DS120R DS135R Installation Manual

D11005 Rev P 8/2017

Contents TROUBLESHOOTING ...... 35 Issues with Vehicle Raising/Pump ...... 37 CONTENTS ...... 2 Issues with Vehicle Lowering/Dump Valve ...... 37 INTRODUCTION ...... 3 Issues with Secondary Volume Assembly ...... 37 SUSPENSION APPLICATION ...... 3 Issues with One Corner Not Leveling Properly ...... 38 SUSPENSION RATING ...... 3 Issues with Height Sensors ...... 38 SERIAL NUMBER TAG INFORMATION...... 3 Issues with Ride/Handling ...... 38 VEHICLE TOWING AND JACKING INFORMATION ...... 4 Issues with Steering Sensor ...... 38 Issues with Vehicle Speed Signal ...... 39 ABBREVIATIONS ...... 4 Issues with Vehicle Brake Signal ...... 39 SPECIAL TOOLS ...... 4 Issues with Door Switch ...... 39 Issues with Vehicle Ignition Signal ...... 39 HYDRAULIC FITTING ASSEMBLY ...... 5 Issues with Vehicle Park Signal...... 39 SAE O-Ring Adjustable Fittings ...... 5 Issues with Driver Interface ...... 39 SAE O-Ring Non-Adjustable Fitting ...... 5 Issues with Power Module ...... 40 JIC 37° Fitting ...... 5 Issues with Strut Assembly ...... 40 PRE-INSTALLATION...... 6 ELECTRICAL SCHEMATICS ...... 41 FRAME PREPARATION ...... 6 APPENDIX A: FRAME DRILLING LOCATIONS ...... 44 AXLE PREPARATION [LEAF SPRING CHASSIS] ...... 8 INSTALLATION CHECK LIST ...... 47 INSTALLATION ...... 9 Front Hangers ...... 9 Axle Clamp Hangers and Seat ...... 10 Control Arms ...... 11 Upper Strut Mounts [DS135N-A (rear mounted fuel tank version)]...... 12 Upper Strut Mounts [DS135N-AF (front mounted fuel tank version)] ...... 13 Upper Strut Mounts [DS135N-AA (OEM AirRide Conversion)] ...... 14 Brake Line Relocation ...... 15 Track Rod and Mount [DS135N-A and DS135N-AF] .... 16 Track Rod and Mount [DS135N-AA] ...... 17 Strut Assembly Installation ...... 18 Jounce Bumpers ...... 19 Height Sensors ...... 20 Secondary Volumes ...... 21 Power Module Installation...... 23 Hydraulic Hose Attachment ...... 24 Steering Sensor Installation ...... 26 External Electrical Installation: ...... 27 Dash Harness Installation ...... 28 Driver Interface Installation: ...... 30 Optional Door Electrical Harness Installation: ...... 30 Initial System Fill ...... 30 Bleeding the System ...... 31 Calibrating the System ...... 31 POST INSTALLATION WELDING ...... 32 SYSTEM OPERATION ...... 33 System Start Up: ...... 33 ON/OFF Button: ...... 33 Warning Light:...... 33 Ride Mode Adjustment: ...... 33 Ride Height Adjustment: ...... 33 Depressurizing the System ...... 34 Calibrating the Steering Sensor Only ...... 35

Introduction This manual provides installation information for the Suspension Rating LiquidSpring CLASS® DS135N series of rear axle suspension systems for the TerraStar Cab Chassis. Model Suspension Rating DS135N-A 13,500 lbs Before you begin installation of the suspension system: DS135N-AA 13,500 lbs 1. Read and understand all instructions and procedures DS135N-AF 13,500 lbs prior to installation of components. WARNING: Overloading suspension system may 2. Read and observe all Warning and Caution hazard result in abnormal handling characteristics and alert messages in this publication. They provide premature wear of components. information that can help prevent serious personal injury, damage to components, or both. Serial Number Tag Information 3. Follow your company’s maintenance and service, installation, and diagnostics guidelines. The serial number is found on an aluminum tag riveted to the Left Hand Suspension Hanger as shown in Figure 2. This 4. Use proper tools when required to help avoid serious information will aid you when contacting the chassis personal injury and damage to components. manufacturer or LiquidSpring LLC. Throughout this manual, important product information is indicated. These terms are defined as follows: NOTE: Includes additional information to enable accurate and easy performance of procedures. IMPORTANT: Includes additional information that if not followed could lead to hindered product performance and/or product failure. CAUTION: A caution indicates procedures that must be followed exactly. Damage to equipment or suspension components and personal injury can occur if the procedure is Figure 1. Suspension Identification not followed.

WARNING: A warning indicates procedures that must be followed exactly. Serious personal injury can occur if the procedure is not followed. LiquidSpring LLC reserves the right to modify the suspension and/or procedures and to change specifications at any time without notice and without incurring obligation. Suspension Application Model Application 2013 and newer TerraStar Cab Chassis, DS135N-A Rear Fuel Tank, Rear Leaf Version 2013 and newer TerraStar Cab Chassis, DS135N-AA AirRide conversion 2013 and newer TerraStar Cab Chassis, DS135N-AF Figure 2. Serial Number Tag Location Front Fuel Tank, Rear Leaf Version

Vehicle Towing and Jacking Information WARNING: Attaching towing equipment to improper locations and failure to utilize Chassis OEM or Vehicle Before attempting any type of towing procedures, contact the Manufacturer recommended towing methods could result in Chassis OEM or Vehicle Manufacturer for instructions. one or more of the following: NOTE: Before towing vehicle, check with local authorities, Damage to the suspension and/or vehicle, such as Department of Transportation, for permissible towing methods. Some states do not permit towing vehicles by chains Loss of vehicle control, or towing straps. Possible disconnect from the vehicle. Do not attach tow apparatus (hooks, chains, straps, etc.) to the suspension components. WARNING: Do not apply jack to bottom of front hanger or other suspension components. Appling a jack to improper locations can result in damage to the suspension and/or vehicle and severe personal injury. Abbreviations The following abbreviations will be used throughout the SLW Spring Lock Washer manual. FW Flat Washer HCS Hex Cap Screw SAE SAE O-Ring Fitting HFB Hex Flange Bolt 37° SAE or JIC 37° Flare Fitting (F – Female) SHCS Socket Head Cap Screw LH Left Handed Part SFHS Serrated Flange Hex Screw RH Right Handed Part STS Self Tapping Screw UCA Upper Control Arm HN Hex Nut, Non-locking LCA Lower Control Arm LHN Locking Hex Nut USM Upper Strut Mount LFN Locking Flange Nut PM Power Module HFW Hardened Flat Washer Special Tools The following tools can assist in installation of the LiquidSpring system.

Bleed Kit (Actron 7840 shown, others similar). Gallon Hand Pump (Autotec 57429 shown, other similar)

Hydraulic Fitting Assembly 2. If O-ring or seal is not pre-installed to fitting male port end, install proper size O-ring or seal, taking SAE O-Ring Adjustable Fittings care not to damage it. 3. Lubricate O-ring with light coat of the system fluid or a compatible lubricant to help the O-ring slide smoothly into the port and avoid damage. 4. Screw fitting into port and tighten to proper torque: -4 fitting: 26-28 ft-lbs (310-341 in-lbs) -12 fitting: 75-83 ft-lbs. JIC 37° Fitting 1. Inspect components to ensure that male and female threads and sealing surfaces are free of burrs, nicks Figure 3. Adjustable SAE fitting and scratches, or any foreign material. Annular tool 1. Inspect components to ensure that male and female marks of 100µin with the thread are permissible. port threads and sealing surfaces are free of burrs, 2. Lubricate the threads and the entire surface of the nicks and scratches, or any foreign material. cone with system fluid. 2. If O-ring or seal is not pre-installed to fitting male 3. Align mating components for hand connection and port end, install proper size O-ring or seal, taking turn flare nut until sealing surfaces make full contact. care not to damage it. 4. Using two wrenches, hold fitting in desired position and tighten to the proper torque: 3. Lubricate O-ring with light coat of the system fluid or a compatible lubricant to help the O-ring slide -4 fitting: 9-12 ft-lbs -10 fitting: 36-63 ft- smoothly into the port and avoid damage. lbs -8 fitting: 27-39 ft-lbs -12 fitting: 65-88 ft- lbs

Figure 4. Locknut completely backed off. 4. Back off lock nut as far as possible. Make sure back- up washer is not loose and is pushed up as far as possible. 5. Screw fitting into port until the back-up washer or the retaining ring contacts face of the port. Light wrenching may be necessary. Over tightening may damage washer. 6. To align the tube end of the fitting to accept incoming hose assembly, unscrew the fitting by the required amount, but not more than one full turn. 7. Using two wrenches, hold fitting in desired position and tighten locknut to the proper torque value: -4 fitting: 14-16 ft-lbs (168-192 in-lbs) -12 fitting: 75-83 ft-lbs. 8. Inspect to ensure that O-ring is not pinched and that washer is seated flat on face of port. SAE O-Ring Non-Adjustable Fitting 1. Inspect components to ensure that male and female port threads and sealing surfaces are free of burrs, nicks and scratches, or any foreign material.

Pre-Installation 8. [AirRide Chassis] Disconnect the air lines running to the rear height control valves at the air tank and plug 1. Check the vehicle wheel alignment prior to the connections. Remove the air lines. installation to insure pre-existing conditions do not exist. 9. [AirRide Chassis] Disconnect the track rod from the frame and RETAIN the track rod frame mount for 2. It is suggested, but not required, to remove the reuse. Remove the OEM reinforcing plates. attached body to ease installation. Note: Do not remove the transverse track rod from 3. A chassis lift can be used in assistance of the the axle. installation of the suspension system. 10. [Leaf spring Chassis] Remove the OEM leaf springs, 4. Measure and record the wheelbase and tire-to-frame axle connection components, forward leaf hanger, dimensions on each side prior to disassembly. rear leaf shackle, and shackle hanger brackets. Frame Preparation 11. Remove the OEM Axle Stop Bumpers. 1. Chock the front tires. 2. Jack up the rear frame of the vehicle to remove the load from the rear leaf springs. 3. Place jack stands under the frame and block the rear tires from moving. Note: Jack stands can be placed under the axle and the tires removed for ease of access. It is recommended to place an additional jack stand under the pinion to prevent the axle from rotating. 4. [AirRide Chassis] Depressurize the air system using dump switch inside cab or by bleeding at the air tank. 5. Disconnect the negative cable from the vehicle battery. 6. Remove the OEM shock absorbers and frame Figure 6. Leaf Spring Chassis components to remove. mounted brackets. 7. [AirRide Chassis] Remove the air springs, height control valves, the trailing arm, axle attachment components, and forward trailing arm frame mount.

Figure 7. Brake line bracket location. 12. [Leaf Spring Chassis] Disconnect the brake line brackets from the framerail on Driver and Passenger side, as shown in Figure 7. Retain mounting hardware. This will be relocated in future steps. Figure 5. AirRide Chassis components to remove.

13. Locate the two upper strut mounts and place along the frame as shown in Figure 8, Figure 9, and Appendix A: Frame Drilling Locations, Figure A 1and Figure A 2.

Figure 8. Location of Drilling Template on Driver Side Frame [DS135N-A, -AF]

Figure 9. Location of Drilling Template on Driver Side Frame [DS135N-AA] 14. Center punch or mark the holes indicated in Appendix A. 15. Drill the holes as indicated. 16. Locate the Volume Mounting Brackets and place along frame as shown in Appendix A: Frame Drilling Locations, Figure A 3. 17. Mark the four holes and drill as indicated.

Axle Preparation [Leaf Spring Chassis] 1. Remove Parking Brake Cable and wiring from top of axle mount and position away from the the axle. 2. Remove the two axle differential bolts as shown in Figure 10.

Figure 12, Tack Welding Axle Mount 8. Remove the template from the axle. 9. Position axle for a flat weld. The axle must be pivoted fore and aft for welding front and rear faces.

Figure 10, Removal of Axle Bolts.

Figure 13, Final Welding on Axle Mount 10. Beginning at the indicated location, back step the start of the weld from 0.315-0.512” to prevent a cold start. 11. Lay a full fillet in a single pass: Fillet size 0.375- 0.50”. 12. Back fill the end of the weld 0.315-0.512” to eliminate craters. 13. Complete the welding on all sides of the bracket

using Steps 9-12. Figure 11, Position Axle Mount using Template 14. Once the axle has cooled, Reinstall the two M14 differential bolts to the axle using sealant and torque 3. Temporarily attach the template to the axle using the to 130 ft/lbs. two differential bolts. Using 7/8” hardware, fasten 15. Apply touch up paint to any bare metal showing on the Axle Mount to the template in the position shown the axle mount and housing. in Figure 11. IMPORTANT: If welding equipment is not capable of 4. Outline the axle mount with a visible paint marker. welding a single pass as specified, multiple passes will be required. 5. Remove the axle mount from the axle and grind away the outlined area to bare metal. Note: When welding multiple passes, the first pass should be centered over the fit-up line. The second pass should be Note: Make sure axle housing is free of paint 1/2” beyond the placed slightly above the first. Blend the weld smoothly with perimeter of the axle mount. the axle mount and the first pass. The third pass should Note: Make sure the axle mount is free of powerdercoat 1/2” penetrate the lower half of the second pass to the edge of the up from bottom edge around the perimeter. axle housing. When making the second and third passes the direction should be reversed. Refer to steps above for back 6. Reattach the axle mount to the template after axle start and back fill. Clean weld before each pass. tube is clean and prepped for welding. 7. Tack weld all 4 sides of the axle mount to the axle housing as shown in Figure 12

Installation Front Hangers

ITEM QTY. PART NUMBER DESCRIPTION 1 12 10874-200 HFB 5/8-11x2.000, Gr. 8 2 12 10012-008 LFN 5/8-11 Gr. G 3 1 10943-001 LH Front Hanger 4 1 10944-001 RH Front Hanger

1. Install the Left Hand Front Hanger (with the serial 3. Torque fasteners as specified above. tag) on to the driver side of the frame. 4. Repeat for the Right Hand Front Hanger (without the 2. Verify that the hanger is level to the framerail. serial tag) on to the passenger side of the frame.

Axle Clamp Hangers and Seat

ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION 1 8 10012-012 LFN ¾-16, Gr. G 3 2 10947-001 Lower Axle Clamp Hanger 2 4 10064-004 U-Bolt ¾-16 x 7.75 Tri-8s 4 2 10949-001 Upper Axle Seat

1. Loosely Install the Axle Seat on to the Drivers Side axle spring seat. The Axle Seat should be flush to the top of the axle with the axle stud in in the slot closest to axle centerline. Reference Figure 14 and Figure 15 for correct orientation.

Figure 15, Axle Seat Orientation 2. Repeat for the Right Hand Axle Seat, Axle Hanger, and 3/4” U-bolts. 3. While U-Bolts are still loose, move on to the Control Arm Installation Figure 14, Aligning Axle Seat on Axle Stud IMPORTANT: Do not tighten U-Bolts at this time. This will ease control arm installation.

Control Arms

ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION 1 4 10006-004 HFW 1.000 5 2 10874-375 HFB 5/8-11x3.750, Gr. 8 2 4 10012-003 LFN 1-8, Gr. G, Top Lock 6 2 10953-001 Assembly, LCA 3 4 10012-008 LFN 5/8-11 Gr. G 7 2 10570-002 Assembly, UCA 4 4 10003-004 HB 1.000-8x6.500, Gr. 8 8 2 10874-600 HFB 5/8-11x6.000, Gr. 8

1. Install the upper and lower control arms between the and Mount [DS135N-A and DS135N-AF] driver side front hanger and axle seat / axle hangers Installation, Page 16 or Track Rod and Mount loosely with hardware shown above. [DS135N-AA], Page 17). Note: Orientate the lower control arms with the height sensor Note: Axle must be held at ride height for tightening control linkage tabs pointing upward. arm bolts to prevent preloading the bushings. IMPORTANT: Bolts inserted into the front hanger must point inboard (towards the frame). Bolts inserted at the axle seat must point outboard (towards tire). Orienting the bolts incorrectly may result in damage to the frame rail 2. Torque U-Bolts as specified in Axle Clamp Hangers and Seat section. 3. Do not tighten control arm fasteners until track rod is in place and vehicle is set to ride height in Track Rod

Upper Strut Mounts [DS135N-A (rear mounted fuel tank version)]

ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION 1 8 10874-200 HFB 5/8-11x2.00, Gr. 8 6 4 10874-250 HFB 5/8-11x2.50, Gr. 8 2 12 10012-008 LFN 5/8-11 Gr G 7 1 10782-004 Lower Crossmember. 3 4 10885-150 HFB ½-13x1.50, Gr. 8 8 1 10956-004 RH Upper Strut Mount 4 4 10012-007 LFN ½-13, Gr. G 9 1 10782-005 Crossmember Reinforcement 5 1 10956-003 LH Upper Strut Mount . 1. Loosely attach the LH and RH Upper Strut Mount to IMPORTANT: The bolts holding the provided the frame located just behind the axle at the Crossmember must point inward to provide clearance to crossmember. The rearmost USM holes line up with the Struts. the rearmost two crossmember holes. IMPORTANT: Before tightening fasteners, verify the top 2. Install the Crossmember Reinforcement inside the of each upper strut mount is level with the top of the OEM crossmember with 5/8”-11 hardware with bolts frame. facing inward. 4. Torque all 5/8”-11 nuts to 172-210 ft-lbs. 5. Torque all 1/2”-13 nuts to 86-105 ft-lbs.

Figure 16. Upper Strut Mount bolt orientation. IMPORTANT: The bolts holding the provided crossmember must be pointing inward to provide clearance to the Struts. 3. Install lower Crossmember Reinforcement using 1/2”-13 hardware with bolts facing inward.

Section A-A, Detail of Crossmember Orientation 12

Upper Strut Mounts [DS135N-AF (front mounted fuel tank version)]

ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION 1 12 10012-007 LFN ½-13, Gr. G 6 12 10874-200 HFB 5/8-11x2.00 Gr. 8 2 12 10012-008 LFN 5/8-11 Gr. G 7 12 10885-150 HFB ½-13x1.50 Gr. 8 3 1 10782-004 Crossmember Reinforcement 8 1 10956-003 LH, Upper Strut Mount 4 2 10795-005 Crossmember End Channel 9 1 10956-004 RH, Upper Strut Mount 5 1 10796-004 Crossmember Channel

1. Loosely attach the LH and RH Upper Strut Mount to 4. Torque all 5/8”-11 nuts to 172-210 ft-lbs. the frame located just behind the axle. The four 5. Torque all 1/2”-13 nuts to 86-105 ft-lbs. rearmost USM holes line up with the four holes in the frame. 2. Install the Crossmember End Channels with 5/8”-11 hardware with bolts facing as shown.

Figure 17. Upper Strut Mount bolt orientation. 3. Install lower Crossmember Reinforcement using 1/2”-13 hardware with bolts facing inward. IMPORTANT: The 1/2"-13 bolts holding the provided Figure 18. Detail of Crossmember Orientation Crossmember must point inward to provide clearance to the Struts. 6. Remove the OEM Rear Crossmember after both crossmember and crossmember reinforcement are IMPORTANT: Before tightening fasteners, verify the top installed of each upper strut mount is level with the top of the frame. 13

Upper Strut Mounts [DS135N-AA (OEM AirRide Conversion)]

ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION 1 12 10012-007 LFN ½-13, Gr. G 6 14 10874-200 HFB 5/8-11x2.00 Gr. 8 2 14 10012-008 LFN 5/8-11 Gr. G 7 12 10885-150 HFB ½-13x1.50 Gr. 8 3 1 10782-004 Crossmember Reinforcement 8 1 10956-003 LH, Upper Strut Mount 4 2 10795-005 Crossmember End Channel 9 1 10956-004 RH, Upper Strut Mount 5 1 10796-004 Crossmember Channel

1. Loosely attach the LH and RH Upper Strut Mount to IMPORTANT: Before tightening fasteners, verify the top the frame located just behind the axle. The two holes of each upper strut mount is level with the top of the over the Jounce Stop Mount align with the frame frame. holes. 4. Torque all 5/8”-11 nuts to 172-210 ft-lbs. 2. Install the Crossmember End Channels with 5/8”-11 5. Torque all 1/2”-13 nuts to 86-105 ft-lbs. hardware with bolts facing as shown.

Figure 19. Upper Strut Mount bolt orientation. 3. Install lower Crossmember Reinforcement using 1/2”-13 hardware with bolts facing inward. IMPORTANT: The 1/2"-13 bolts holding the provided Crossmember must point inward to provide clearance to the Struts.

Figure 20. Detail of Crossmember Orientation.

Brake Line Relocation 1. Locate the OEM passenger side rear brake line bracket and hardware removed from the framerail in Frame Preparation Page,6. See Figure 21

Figure 22, Drilling/Attaching OEM bracket to Crossmember 4. Install OEM hardware to bracket and torque to 16 ft- lbs. 5. Repeat steps 2,3,4 for driver side. 6. Secure the rubber flexible brake lines to the underside of the Upper Strut Mounts by using 3/8” Loop clamps and 5/16-18 hardware. See Figure 23.

Do on both driver and passenger sides. Torque to 16 Figure 21, OEM Brake Bracket Relocating ft-lbs. 2. Using a pair of pliers, remove the clip holding the hydraulic brake fitting to the bracket. Rotate the bracket rearward ≈60° and reinstall the clip. Note: Do not separate the Hydraulic Brake line. 3. Drill a Ø.406” hole into the bracket as shown in Figure 22.

Figure 23, Securing Brake lines behind strut

Track Rod and Mount [DS135N-A and DS135N-AF]

ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION 1 4 10874-200 HFB 5/8-11x2.000, Gr. 8, 5 1 10789-016 Track Rod Frame Mount 2 4 10012-008 LFN 5/8-11 Gr. G 6 2 10006-003 HFW .875, Zinc 3 1 10951-007 Track Rod Axle Mount 7 2 10012-017 LFN 7/8-9 Gr. G 4 1 11198-001 Track Rod Assembly 8 2 10002-550 HB 7/8-9x5.500, Gr. 8

1. Install Track rod frame mount inside passenger side 4. Torque the two (2) 7/8” Track Rod mounting bolts to framerail and torque to 172-210 ft-lbs. 491-600 ft-lbs. 2. Loosely attach the Track Rod Assembly to the Track 5. Torque the eight (4) 1” Control Arm mounting bolts Rod Axle Mount and to the Frame Mount. to 600 ft-lbs. 3. Jack each side of the axle until approximately design 6. Torque the four (4) 5/8” Control Arm mounting bolts ride height position. See Figure 24. to 172-210 ft-lbs. IMPORTANT: Torque all control arm fasteners while axle is at approximate ride height

Figure 24, Lift to Design Ride Height.

Track Rod and Mount [DS135N-AA]

TEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION 1 6 10012-012 LFN 5/8-11 Gr G 3 4 10874-200 HFB 5/8-11x2.000, Gr. 8, 2 1 10569-002 Backing Plate, Track Rod 4 2 10874-500 HFB 5/8-11 x 5, Gr. 8

1. Install Track Rod Backing Plate to the inside of the 4. Torque all the 5/8” Track Rod mounting bolts to 172- passenger side frame using four outer holes. The 210 ft-lbs. curved portion of the plate is directed towards the 5. Torque the eight (4) 1” Control Arm mounting bolts rear. Torque to 172-210 ft-lbs. to 600 ft-lbs. IMPORTANT: Orientate bolts pointing inboard. 6. Torque the four (4) 5/8” Control Arm mounting bolts 2. Jack each side of the axle until approximately design to 172-210 ft-lbs. ride height position. See Figure 25. IMPORTANT: Torque all control arm fasteners while axle is at approximate ride height.

Figure 25, Lift to Design Ride Height. 3. Attach the track rod and the OEM track rod frame- mount to the backing plate and frame. Bolts can point either direction.

Strut Assembly Installation

ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION 1 4 10640-002 Bearing Spacer, 1.25x1.02x.318 5 4 10012-003 LFN 1-8, Gr. G, Top Lock 2 4 10006-004 HFW 1.000 6 1 10877-003 RH Strut Assembly 3 2 10003-009 HB 1-8x8.000, Gr. 8 7 1 10877-004 LH Strut Assembly 4 2 10003-005 HB 1-8x4.500, Gr. 8

1. Install the Left Hand Strut Assembly as shown 4. Torque Lower strut fasteners to 250 ft-lbs. Do not making sure to install bearing spacers on lower over torque. connection. Note: Point strut hydraulic port forward. 2. Repeat for installation of Right Hand Strut Assembly, Bearing Spacers, and Hardware. 3. Torque Upper strut fasteners to 600 ft-lbs.

Jounce Bumpers

ITEM QTY PART NUMBER DESCRIPTION 1 2 10867-003 Jounce Bumper, Ø2.375 x 3.00” 2 2 10502-001 HFB M10-1.5 x 30 CL 10.9

1. Install Jounce Bumpers as shown to Upper Strut Mounts. 2. Torque M10 fasteners to 35 ft-lbs.

Height Sensors

ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION 1 2 10586-001 Height Sensor Assembly 4 4 10886-125 HFB 5/16-18 x 1.25, Gr. 8 2 2 10587-006 Linkage Assembly 5 2 10591-003 Ball Stud 5/16-18 x .75L 3 6 10012-010 LFN 5/16-18, Gr. G

IMPORTANT: Strut assemblies must be installed prior to the installation of the height sensors. 1. Install Height Sensor components and hardware as shown. Be sure to attach the ball stud to the inboard hole on the control arms as shown above. 2. Torque all 5/16 hardware to 14-17 ft-lbs. 3. Snap the Linkage Assemblies to the ball studs attached to the lower control arms and to the ball studs on the Height Sensor arms. Install locking clips as shown in Figure 26.

Figure 26, Height Sensor Linkage Installation.

Secondary Volumes

ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION 1 4 10843-003 T-Bolt Clamp 4 1 10597-027 LH, Pass. Volume Assembly 2 4 10885-150 HFB ½-13x1.500, Gr. 8 5 1 10597-028 RH, Driver Volume Assembly 3 4 10012-007 LFN ½-13, Gr. G 6 2 10830-009 Volume Mount

WARNING: Each Volume Assembly is heavy (in excess of Note: It’s advised to install the Powermodule Manifold 100 lbs). Use of a portable lift, crane, or suitable jack is Bracket at this time to prevent drilling additional holes for recommended to support the Volume Assembly during mounting. See Power Module Installation. installation. 2. Torque the 1/2”-13 fasteners to 86-105 ft-lbs. 1. Install the (2) Volume Mounts inside the driver side 3. Locate (2) T-Bolt Clamps, open the mounts, and framerail to the holes previously drilled (In Frame place them in the mounts, around the two pegs. Preparation, Page 6) 4. Secure both clamps around the volume and torque the T-Bolt nut to 240 in-lbs. See Figure 28 for locating volumes.

Figure 27, RH Secondary Volume Assembly mounting.

Figure 28, Secondary Volume Assembly mounting location. 5. Repeat for driver side mounting underneath the passenger side volume.

Power Module Installation.

ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION 1 1 10799-009 PM Manifold Bracket 6 2 10510-002 STS #10-16 x .750, Hex Head 2 1 10798-010 PM Reservoir Mount 7 3 10012-007 LFN 1/2-13, Gr. G 3 2 10252-003 SFHS 3/8-16 x .625, Gr 8.2 8 3 10855-150 HFB 1/2-13x1.500, Gr. 8 4 2 10805-004 Grommet, .19ID x .56OD x .38T 9 1 10941-005 Power Module Assembly 5 2 10088-001 FW #10 10 2 10322-021 Hyd Fit 90, -4 37 x -4 37 F

1. Locate the Power Module Assembly and Power 5. After mounting power module with the manifold Module Mounting Kit. bracket using (2) 1/2”-13 fasteners, mark and drill a Ø.531” hole for mounting the reservoir bracket to the 2. Follow Instructions inside the mounting kit for framerail using (1) 1/2”-13 fasteners. attaching the mounting brackets to the power module 6. Torque 1/2”-13 fasteners to 96 ft-lbs. 3. Mount power module to the driver side framerail using the existing fasteners used to hold the secondary volumes. 4. If unable to use the same location as volume mounts, you must drill additional holes for mounting. Reference Appendix A: Frame Drilling Locations, Figure A 3 for two-hole pattern.

Hydraulic Hose Attachment CAUTION: Attachment of the hydraulic hoses may result in some spillage of fluid. Use of oil absorbent mats is recommended.

CAUTION: During shipping, the fluid inside of the volume may have heated up causing increased pressure. Always open the bleed screw to relieve pressure prior to removing plugs in the hoses. Locate 3/16” ID PVC Tubing (not included with kit). Note: Alternatively, a bleed kit similar to the Actron 7840 Bleed Kit or Lisle 19200 Brake Bleeding Kit can be Figure 30. Installation of -10 hose to strut. used. Refer to Special Tools Page 4 9. Route the hose from the volume to the bulk head 1. Attach the PVC tubing to one of the upper bleed fitting as shown in Figure 31. Remove plug from end screws on the Left Hand Secondary Volume of hose and attach hose end to the bulkhead fitting. Assembly and place the other end in a bucket. Torque to 36-63 ft-lbs. CAUTION: Make sure the hose is not chafing or in contact with any sharp edges.

Figure 29. Bleed screw locations. 2. Open the bleed screw slightly to relieve any residual pressure. 3. After pressure is relieved, close the bleed screw and Figure 31. Driver side -10 hose attachment.. torque to 13-18 ft-lbs. 10. Repeat with the opposite side. Verify to route hose away from exhaust. 4. Install the Bulkhead fittings and locknuts into the Ø7/8” holes previously drilled into the frame. CAUTION: Make sure the hose adequately clears the exhaust 5. Torque the bulkhead lock nut to 85-95 ft-lbs. to prevent any contact. 6. Locate the -10 hose assembly, with 90° fitting on one end. 7. Remove the cap from the strut and attach the straight fitting to the strut port. Hand tighten only at this time. 8. Route the hose to the bulk head fitting and attach hose. Torque both ends to 36-63 ft-lbs.

12. Remove the plug from the hose end and attach to the 90° bottom mounted fitting indicated “L”. Torque to 12 ft-lbs. Do not over tighten. 13. Route the Right Hand (Passenger side) -4 (1/4”) hydraulic hose to the power module assembly. Use of hose clamps is recommended to secure the hose from movement or chafing. CAUTION: Make sure that the hose is not chafing or in contact with any sharp edges or with the exhaust system. 14. Remove the plug from the hose end and attach to the 90° bottom mounted fitting indicated “R”. Torque to 12 ft-lbs. Do not over tighten. Note: Use 1/4” hardware provided in kit for mounting loop clamps. Refer to Figure 28, Secondary Volume Assembly mounting location. 15. Clean up any fluid spillage. 16. Verify the -10 hose fittings to the secondary volume assemblies are torqued to 36-63 ft-lbs on the JIC Figure 32. Power Module hose attachment. connections 11. Route the Left Hand (Driver side) -4 (1/4”) hydraulic 17. Verify the -12 SAE fitting to the secondary volume hose, attached to the volume assembly, to the Power assemblies are 75-83 ft-lbs. Module, See Figure 32. Use of loop clamps is recommended to secure the hose from movement or 18. Verify the -4 SAE jam nut to the secondary volume chafing. assemblies are torqued to 14-16 ft-lbs. CAUTION: Make sure the hose is not chafing or in contact 19. Verify the -4 hose fitting to the 90° fitting at the with any sharp edges. secondary volume assemblies are 12 ft-lbs. 20. Re-install tires and wheels as per OEM instructions.

Steering Sensor Installation

ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION 1 1 10587-006 Linkage, 3.938” SS 6 1 10586-003 Asy, Steering Sensor 2 2 10886-125 HFB 5/16-18, Gr. G, BO 7 1 10904-005 Ball Stud Bracket 3 2 10012-010 LFN 5/16-18, Gr. G, BO 8 1 10904-008 Ball Stud Bracket Weldment 4 2 10989-100 HFB 1/4-20x1”, Gr. 8, BO 9 1 10904-007 Steering Sensor Mount Plate 5 2 10012-009 LFN 1/4-20, Gr. G, BO

1. Locate the steering gearbox and pitman arm inside 5. Torque OEM Fender well fasteners holding steering the driver side wheel well. sensor bracket to 18 ft-lbs See Figure 34. 2. The center of the Ball Stud Bracket must be located IMPORTANT: Steer wheels full left and right to verify 4” down from the centerline of the output shaft on the steering sensor components move freely and do not make gearbox. See Figure 33 for measurement. contact.

Figure 33, Ball Stud Bracket Location

3. Torque 1/4-20 fasteners to 10 ft-lbs. Figure 34, View on chassis 4. Torque 5/16-18 fasteners to 14-17 ft-lbs.

External Electrical Installation: 12. Locate the J35 branch and route to the steering sensor 1. Locate the External Electrical Harness attached to the mounted on the pitman arm. Route the connector power module. under the inner fender well right at the sensor and make the connection. Leave as little wire harness in 2. Unroll the wiring harness and using the External the wheel well area as possible. Secure the harness. Electrical Harness wiring diagram, found in the Electrical Schematics section, identify the Important: Verify the wiring harness does not contact connection ends. heat source or moving components. 3. Locate the trunk containing Height Sensor (J21 and 13. Locate the Red 8ga battery connection branch. J22) and the Rate Valve (J23 and J24) connections. 14. Route branch to the driver side battery positive 4. Route the trunk towards the height sensors and rate terminal. valves. 15. Locate the Battery Fuse Lead containing the 80 amp fuse. 16. Crimp the fuse lead to the 8ga battery connection branch blunt end. 17. Melt the heat shrink on the crimped connection to seal the splice. 18. Remove the 80 amp fuse and retain. 19. Connect to the positive terminal post per OEM Upfitter wiring instructions.

Figure 35. Rate valve and height sensor electrical connections. 5. Connect height sensor and rate valve connections. Note: Connection after routing the harness and prior to installing the height sensor may aid in electrical connection. 6. Secure harness to OEM harness on driver side. Use of plastic clips is recommended. 7. Locate the Black 8ga wire ground ring terminal, J30, branch near the power module. 8. Locate and drill Ø1/4” hole in frame. Remove frame coating(s) as needed to ensure metal-to-metal contact between the ring terminal and frame. 9. Attach the ground ring terminal, J30, to the chassis frame for grounding. Sealant should be applied after ring terminal is secured. 10. Route the remaining trunk (containing blunt wires and steering sensor blunt wires) towards the firewall. Secure to OEM wiring harness. 11. Route J30 branch through the firewall rubber pass through grommets on the driver side.

Dash Harness Installation Note: For Vehicles equipped with the 12VZA circuit, 1. Locate the dash harness. follow steps 7-9 for wiring up the speed signal. 2. Locate and identify the following 18ga wires in the Note: For Vehicles NOT equipped with the 12VZA circuit, two external wiring harness branches passed through the follow steps 10-16 for wiring up the speed signal. firewall: 7. Locate the 96” violet/white wire in the dash harness. Red (Battery Power) Route the wire through the firewall grommet and into Yellow (Ignition) the engine compartment. Route to the vehicle Black (Ground) 12VZA Bodybuilder circuit connector near White (CAN High) transmission dipstick. See Figure 37. White/Black (CAN Low) Yellow/Black (Park) Violet/White (Speed) Pink/Black (Brake)

3. Crimp each wire to the corresponding blunt wire in the dash harness. Match wire colors, crimp using butt splices, and install heat shrink.. 4. Locate the 120” Red, Yellow, and Pink/Black 18ga wires in the dash harness. Route the wires to the passenger side fuse panel located behind the dash cover. It is advised to route along and zip tie to the 12VZA OEM harness under the dash. Bodybuilder 5. Make the following connections into the fuse panel: Crimp each wire using butt splices. Heat shrink Connector sealing is recommended.

Figure 37, 12VZA Connector Liquidspring Dash  Vehicle Fuse Panel Harness 8. Splice the violet/white wire to wire K47B (Vehicle Red 18ga (BAT)  Red A14G Pigtail Speed Output). Yellow 18ga (IGN)  Pink A13B Pigtail Note: If you have the proper tools to install the factory Pink/Black 18ga Red A70BB (R3 Body  Deutsch terminal in the mating connector, this method is (Brake) Stop Relay) preferred, otherwise butt splice to the K47B wire behind the connector. 6. Attach both the Ground ring terminal (J32) and Park signal ring terminal (J31) from the dash harness to the firewall ground posts. See Figure 36.

K47B (Vehicle Speed Output)

Figure 38, Closeup of 12VZA Connector 9. Locate the 96” violet/white wire in the dash harness. Route the wire through the firewall grommet and into the engine compartment. Route to the vehicle ECU. See Figure 39. Figure 36. Inside Cab Ground Locations (circled).

Figure 41. Unlock the connector with screwdriver. 12. Locate the cavity plug in slot 89 and remove from connector using removal tool. See Figure 42. Figure 39. Engine Wire Channel. 10. Locate and remove the top connector on vehicle ECU. See Figure 40

Figure 42. Removal of cavity plug in slot 89. 13. Insert the terminal on the Violet/white wire into slot 89 in the correct orientation. See Figure 43.

Figure 40, Vehicle ECU - Top Connector Removal 11. Using Screwdriver, pry the white terminal lock out as shown in Figure 41. IMPORTANT: The terminal lock only moves about 1/4”, do not pry completely out of the connector body.

Figure 43, Installing Terminal into slot 89 in ECU Connector 14. Push the connector lock back inside the connector. 15. Reconnect the connector to the vehicle ECU. 16. Secure all wires away from moving parts.

shrinkable butt-splice. Crimp the connection(s) accordingly and apply heat to the insulator to seal the Driver Interface Installation: connection(s). 1. Locate the Driver Interface. Initial System Fill 2. Mount the Driver Interface to the dash in an 1. Install the wheels and tires. Torque wheel nuts to appropriate location. OEM specifications. 3. Route the Driver Interface harness to the dash 2. Reconnect the negative cable to the vehicle battery. harness connector, J26, and connect. 3. Verify that the front wheels are steered straight 4. Secure all wires under the dash. ahead. 5. Replace the 80 amp fuse at the battery. 4. Lower the vehicle to the ground and remove any jack Optional Door Electrical Harness Installation: stands from under the vehicle. The suspension The optional door harness can be used to remotely should be in the kneeled position. activate the system “kneeling” feature in which the 5. Locate the container of Compressible Fluid. suspension automatically lowers to a point slightly less than maximum jounce travel. The door harness 6. Remove the breather cap from the Power Module can be utilized in two actuation methods. reservoir. IMPORTANT: Do not connect positive (12VDC) signal to 7. Fill the reservoir approximately 2/3 full. either the W98 Tan/Blk or W93 Brown wires. Applying 8. Turn the ignition key to “Run” and ensure that the positive (12VDC) to either of these wires can result in ECU LiquidSpring driver display LEDs light up and that failure. the red “Warning” LED is not lit. If the red A. Single Wire - Ground Signal From Source “Warning” LED is lit, proceed to the Trouble Shooting Section. Ground is provided to the door harness Brown (W93) wire from a grounding source (e.g. WARNING: Do not run vehicle in an enclosed building multiplex signal, switch, etc.). If a remote switch without adequate ventilation or without ducting exhaust is used, it is recommended to use a normally fumes outside. Operation of a vehicle inside an enclosed closed (NC) door switch which remains open building can lead to serious injury or death. when the door is closed (or closed when the door 9. Press and release the Red ON/OFF button on the is opened). One side of the switch must be driver display. All LEDs on the driver display should connected to a ground source and the other side go out. routed to the door harness. If multiple switches are used, they should be wired in a parallel 10. Press and release the Red ON/OFF button again. The arrangement with the door harness. Requires LEDs on the driver display should all flash and then single wire routed from source to door harness. only the four yellow arrow LEDs, one green ride mode indicator LED, and one green ride height B: Dual Wire – Ground Signal From System indicator LED should remain lit. Ground is provided by the suspension system 11. The green ride height indicator LED should indicate when the Brown (W93) wire is connected to the “Low” and begin flashing as the pump/motor starts. Tan/Black (W98) wire of the door harness. This If pump/motor does not start, check Trouble Shooting arrangement requires a remote switch that is a Electrical Section. normally closed (NC) door switch which remains open when the door is closed (or closed when the 12. Monitor the fluid level in the reservoir. If the level door is opened). One side of the switch needs to drops below 1/4 of the tank, press and release the Red be connected to the door harness Brown (W93) ON/OFF button to shut off the system, refill the wire and the other side to the door harness reservoir, and turn the system back on by pressing the Tan/Black (W98) wire. Requires two wires Red ON/OFF button. routed from switch to door harness. 13. If the suspension system does not begin to rise to a 1. Door harness wires are located on the main external preset ride height after 3 minutes, stop the system and wiring harness as a branch near the power module. check the following first and then repeat this step: 2. Unwrap the door harness wires. a. Check for any fluid leaks. 3. Based on the selected actuation method above, strip b. Check that the hoses are properly connected. the end(s) of the door harness blunt wire(s) and connect the end(s) to the signal source using a heat 30

c. Completely depressurize the system. See Note: The LiquidSpring Calibration routine will automatically Depressurizing the System section, under System determine maximum and minimum suspension ride height. Operation Based on those ride heights, the system will determine the correct normal design ride height. The calibration system will 14. After the suspension system stops leveling, check the also calibrate the steering sensor. fluid level in the reservoir. If low, fill to the indicated line. 1. Verify that the front wheels are steered straight ahead. 2. Lower the vehicle to the ground and remove any jack stands and any other obstructions from under the vehicle. 3. To begin the calibration, turn the ignition key to “Run” and ensure that the LiquidSpring driver display lights up and that the red “Warning” LED is not lit or flashing. WARNING: Do not run vehicle in an enclosed building Figure 44. Final fill fluid level. without adequate ventilation or without ducting exhaust Bleeding the System fumes outside. Operation of a vehicle inside an enclosed building can lead to serious injury or death. 1. Locate 3/16” ID PVC Tubing (not included with kit). Note: Alternatively, a bleed kit similar to the Actron 4. Press and release the Red ON/OFF button on the 7840 Bleed Kit or Lisle 19200 Brake Bleeding Kit driver display. All LEDs on the driver display should (found at Sears) can be used. go out. 2. Attach the PVC tubing to one of the upper bleed 5. Press and release the Red ON/OFF button again. The screws on the Left Hand Secondary Volume LEDs on the driver display should all flash and then Assembly and place the other end in a bucket. only the four yellow arrow LEDs, one green ride mode indicator LED, and one green ride height indicator LED should remain lit. 6. Press and hold both Ride Height Adjustment Buttons simultaneously until the SPORT, COMFORT, HIGH, and LOW green LED’s begin to flash. The suspension system will begin to rise to the full high position, and then lower to the full lowered position. 7. After the system completes the calibration routine, the suspension will return to the original ride height. 8. Turn off the ignition for at least 3 minutes. Note: The suspension system will not use the calibrated ride height settings until power has been cycled.

Note: Pressing the red ON/OFF button on the driver Figure 45. Bleed screw locations. display does not cycle power to the LiquidSpring 3. Open the bleed screw slightly. suspension system, but only will enable/disable the system. 4. After air bubbles are no longer present, close the bleed screw and torque to 13-18 ft-lbs. 9. Turn the ignition back to Run,. 5. Repeat with remaining three bleed screws. 10. Press and release the Red ON/OFF button on the driver display. All LEDs on the driver display should Calibrating the System go out. IMPORTANT: Proper calibration of the system must be conducted with the vehicle loaded to the as delivered 11. Press and release the Red ON/OFF button again. The condition with body installed. For calibration on an empty LEDs on the driver display should all flash and then chassis cab, LiquidSpring recommends weight be added to only the four yellow arrow LEDs, one green ride the frame approximately equal to the planned body to mode indicator LED, and one green ride height allow for proper bushing deflections. indicator LED should remain lit. 12. Calibration is now completed.

Post Installation Welding WARNING: Prior to any chassis welding conducted after the installation of the LiquidSpring suspension system, disconnect cables from battery, disconnect ECU Header connectors (see below), and Power Module ground connection (see below).

Figure 46. ECU disconnects prior to welding on chassis.

System Operation

System Start Up: Warning Light:  In most instances, the suspension system can be left If the Red LED warning light is continuously illuminated alone to operate automatically. along with one or more of the other indicator lights, please refer to the Troubleshooting Section on page 35.  After startup, all the indicator lights will flash on for 1-2 seconds, and then the Green Ride Height Ride Mode Adjustment: Indication LED and Green Ride Mode Indication Press the UP/DOWN arrow buttons to change the ride LED will light to show the current Ride Mode and mode between SPORT, NORMAL, and COMFORT. The Ride Height. Green indicator light will show the set mode.  The four yellow LED’s will light up if the steering  Comfort Mode provides a smooth, soft ride. Use for wheel is approximately 10°-20° each side of straight normal city and highway driving. ahead, but will not light up when steering wheel  Sport Mode provides more “feel” or response to the exceeds 20° from center. If the vehicle is steered road conditions. Use where road conditions or straight ahead and the four yellow LED’s are not lit personal preference demand more control. (and the red warning LED is not lit) see Calibrating  Normal Mode is a balance between Comfort and the Steering Sensor Only. Sport. Use where more control than Comfort is  When the steering wheel is turned more than 20° off desired, but better ride than Sport. center, the four Yellow Steering Centering Indication The setting can be changed at any time. Based on road LED will not be lit. conditions, steering wheel angle, and the vehicle speed, ON/OFF Button: the system automatically adjusts to provide the best handling while providing a smooth ride. All three settings Pressing the ON/OFF button will enable/disable the will feel similar on a smooth road. suspension. When the suspension is ON, relevant LED’s are lit up. When the suspension is OFF, none of the Ride Height Adjustment: LED’s are lit. It is recommended to leave the suspension Press the UP/DOWN arrow buttons to change ride height ON at all times unless the vehicle or suspension is being from NORMAL to HIGH (body up) or LOW (body serviced. down). IMPORTANT: After turning the vehicle ignition off,  A solid green LED will indicate the selected the suspension system will remain powered for 1 hour height. A flashing green LED will indicate the before shutting off. current height and that height adjustment is

occurring. When a single solid green LED is lit, “Warning” LED is lit, proceed to the Trouble the selected height has been achieved. Shooting Section.  Two solid green LEDs will be lit if the current height is not the selected height and height WARNING: Do not run vehicle in an enclosed adjustment is not occurring. building without adequate ventilation or without ducting exhaust fumes outside. Operation of a vehicle  If LOW or HIGH heights are selected while the inside an enclosed building can lead to serious injury vehicle is traveling at less than 10 mph or or death. stopped, the suspension height is either lowered or raised. 1. Press and release the Red ON/OFF button on the  If LOW or HIGH heights are selected while the driver display. All LEDs on the driver display should vehicle is traveling at greater than 10 mph, the go out. suspension will ignore the selected height and remain in NORMAL height unless the vehicle 2. Press and release the Red ON/OFF button again. The speed goes below 10 mph within 2 minutes of LEDs on the driver display should all flash and then selecting the height. In this instance, the only the four yellow arrow LEDs, one green ride NORMAL height green LED will flash and the mode indicator LED, and one green ride height selected height green LED will be lit solid until indicator LED should remain lit. the speed goes below 10 mph within 2 minutes 3. Press and release the HEIGHT DOWN arrow button of selecting the height. If the vehicle speed to lower the vehicle to the LOW height. doesn’t go below 10mph within the 2 minute period, the suspension will remain in NORMAL 4. Press and hold the HEIGHT DOWN arrow button for height indicated by only the NORMAL height approximately 2 minutes. green LED lit solid. 5. Release the HEIGHT DOWN arrow button.  If LOW height is selected and the ignition is turned off before LOW height is achieved, the 6. Press and release the ON/OFF button to disable the system will continue to lower to LOW height. system. When LOW height is selected the system will 7. Turn off the vehicle ignition. monitor and maintain the kneeled position by only lowering as needed for 1 hour after the If any of the hydraulic connected components is to be ignition is turned off. removed and serviced, it is recommended to also follow  If HIGH height is selected and the ignition is the following steps: turned off before HIGH height is achieved, the 8. Locate 3/16” ID PVC Tubing. Note: Alternatively, a system will stop adjusting ride height. When bleed kit similar to the Actron 7840 Bleed Kit can be HIGH height is selected the system will monitor used. and maintain the current position by only lowering as needed for 1 hour after the ignition is 9. Attach the PVC tubing to one of the upper bleed turned off. screws on the Left Hand Secondary Volume  The door switch function (if equipped) is Assembly and place the other end in a bucket. disabled when the driver display LOW or HIGH height is selected before the door is opened on vehicles equipped with a door switch for kneeling. IMPORTANT: While parked for an extended time with the vehicle and/or suspension system turned off, suspension ride will change with temperature change. Increases in ambient temperature or parking in direct sunlight can cause the suspension ride height to increase. As temperature lowers, the suspension ride height can decrease.

Depressurizing the System Figure 47. Bleed screw locations. 1. Turn the ignition key to “Run” and ensure that the 10. Open the bleed screw slightly to relieve any residual LiquidSpring driver display LEDs light up and that pressure. the red “Warning” LED is not lit. If the red

11. After pressure is relieved, close the bleed screw and 1. Verify that the front wheels are steered straight torque to 13-18 ft-lbs. ahead. Notes: 2. To begin the calibration, turn the ignition key to “Run” and ensure that the LiquidSpring driver  Jacking up the chassis of a lowered, depressurized display lights up and that the red “Warning” LED is chassis will cause a slight vacuum in the system and not lit or flashing. minimize fluid loss while disconnecting hoses. WARNING: Do not run vehicle in an enclosed  For service of non-hydraulic connected suspension building without adequate ventilation or without components, the suspension system can be first raised ducting exhaust fumes outside. Operation of a vehicle to the HIGH height, appropriate jack stands placed inside an enclosed building can lead to serious injury under the chassis, then depressurized as listed above or death. lowering the chassis onto the jack stands. Calibrating the Steering Sensor Only 3. Press and release the Red ON/OFF button on the driver display. All LEDs on the driver display should Note: The yellow lights only light up when the steering go out. sensor indicates the center location. They will not be lit outside of 10°-20° off center. 4. Press and release the Red ON/OFF button again. The LEDs on the driver display should all flash and then IMPORTANT: The LiquidSpring CLASS® system only the four yellow arrow LEDs, one green ride includes an automatic self-centering routine. In mode indicator LED, and one green ride height conditions such as driving on highway with significant indicator LED should remain lit. side wind, the yellow lights may temporarily not be lit when the steering wheel is exactly centered. Rotate 5. Press and hold both Ride Height Adjustment Buttons slowly from center to full steering stop, then repeat the simultaneously until the SPORT, COMFORT, HIGH, opposite direction. If the yellow lights momentarily and LOW green LED’s begin to flash. light up during the travel in one or the other direction, 6. As soon as the four green LED’s begin to flash, press the system is operating normally and the steering the ON/OFF button to stop the process. sensor does not need to be manually re-centered. Continue operating normally. 7. Verify that the four yellow arrow LED’s are lit. If the yellow lights do not light up at all during turning 8. Steering calibration is completed. the steering wheel, following the instructions below.

Troubleshooting The LiquidSpring CLASS® system includes on-board diagnostics to assist in pin-pointing potential issues. When a fault in the system occurs, the red warning light on the Drivers Interface will light along with one or more of the other lights on the interface. Driver Interface Condition Cause Correction Lights Warning + Battery Voltage in Vehicle charging system providing incorrect Inspect and replace as necessary. RIDE: SPORT excess of 16VDC voltage. LiquidSpring system not connected to 12VDC Inspect and replace as necessary electrical system Warning + Pump Motor runs in See Issues with Vehicle Raising/Pump Section See Issues with Vehicle Raising/Pump Section RIDE: NORMAL excess of 3 minutes Warning + Battery Voltage below 9 Vehicle charging system providing incorrect voltage Inspect and replace as necessary RIDE: COMFORT VDC Low vehicle battery Inspect and replace as necessary Warning + Issue with Right Hand See Issues with Height Sensors Section See Issues with Height Sensors Section HEIGHT: HIGH Height Sensor Warning + System kneels in excess See Issues with Vehicle Lowering/Dump Valve See Issues with Vehicle Lowering/Dump Valve HEIGHT: NORMAL of 3 minutes without Section Section suspension movement Warning + Issue with Left Hand See Issues with Height Sensors Section See Issues with Height Sensors Section HEIGHT: LOW Height Sensor Slow or Fast Blinking Driver Interface can not See Issues with Driver Interface See Issues with Driver Interface Warning Light communicate with ECU.

Issues with Vehicle Raising/Pump Condition Cause Correction Vehicle Leveled, Pump continues to run Pump motor shorted out. Contact LiquidSpring for further instructions. Software issue Turn off ignition, wait 30 seconds, restart vehicle. Excessive noise in height sensor See Issues with Height Sensors Vehicle Not Leveled (or Raised), Pump Reservoir fluid level low Fill reservoir to specified level. runs Hydraulic leak in system Check for fluid leaks and repair or replace. Vehicle overloaded Check vehicle loading and correct. Air in pump Check fluid level in reservoir and fill accordingly. Fully depressurize system and restart leveling. Internal leak in power module Replace power module. Height sensor error See Issues with Height Sensors Vehicle Not Leveled (or Raised), Pump System not turned on. Turn system on. does not run Blown fuse Check system fuses Loss of electrical power Check wiring between power module and battery. Pump runs for short time then stops Motor controller over temperature Contact LiquidSpring for further instructions. Pump runs intermittently Loose connector or wiring Check wiring harness connections and battery connections. Repair as necessary.

Issues with Vehicle Lowering/Dump Valve Condition Cause Correction Vehicle does not lower (kneel). System not turned on Turn system on Blown fuse Check system fuses and replace as necessary Obstacle under vehicle frame Remove obstacle Wiring harness disconnected Check wiring harness connections and reconnect Loss of electrical power Check wiring between power module and battery Power module filters plugged Contact LiquidSpring for further instructions Internal power module blockage Contact LiquidSpring for further instructions Vehicle slow lowering (kneeling) Partial internal power module blockage Contact LiquidSpring for further instructions

Issues with Secondary Volume Assembly Condition Cause Correction Hydraulic Leak Weld failure between tube and end Replace secondary volume welded assembly Weld failure between tube and manifold Replace secondary volume welded assembly Cylinder fracture Replace secondary volume welded assembly Bleed screw loose Tighten bleed screws to appropriate torque Fitting loose Tighten all fittings Hose failure Replace failed hose Hose cut Replace failed hose loose or no longer attached Bolts attaching bracket to frame broken / Replace bolts and tighten to required torque came out Bolt attaching volumes to bracket broke / Replace bolts and tighten to required torque came out Weld Failure Replace brackets Structural failure Replace brackets

Issues with One Corner Not Leveling Properly Condition Cause Correction One side will not raise or lower Internal power module blockage Contact LiquidSpring for further instructions Low voltage Check battery voltage. Wiring harness disconnected Check wiring harness connections and reconnect Obstacle under vehicle frame Remove obstacle Power module filters plugged Contact LiquidSpring for further instructions Height sensor error See Issues with Height Sensors One corner raises and lowers slower than Internal power module blockage Contact LiquidSpring for further instructions other corners Filter partially clogged Contact LiquidSpring for further instructions

Issues with Height Sensors Condition Cause Correction Vehicle or corner stops leveling at Damaged height sensor and/or linkage Inspect height sensor components. Replace as necessary. incorrect height Incorrect calibration Recalibrate vehicle – see System Operation section. Incorrect height sensor installation Inspect height sensor components and correct. Corner height where leveling stops is Sensor or Linkage loose Inspect installation of height sensor and linkages and tighten if necessary inconsistent Loose connector / wire Inspect wiring between sensor and power module for loose connection Vehicle will not level - no height sensor Height Sensor wiring shorted, broken, or Inspect wiring between sensor and power module. signal disconnected Malfunction in Sensor Replace sensor. No Height Sensor Signal change while Linkage broken/disconnected Inspect installation of height sensor and linkages. Correct and/or replace. driving

Issues with Ride/Handling Condition Cause Correction Vehicle rolls side to side excessively System inactive (Drivers interface dark) Turn system on (press On/Off button) No electrical power to system Inspect and replace as necessary Strut bushings worn Inspect and replace as necessary Control arm bushings worn Inspect and replace as necessary Sway bar bushings worn Inspect and replace as necessary Strut mounting loose Inspect and replace as necessary Rate Valve wiring shorted, broken, or Inspect wiring and correct/replace as necessary. disconnected Voltage to Rate Valve solenoid too low Check battery voltage. Rate Valve Poppet Jammed open Contact LiquidSpring for further instructions No vehicle speed signal See Issues with Vehicle Speed Signal section. Excessive stiffness when on flat, straight Short to Rate Valve Check wiring between rate valve (on secondary volume) and power road module for signs of shorts. Replace as necessary. Wiring to Rate Valve incorrect Inspect wiring and correct as necessary

Issues with Steering Sensor Condition Cause Correction No steering signal ( reduced roll control Steering sensor wiring broke or Inspect wiring to steering sensor and correct as necessary. when cornering) incorrect. Steering sensor malfunction Replace sensor Steering sensor not installed correctly Inspect installation and correct as necessary Yellow lights on driver display not lit Zero point of steering sensor incorrect. See Calibrating the Steering Sensor Only. when steered straight ahead. Intermittent steering sensor signal Loose connector / wire Check wiring between Steering sensor and Power module for loose connection.

Issues with Vehicle Speed Signal Condition Cause Correction System leveling excessively while Speed Sensor wiring shorted, broken, or Inspect wiring and repair/replace as necessary driving. disconnected Speed signal malfunction Replace OEM speed sensor. See OEM service manual. Intermittent speed sensor signal Loose connector / wire Check wiring between Speed sensor and Power module for loose connection.

Issues with Vehicle Brake Signal Condition Cause Correction Vehicle will not level Brake signal wire not correctly tapped. Inspect wiring and repair/replace as necessary. Brake switch malfunction Replace OEM speed sensor. See OEM service manual. Intermittent leveling Loose connector / wire Inspect wiring and repair/replace as necessary.

Issues with Door Switch Condition Cause Correction Vehicle will not kneel when rear door Short or break in wiring between door Inspect wiring and repair/replace as necessary. opened switch and power module. Door switch malfunction Inspect door switch and repair/replace as necessary Vehicle kneels whenever speed below Short or break in wiring between door Inspect wiring and repair/replace as necessary. 5mph switch and power module. Door Switch out of adjustment Check installation of door switch and adjust as necessary Door switch malfunction Inspect and replace per body builder instructions. Intermittent door switch signal Loose connector / wire Inspect wiring and repair/replace as necessary.

Issues with Vehicle Ignition Signal Condition Cause Correction System does not turn on (no leveling or No ignition signal to controller or driver Inspect wiring and repair/replace as necessary. stiffness control) interface Ignition "sensor" malfunction Inspect and replace per OEM service manual. System does not turn off once ignition Signal side short to battery Inspect wiring and repair/replace as necessary. switched off Ignition "sensor" malfunction Inspect and replace per OEM service manual. System intermittently works Loose connector / wire Inspect wiring and repair/replace as necessary.

Issues with Vehicle Park Signal Condition Cause Correction System will start up but won't level when No park signal to controller Inspect wiring and repair/replace as necessary. parked Park sensor malfunction Inspect and replace per OEM service manual. System levels when stopped and not in Park signal always on Inspect wiring and repair/replace as necessary. park Park sensor malfunction Inspect and replace per OEM service manual. Intermittent leveling when stopped in or Loose connector / wire Inspect wiring and repair/replace as necessary. out of park

Issues with Driver Interface Condition Cause Correction Warning light blinks, system appears to CAN wires crossed or not connected. Inspect wiring and repair/replace as necessary. level. Malfunctioning Driver Interface Inspect and replace as necessary. Warning light blinks, system does not No power to ECU (5A 18ga Red Wire) Inspect wiring and repair/replace as necessary. appear to operate (level) No ignition signal to ECU (Yellow Wire) Inspect wiring and repair/replace as necessary. CAN wires crossed or not connected. Inspect wiring and repair/replace as necessary.

Issues with Power Module Condition Cause Correction Pump exhibits high pitch whine The Check Valve is stuck open Replace Power Module immediately after pump stops or when vehicle lowering Pump running under heavy load and The Check Valve is only partially open Replace Power Module leveling slow Pump running under heavy load and no The Check valve is stuck closed Replace Power Module leveling Hydraulic fluid leaking from Power O-ring failure Replace O-ring Module Manifold cracked Replace Power Module Fitting loose Tighten fittings Valve loose Tighten valves to correct torque Bolts between manifolds loose/broken Replace and /or tighten bolts to correct torque Hydraulic line loose Tighten hydraulic line correctly Bolts between reservoir and manifold Replace and/or tighten bolts to required torque loose/broken Broken / cracked reservoir Replace reservoir

Issues with Strut Assembly Condition Cause Correction Hydraulic Leak Weld failure between cylinder and end Replace strut Cylinder fracture Replace strut Threads stripped between cylinder and Replace strut gland Seals worn out Replace strut Rod severely scratched or dented Replace strut Fitting loose Tighten or replace fittings Hose failure Replace failed hose Hose cut Replace failed hose Rod broken at bushing housing Weld failure Replace strut Rod doesn't move freely in/out cylinder Piston jammed in cylinder Replace strut Rod moves very easily in/out cylinder Piston broken therefore no damping Replace strut Reduced damping level Damping components broken/worn out Replace strut Strut upper mount not securely attached Bolts attaching bracket to frame broken / Replace bolts and tighten to required torque to frame or Strut came out Bolt attaching strut to bracket broke / Replace bolts and tighten to required torque came out Weld Failure Replace strut upper mount Structural failure Replace strut upper mount Strut lower mount not securely attached Bolts attaching bracket to axle broken / Replace bolts and tighten to required torque to axle or strut came out Bolt attaching strut to bracket broke / Replace bolts and tighten to required torque came out Weld Failure Replace strut lower mount Structural failure Replace strut lower mount

Electrical Schematics

Appendix A: Frame Drilling Locations

Figure A 1: Driver side template location for upper strut mount and bulkhead fitting frame drilling

Figure A 2 Passenger side template location for upper strut mount, and bulkhead fitting frame drilling.

Figure A 3 Secondary volume bracket mount locations for drilling.

46 DS135N

INSTALLATION CHECK LIST Installer: Installation Date: Inspector: Inspection Date: Suspension S/N: VIN:

FRAME PREPARATION: ☐Battery Disconnected ☐Upper Strut Mount, Track Rod Frame Mount, and Secondary Volume Assy holes drilled.

AXLE PREPARATION: ☐Weld Track Rod Mount to Axle

☐OEM M14 Bolts reinstalled and torqued to 130 ft-lbs.

FRONT HANGER INSTALLATION: ☐Front Hangers are level with framerail. ☐5/8”-11 Nuts torqued to 172-210 ft-lbs.

UPPER STRUT MOUNT/CROSS MEMBER REINFORCEMENT/TRACK ROD FRAME MOUNT INSTALLATION: ☐Upper Strut Mounts level with top of frame. ☐Cross member Reinforcement orientated correctly. ☐Bolts oriented per Installation Manual Views. ☐5/8”-11 Nuts torqued to 172-210 ft-lbs. ☐1/2”-13 Nuts torqued to 86-105 ft-lbs. ☐OEM brake brackets reattached to crossmember and torqued to 18 ft-lbs. ☐Brake flexible lines attached to Upper Strut Mounts with 3/8” clamps and torqued to 18 ft-lbs. ☐Removed OEM rear crossmember [Only DS135N-AF, front mount fuel tank version].

AXLE CLAMP INSTALLATION: ☐3/4”-16 U-Bolts torqued in stages up to 295 ft-lbs.

CONTROL ARMS INSTALLATION: ☐Lower Control Arms correctly orientated. ☐1”-8 Nuts torqued to 600 ft-lbs, at ride height. ☐5/8”-11 Nuts torqued to 172-210 ft-lbs at ride height.

TRACK ROD INSTALLATION: ☐7/8”-9 Nuts torqued to 491-600 ft-lbs.

STRUT INSTALLATION: ☐1”-8 Upper Nuts torqued to 600 ft-lbs. ☐1”-8 Lower Nuts torqued to 250 ft-lbs.

JOUNCE BUMPER INSTALLATION: ☐M10-1.5 Bolts torqued to 35 ft-lbs.

HEIGHT SENSOR INSTALLATION: ☐5/16”-18 Nuts torqued to 14-17 ft-lbs. ☐Locking Clips installed.

PARKING BRAKE CABLE INSTALLATION: ☐Parking brake cable reattached to axle.

47 DS135N

POWER MODULE/SECONDARY VOLUME INSTALLATION: ☐1/2”-13 Nuts torqued to 86-105 ft-lbs. ☐3/8”-16 Screws torqued to 39 ft-lbs. ☐Reservoir Mount Self Tapping Screws tightened to snug only. ☐5/16”-24 Clamp Fasteners torqued to 240 in-lbs. ☐Replace top plug with Breather Cap.

HOSE INSTALLATION: ☐Bulkhead Fitting Locknut torqued to 85-95 ft-lbs. ☐-4 Hose Fittings torqued to 12 ft-lbs. ☐-10 Hose Fittings torqued to 36-63 ft-lbs. ☐Bleed Screws closed and torqued to 13-18 ft-lbs. ☐Hoses secured with standoffs.

STEERING SENSOR INSTALLATION: ☐OEM fender well bracket bolts torqued to 18 ft-lbs. ☐Ball Stud Bracket on Pitman arm positioned 4”±1/8” down from CL of gearbox shaft. ☐1/4-20 fasteners torqued to 10 ft-lbs. ☐5/16-18 fasteners torqued to 14-17 ft-lbs. ☐Clearance to steering sensor components when wheels are turned full left and full right.

WIRING HARNESS INSTALLATION: ☐Dash harness installed ☐All appropriate wiring splices made. ☐Driver Interface installed and connected to Dash Harness. ☐External harness routed and secured. ☐External harness connected to Rate Valves, Height Sensors, Steering Sensor. ☐Speed signal from dash harness installed into vehicle ECU connector or K47B wire on 12VZA circuit. ☐Battery harness installed with Fuse Lead and connected to Battery and Power Module. ☐Door harness installed (if equipped with rear door switch). ☐All connections sealed. ☐All harnesses properly secured from chaffing, heat, and located away from moving parts.

INTIAL FILL/CALIBRATION: ☐Battery connected. ☐Suspension rose to ride height. ☐Reservoir at proper level. ☐Calibration completed.