When aligned, tighten the lower end by holding the air
springandturningtheboltwitha
3
/4” open end wrench
(Figure26).Snug(10ft-lbs)willbesufcientandwillalso
preventstrippingthethreads.Do not attempt to hold the
air spring with any type of tool.
3.Figure27showsthecompletedinstallation.
Figure 24
Figure 25
Figure 26
Figure 27
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Ext. 2
Valve
Core
Barbed
Air Line
Connection
IX.CheckingforLeaks
1.Inatetheairspringto60p.s.i.
2. Sprayallconnectionsandtheinationvalveswithasolution
of
1
/5liquiddishsoapand
4
/5watertocheckforleaks(Figure
28).Youshouldbeabletospotleakseasilybylookingfor
bubblesinthesoapywater.
3.Afterthetest,deatethespringstothe minimumpressure
requiredtorestoretheNormalRideHeight,butnotless
than10p.s.i.
4. IMPORTANT:Checktheairpressureagainafter24hours.
A2to4p.s.i. lossafterinitialinstallationisnormal.Retest
forleaksifthelossismorethan5lbs.
X.FixingLeaks
1.
Ifthereisaproblemwiththeswiveltting,then:
a. Checktheairline connectionbydeatingthespring
andremovingthelinebypullingthecollaragainstthe
ttingandpullingrmlyontheairline.Trim1”offthe
endoftheairline.Besurethecutiscleanandsquare.
Reinserttheairlineintothepush-to-connecttting.See
Figure29.
b. Checkthethreadedconnectionbytighteningtheswivel
tting another
1
/2 turn.If it still leaks, deate the air
spring,removethetting,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.SeeFigure29.
2.Ifthereisaproblemwiththeinationvalve,then:
a. Checkthevalvecorebytighteningtheitwithavalve
coretool.
b. Checktheairlineconnection(Figure30)byremoving
the air line from the barbed type tting.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ttinganduseapairofpliersor
vise-gripstopull/twisttheairlineoffthetting.
3.If the preceding steps have not resolved the problem,
call Air Lift Technical Service at 1-800-248-0892 for
assistance.
Figure 28
Figure 29
Figure 30
Air Line
Connection
Collar
SwivelFitting
Threaded
Connection
Technical Support
1-800-248-0892
Ext. 2
Figure 31
Figure 32
Figure 33
Figure 34
XI.TroubleshootingGuide
Problems maintaining air pressure, without on-board
compressor.
1.Leaktesttheairlineconnectionsandthreadedconnection
oftheelbowintotheairspring(Figure28).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(Figure31).
SeeSectionXforrepair.
3. Inspectairlinestobesureitisnotpinched.Tiestrapsmay
betootight.Loosenorreplacestrap.Replaceleaking
components(Figure32).
4.Inspectairlineforholesandcracks(Figure33).Replace
asneeded.
5.A kink or fold in the air line (Figure 34).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 1-800-
248-0892 for assistance or a replacement air spring.
Technical Support
1-800-248-0892
Ext. 2
XI.Checklist
You can protect your warranty on this product and prevent unnecessary wear by ensuring the following
checks have been made:
SectionI–Installation(Tobecompletedbytheinstaller):
SectionII-PostInstallationChecklist(Tobecompletedbytheowner):
1. ClearanceTest-Inatetheairspringsto60p.s.i.andensurethereisatleast
1
/2 “ clearance around
eachsleevefromanythingthatmightrubagainstthem.Besuretocheckthetire,brakedrum,frame,
shockabsorbersandbrakecables.
2. LeakTestBeforeRoadTest–Inatetheairspringsto60p.s.i.,checkallconnectionsforleakswith
asoapywatersolution.Seepages9and10ofthemanualfortipsonhowtospotleaks.Allleaks
mustbeeliminatedbeforethevehicleisroadtested.
3. HeatTest–Besurethereissufcientclearancefromheatsources-atleast6”forairspringsandair
lines.Ifaheatshieldwasincludedinthekit-installit.Ifthereisnoheatshield,butoneisrequired,
call1-800-248-0892.
4. FastenerTest–Recheckallboltsforpropertorque.
TorqueGuide:
 WHST 15ft-lbs
 U-boltLockNuts 16ft-lbs
 LowerBoltforAirSpring 10ft-lbs
5. RoadTest–Thevehicleshouldberoadtestedaftertheprecedingtests.Inatethespringsto25
p.s.i.(50p.s.i.ifvehicleisloaded).Drivethevehicle10milesandrecheckforclearance,loose
fastenersand/orairleaks.
6. OperatingInstructions–Ifprofessionallyinstalled,
theinstallershould
reviewtheoperatinginstructions
onpage12withtheowner.Besuretoprovidetheownerwithallofthepaperworkthatcamewith
thekit.
1.OvernightLeakdownTest–Recheckairpressureaftervehiclehasbeenusedfor24hours.If
pressurehasdroppedmorethan5p.s.i.then,youhavealeakthatmustbexed.Eitherxthe
leakyourself(seepages9and10)orreturntotheinstallerforservice.
2.AirPressureRequirements–Iunderstandthattheairpressurerequirementsofmyairspring
systemareasfollows:
 Minimum___________Maximum___________
IalsounderstandthatImustinatetheairspringsuntiltheRideHeightmeasurementthatwas
recordedonpage2hasbeenrestored.Regardlessofload,theairpressureshouldalwaysbe
adjustedsothattheRideHeightismaintainedatalltimes.
3.ThirtyDayor500MileTest.IunderstandthatImustrechecktheairspringsystemafter30
daysor500miles,whichevercomesrst.Ifanypartshowssignsofrubbingorabrasion,the
sourceshouldbeidentiedandmoved,ifpossible.Ifit isnotpossibletorelocatethecauseof
theabrasion,the
airspringmayneedtoberemounted.If
professionallyinstalled,theinstaller
shouldbeconsulted.Checkallfastenersfortightness.
Technical Support
1-800-248-0892
Ext. 2
“The Choice of the Professional Installer”
ForTechnicalAssistancecall1-800-248-0892
Thank you for purchasing Air Lift Products
MailingAddress: StreetAddress:
AIRLIFTCOMPANY AIRLIFTCOMPANY
P.O.Box80167 2727SnowRd.
Lansing,MI48908-0167 Lansing,MI48917
LocalPhone:(517)322-2144
Fax:(517)322-0240
Printed in the USA
XII.MaintenanceandOperations
Byfollowingthesesteps,vehicleownerswillobtainthelongestlifeandbestresultsfromtheirair
springs.
1.Checktheairpressureweekly.
2.AlwaysmaintainNormalRideHeight.Neverinate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inationvalvecorebeforedeatingandremovingtheairspring.(Seepage9.)
4.Whenincreasing load,alwaysadjusttheairpressuretomaintaintheNormalRideHeight.Increase
ordecreasepressurefromthesystemasnecessarytoattainNormal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:Foryoursafetyandtopreventpossibledamagetoyourvehicle,do not exceed maximum
Gross Vehicle Weight Rating (GVWR), as indicated by the vehicle manufacturer.Althoughyour
airspringsareratedatamaximumination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.Sleevesrequirelessair
volumethanatireandinatequickly.
7.Should it become necessary to raise the vehicle by the frame, make sure the system is at minimum
pressure (5 p.s.i.) to reduce the tension on the suspension/brake components. Use of on–board
leveling systems do not require deflation or disconnection.
5p.s.i.
100p.s.i.
Failure to maintain correct minimum pressure (or pressure proportional to
load), bottoming out, over-extension, or rubbing against another component
will void the warranty.
Maximum Air PressureMinimum Air Pressure
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Air Lift 59537 Installation guide

Air Lift
Brand
Air Lift
Model
59537
Type
Installation guide
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