No. 39301 E450 Spring Beam
INSTALLATION GUIDE
For maximum effectiveness and safety, please read these instructions completely before proceeding with installation.
Failure to read these instructions can result in an incorrect installation. MN-664 • (02704) ECR 6094 RoadTamer
TABLE OF CONTENTS
Introduction ...... 2 Important Safety Notice ...... 2 Notation Explanation ...... 2 Installation Diagram ...... 3 Hardware List ...... 3 Torque Specifi cations ...... 3 Installing the RoadTamer System ...... 4 Disassembly ...... 4 Front Spring Eye Hanger Assembly ...... 4 Spring Beam/Retainer Bracket Assembly ...... 5 Spring Beam to the Front Spring Eye Adapter ...... 5 Attaching the Axle/Spring Beam Saddle/Perch ...... 6 Attaching the Panhard Rod and Panhard Rod Bracket ...... 7 Attaching the Upper Brackets ...... 9 Driver Side Jounce Bumper Bracket ...... 10 Installing the Original Jounce Bumpers ...... 10 Installing the Rolling Lobe Sleeves ...... 11 Adjusting the Rear Suspension ...... 12 Installing the Air Lines ...... 12 Installing the Shock Extensions ...... 13 Attaching the Electronic Height Sensor Units (EHS) and Magnets ...... 14 Installation Checklist...... 15 Troubleshooting Guide ...... 16 Maintenance and Servicing ...... 17 Maintenance Guidelines ...... 17 Servicing the Roadtamer System ...... 17 Warranty and Return Policy ...... 17 Replacement Information ...... 18 Contact Information ...... 18
MN-664 1 RoadTamer Introduction
The purpose of this publication is to assist with the installation, maintenance and troubleshooting of the RoadTamer System.
It is important to read and understand the entire installation guide before beginning installation or performing any maintenance, service or repair. The information here includes a hardware list, torque specifi cations, step-by-step installation information, maintenance tips, safety information and a troubleshooting guide.
Air Lift Company reserves the right to make changes and improvements to its products and publications at any time. Contact Air Lift Company at (800) 248-0892 for the latest version of this manual. IMPORTANT SAFETY NOTICE The installation of this kit does not alter the Gross Vehicle Weight Rating (GVWR) or payload of the vehicle. Check your vehicle’s owner’s manual and do not exceed the maximum load listed for your vehicle.
Gross Vehicle Weight Rating: The maximum allowable weight of the fully loaded vehicle (including passengers and cargo). This number — along with other weight limits, as well as tire, rim size and infl ation pressure data — is shown on the vehicle’s Safety Compliance Certifi cation Label.
Payload: The combined, maximum allowable weight of cargo and pasengers that the truck is designed to carry. Payload is GVWR minus the Base Curb Weight. NOTATION EXPLANATION Hazard notations appear in various locations in this publication. Information which is highlighted by one of these notations must be observed to help minimize risk of personal injury or possible improper installation which may render the vehicle unsafe. Notes are used to help emphasize areas of procedural importance and provide helpful suggestions. The following defi nitions explain the use of these notations as they appear througout this guide.
DANGER INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH. INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE WARNING PERSONAL INJURY OR DEATH.
CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO THE MACHINE OR MINOR PERSONAL INJURY.
NOTE Indicates a procedure, practice or hint which is important to highlight.
2 MN-664 RoadTamer Installation Diagram F
P AA X M L S T Q S R F H G Y K R
W C
J T I I N J E D O A V B O U fi g . 1 HARDWARE LIST
Item Part # Description ...... Qty A 07836 Spring Hanger Outer Plate R.H...... 1 B 07935 Spring Hanger L.H...... 1 C 03935 Axle Bracket L.H...... 1 D 03856 Formed Plate ...... 1 E 26471 Panhard Rod ...... 1 F 07915 Upper Bracket ...... 2 G 10803 Panhard Upper Bracket Support ...... 1 H 10688 Panhard Upper Bracket ...... 1 I 10687 Shock Extension Bracket ...... 2 J 13962 Spacer ...... 2 K 13961 Spacer ...... 1 L 10702 Magnet Bracket ...... 1 TORQUE SPECIFICATIONS M 10691 Magnet Bracket ...... 1 N 10708 JB Spacer Flat Plate ...... 1 ½” Hardware (bolts) ...... 90 ft/lbs O 06158 Retainer Plate ...... 2 CAM bolt assembly...... 215 ft/lbs P 10679 Square U-Bolt ...... 2 Axle/panhard rod M20 bolt ...... 450 ft/lbs Q 10804 Round U-Bolt ...... 2 *R 24050 Height Sensor ...... 2 U-bolts ...... 300 ft/lbs *S 10966 Magnet ...... 2 Rolling lobe ½” hardware...... 25 ft/lbs T 10824 Spring Support Plate ...... 2 Rolling lobe ¾” hardware...... 50 ft/lbs U 32204 Right Spring Beam ...... 1 Front ¾” pivot bolts ...... 420 ft/lbs V 32103 Left Spring Beam ...... 1 All 3/18” hardware ...... 44 ft/lbs W 26886 CAM Bolt Assembly ...... 1 Shock M12 hardware...... 65 ft/lbs X 10689 Left JB Spacer ...... 1 Y 10819 Anti-Rotation Bracket ...... 1 +Z 58217 RL Sleeves ...... 2 AA 10832 Limiting Straps ...... 2 *These parts are included in the control kit. +Not shown in installation diagram.
MN-664 3 RoadTamer Installing the RoadTamer System DISASSEMBLY 1. Elevate the rear of the vehicle and secure the frame with jack stands or a frame-contact hoist. Secure the axle (fi g. 2). IT WILL BE NECESSARY TO SUPPORT THE DRIVE SHAFT/PINION SO THE CAUTION DIFFERENTIAL WILL NOT ROTATE WHEN THE SPRINGS ARE REMOVED. Axle
Tire
fi g . 2
Jack stands 2. Remove the tires. NOTE Not necessary if working on a bare chassis. 3. Remove jounce bumpers and retain for future use. 4. Remove rear tail pipe exhaust hanger from the side of the frame. 5. Remove the lower shock bolts and pull the shocks away from the mount. 6. Remove the leaf springs. FRONT SPRING EYE HANGER ASSEMBLY 1. If necessary, drill the existing hole in the frame fl ange (located just forward of the spring eye mount) out to ½” (fi g. 3). BEFORE DRILLING, CHECK THE BACK-SIDE OF THE FRAME FOR CLEARANCE ISSUES CAUTION WITH THE BRAKE LINES, GAS LINES, AND ELECTRICAL LINES. ANY OBSTACLES WILL NEED TO BE TEMPORARILY RELOCATED TO CLEAR THE AREA. 2. Drill the stock spring eye hanger braket holes out to ¾” to accept the supplied ¾” hardware. Set the adapter into place. Nest the adapter into the stock front spring eye hanger and loosely attach with ¾” bolt, fl at washers and nyloc nut (fi g. 4). NOTE Insert the bolt from the outside of the frame so the nut is on the inside of the frame. CAUTION IT WILL BE NECESSARY TO REMOVE EXCESSIVE UNDERCOATING FROM AROUND ALL BOLT HOLES PRIOR TO ASSEMBLY OF THE BRACKETS TO THE FRAME. 3. Attach the bracket to the frame using ½” bolts, fl at washers, and nyloc nuts into the existing holes in the side of the frame and into the hole that was previously drilled in step 1. Insert the bolts from the inside of the frame so that the nyloc nuts are on the outside of the frame (fi g. 3 and fi g. 4). Snug the bolts on the fl ange and web of the frame. Torque the ½” hardware to 90 ft/lbs.
¾” Flat washer ¾” Bolt
If needed, drill this hole out to ½”. ¾” Nyloc nut
¾” Flat washer fi g . 3 ¾” Bolt
4 MN-664 RoadTamer
4. Drill a ½” hole through the frame using the last hole in the bracket as a template. Insert ½” hardware and torque to 90 ft/lbs. BE AWARE OF THE FUEL AND BRAKE LINES. PROTECT THESE LINES WHEN CAUTION DRILLING. 5. Repeat steps 1-4 for the other side of the chassis.
Stock spring eye hanger
Spring eye adapter
½” Flat washer
½” Nyloc nut
¾” Flat washer fi g . 4
¾” Bolt ¾” Nyloc nut ¾” Flat washer
SPRING BEAM/RETAINER BRACKET ASSEMBLY 1. Attach the retainers to the spring beams using the ½” socket head bolt, fl at washer, and nyloc nut. Be sure the head of the bolt is pointing up (fi g. 5). 2. Align the u-bolt holes parallel to the spring uniformly and tighten securely.
½” Socket head bolt
Spring retainer fi g . 5
½” Flat washer
Nyloc nut
SPRING BEAM TO THE FRONT SPRING EYE ADAPTER 1. Set the spring beam assemblies under the axle and attach to the front spring eye adapter using the ¾” bolt, fl at washers and nyloc nuts (fi g. 6). Do not tighten hardware at this time. Let the spring beam rest on the fl oor or let it hang for the next step.
Eye adapter Eye hanger
¾” Flat washer ¾” Nyloc nut
¾” Bolt ¾” Flat washer
Spring beam fi g . 6
MN-664 5 RoadTamer
ATTACHING THE AXLE/SPRING BEAM SADDLE/PERCH 1. The driver side bracket (03935) has to be installed by setting it over the axle/spring perch from the front of the axle, pushing the bracket rearward so that the pocket with the larger nut is facing forward (fi g. 7). 2. Raise the spring up under the axle/spring beam saddle making sure the centering pin in the spring beam indexes into the hole on the bottom of the bracket. A jack can be used to support the spring. IT WILL BE NECESSARY TO SUPPORT THE DRIVE SHAFT/PINION SO THE CAUTION DIFFERENTIAL DOES NOT ROTATE WHILE ATTACHING THE BRACKETS.
Driver side Rear
U-bolt
Height sensor bracket
Anti-rotation bracket
Axle bracket
Stock spring perch
Spring retainer fi g . 7
¾” Washer
¾” Nyloc nut
3. Insert one square u-bolt forward of the axle through the anti-rotation bracket and into the lower spring retainer (fi g. 7). Cap with thick ¾” washers and 3/4” tall nuts. Leave loose so that a pry bar can be inserted between the u-bolt and the anti-rotation bracket and top plate. 4. Using the u-bolt for leverage, pry down the upper plate, making sure the anti-rotation bracket indexes into the stock spring perch (fi g. 8). 5. Set the magnet bracket (10691) in between the u-bolt and the top of the anti-rotation bracket so that the magnet mount is facing forward of the axle (fi g. 7).
Using a pry bar between the u-bolt Pry bar and the anit-rotation bracket and top plate, pry the top plate down as far as possible. U-bolt
Anti-rotation bracket
Top plate fi g . 8
6 MN-664 RoadTamer
6. Install the rear square u-bolts over the top and down through the lower spring retainer (fi g. 7). Attach using the ¾” large nuts and ¾” washers. Tighten u-bolts uniformly. Make sure that the centering pin in the anti-rotation bracket indexes into the stock spring perch on the axle (fi g. 7). Also make sure the magnet bracket stays parallel to the spring. Snug assembly only. Do not tighten at this time. 7. For the passenger side installation, you will need to install the magnet bracket to the axle/spring beam saddle using two ¼” bolts, ¼” fl at washers, and nyloc nuts (fi g. 9). 8. Set the assembly under the axle with the magnet bracket facing forward. The bracket should rest under the stock spring perch on the axle. Lift up the spring beam so that the centering pin indexes into the axle/spring beam saddle (fi g. 9). A jack can be used to support the spring. 9. Attach the assembly together over the axle and through the spring retainer with the round u-bolts (fi g. 9). Cap the u-bolts with the large ¾” nuts and washers. Snug assembly only. Do not tighten at this time.
Passenger side
U-bolt
Height sensor bracket Stock spring perch ¼” Bolt
¼” Flat washer
Axle bracket
Spring retainer fi g . 9 ¾” Washer
¾” Nyloc nut
ATTACHING THE PANHARD ROD AND PANHARD ROD BRACKET 1. Set the panhard rod into place over the axle and into the left side axle/spring beam saddle bracket (fi g. 10). Attach using the M20 bolt and ¾” fl at washer. Torque to 450 ft/lbs. CAUTION BE CAREFUL SO AS NOT TO BREAK THE ABS CONNECTOR ON TOP OF THE RIGHT PINION HOUSING OF THE AXLE ASSEMBLY. Axle bracket
¾” Flat washer
Panhard rod fi g. 10
M20 bolt
MN-664 7 RoadTamer
2. Set the panhard rod bracket (10688) onto the right hand frame rail, slightly forward of the axle, while inserting the open end of the panhard rod into the pocket of the bracket (fi g. 11). CAUTION IT WILL BE NECESSARY TO REMOVE EXCESSIVE UNDERCOATING FROM AROUND ALL BOLT HOLES PRIOR TO ASSEMBLY OF THE BRACKETS TO THE FRAME.3. Insert a 5/16” bolt (or equivalent) through the small hole in the side bracket, then through the existing hole in the side of the frame to line the bracket up correctly to the frame (fi g. 12). Panhard rod Use this Nut small hole.
fi g. 12 fi g. 11 Lock washer CAM bolt Flat washer CAM washer Forward 4. Loop the limiting strap around the axle below the frame (fi g. 13). CAUTION BE SURE THE LIMITING STRAP IS BETWEEN THE AXLE AND THE BRAKE LINE SO THAT THE BRAKE LINE DOES NOT GET PINCHED.
Limiting strap fi g. 13
Brake line
5. Insert a 3/8” - 24 bolt, lock washer, and fl at washer through the limiting strap and into the existing jounce bumper hole and attach the bracket to the bottom of the frame rail. Snug bolt only. Do not tighten at this time (fi g. 14). 6. Using a c-clamp or welding brackets, secure the bracket to the frame making sure the small hole is still lined up and the panhard rod is in the pocket.
Inner bracket Forward Nyloc nut ½” Washer ½” Washer Nyloc nut 3/8” Bolt ½” Flat washer Lock washer ½” Bolt Flat washer
Existing jounce Flat washer bumper hole
CAM washer ½” Bolt fi g. 14 CAM bolt
8 MN-664 RoadTamer
7. Drill three ½” holes through the frame using the upper bracket as a template. Install the inner bracket into the inside of the frame (fi g. 14). 8. Insert the long ½” bolt and fl at washer from the back, through the bracket, panhard rod bracket, spacer, panhard rod bracket, inner bracket and cap on the front side with a fl at washer and nyloc nut (fi g. 14). Leave loose at this time. 9. Attach the assembly with the ½” bolts, fl at washers and nyloc nuts (fi g. 14). Leave loose at this time. 10. Insert the 5/8” cam bolt and washer through the panhard rod bracket and panhard rod from the back to the front. Cap with cam bolt fl at washer, another fl at washer, lock washer and nut (fi g. 11 & fi g. 14). Do not tighten at this time. 11. Torque all ½” hardware to 90 ft/lbs at this time. Torque the 3/8” hardware to 44 ft/lbs and remove the clamping devices previously used. ATTACHING THE UPPER BRACKETS 1. Set the upper bracket onto the frame rail, rear of the axle and above the spring beam (fi g. 15 and fi g. 16). Align the small holes on the side of the frame with the holes in the bracket. 2. Clamp the upper bracket onto the frame using c-clamps or welding clamps. 3. Drill four ½” holes through the frame using the upper bracket as a template (fi g. 16). BEFORE DRILLING, CHECK THE BACK-SIDE OF THE FRAME FOR CLEARANCE ISSUES CAUTION WITH THE BRAKE LINES, GAS LINES, AND ELECTRICAL LINES. ANY OBSTACLES WILL NEED TO BE TEMPORARILY RELOCATED TO CLEAR THE AREA. 4. Install the upper bracket using four ½” bolts, small fl at washers (in the top holes,) and large fl at washers (in the bottom holes). Cap with nyloc nuts (fi g. 16). Torque to 90 ft/lbs. IT WILL BE NECESSARY TO REMOVE EXCESSIVE UNDERCOATING FROM AROUND CAUTION ALL BOLT HOLES PRIOR TO ASSEMBLY OF THE BRACKETS TO THE FRAME. NOTE Air Lift recommends installing the bolts from the inside of the frame. 5. Repeat on the opposite side. Nyloc nut Drill holes to ½”
Locating holes Locating holes
Small flat washer
fi g. 15 Large flat Passenger side washer
½” Bolt fi g. 16
Passenger side
MN-664 9 RoadTamer
DRIVER SIDE JOUNCE BUMPER BRACKET 1. Attach the jounce bumper spacer bracket under the left side frame rail using the original hole that the stock jounce bumper was removed (fi g. 17). 2. Loop the limiting strap around the axle below the frame (fi g. 18). CAUTION BE SURE THE LIMITING STRAP IS BETWEEN THE AXLE AND THE BRAKE LINE SO THAT THE BRAKE LINE DOES NOT GET PINCHED. 3. Attach the limiting strap and bracket to the frame with the 3/8” - 24 bolt, lock washer, and fl at washer. 4. Install the bracket with the fl ange facing the rear of the vehicle. Torque the bolt to 44 ft/lbs. 3/8” Bolt Stock brake line bracket Flat washer Lock washer fi g. 18 fi g. 17 Limiting strap Jounce bumper Limiting strap bracket Brake line Jounce bumper INSTALLING THE ORIGINAL JOUNCE BUMPERS Driver side: 1. Attach the original jounce bumper to the jounce bumper spacer using the original mounting hardware. 2. Index the small tab on the jounce bumper into the bracket and tighten securely (fi g. 17). Passenger side: 1. Set the jounce bumper spacer plate over the stock jounce bumper so that the tab on the jounce bumper lines up with the hole in the plate. 2. Install the jounce bumper back onto the panhard rod/jounce bumper spacer bracket using the original mounting hardware (fi g. 19). NOTE Be sure to install the jounce bumper so that the small tab hole faces forward on the vehicle.
fi g. 19
Jounce bumper Jounce bumper spacer
10 MN-664 RoadTamer
INSTALLING THE ROLLING LOBE SLEEVES 1. Set a spring support bracket onto the spring beam and align the holes (fi g. 20). 2. Insert the stud on the bottom of the rolling lobe spring, through the support bracket and spring beam. 3. Repeat for the other side. NOTE It may be helpful to have a jack under the axle assembly to raise and lower the axle. 4. Raise the axle so the studs in the top of the rolling lobe spring index into the corresponding holes in the upper bracket. 5. Install the ½” nut and serrated lock washer onto the bottom and top ½” studs. Leave loose at this time. 6. Install the ¾” nut onto the top ¾” stud. Leave loose at this time. 7. Install ¼” elbow fi tting into the ¾” stud on top.
Spring support bracket
¼” Fitting Spring beam
¾” Nut ½” Nut
½” Lock washer
¾” Stud Upper bracket ½” Stud
Rolling lobe sleeve
Spring support bracket
Spring beam fi g. 20
½” Nut ½” Lock washer
MN-664 11 RoadTamer
ADJUSTING THE REAR SUSPENSION 1. Jack up or drop the rear axle assembly so that there is a mounting distance of 11½” between the upper bracket and the spring beam (fi g. 21). 2. Using the cam bolt on the right side panhard rod/bracket, adjust the rear end so the wheel to frame distance is equal. NOTE You can use the spring perch on the axle for this measurement also. 3. Torque the cam bolt nut, holding the cam bolt so as not to move while tightening, to 215 ft/lbs.
fi g. 21
11½”
4. Torque the axle u-bolts evenly in a crisscross pattern to 300 ft/lbs (fi g. 22). 5. Adjust the rolling lobe so that it is perpendicular to the top and lower mount. 6. Torque the ½” hardware on the rolling lobe air spring to 25 ft/lbs. 7. Torque the ¾” hardware on the rolling lobe air spring to 50 ft/lbs. 8. Torque the four front ¾” pivot bolts to 420 ft/lbs.
1 3
4 2
fi g. 22
INSTALLING THE AIR LINES 1. Choose a convenient location for mounting the infl ation valves. Popular locations for the infl ation valve are: the wheel well fl anges, the license plate recess in the bumper, under the gas cap access door, or through the license plate itself. NOTE Whatever the chosen location is, make sure there is enough clearance for an air chuck around the infl ation valves.
2. Drill a 5/16 “ hole to install the infl ation valves. 3. Cut the air line assembly in two equal lengths. WHEN CUTTING OR TRIMMING THE AIR LINE, USE A RAZOR BLADE OR A VERY CAUTION SHARP KNIFE. A CLEAN, SQUARE CUT WILL ENSURE AGAINST LEAKS. 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 (FIG. 23).
12 MN-664 RoadTamer
5. Route the air line along the frame to the air fi tting on the air spring. Keep at least 6” of clearance between the air line and heat sources, such as the exhaust pipes, muffl er, or catalytic converter (fi g. 24). Avoid sharp bends and edges. Use the plastic tie straps to secure the air line to fi xed, non-moving points along the chassis. Be sure that the tie straps are tight, but do not pinch the air line. Leave at least 2” of slack to allow for any movement that might pull on the air line. 6. 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 fi tting. This is a push-to-connect fi tting. Simply push the air line into the straight fi tting until it bottoms out (9/16” of air line should be in the fi tting).
Exhaust 6”
fi g. 23 Good cut Bad cut fi g. 24 Air line
INSTALLING THE SHOCK EXTENSIONS 1. Set the shock extension bracket over the stock shock bracket and align the holes (fi g. 25).
Shock extension bracket
Washer fi g. 25 Nyloc nut Stock shock bracket 3/8” Bolt 2. Attach the bracket by using the 3/8” bolt, washers and nyloc nut. Leave loose at this time. 3. Insert a M12 bolt and washer through the shock extension, shock bracket, spacer, shock bracket and shock extension. Cap with a fl at washer and M12 nyloc nut (fi g. 26).
M12 nyloc nut
Flat washer fi g. 26
M12 washer Spacer M12 bolt
MN-664 13 RoadTamer
4. Attach the shock in the same manor, but it will be necessary to add 3/8” washers between the shock and the shock extension to properly install (fi g. 26). 5. Torque the 3/8” hardware to 44 ft/lbs. Torque the M12 hardware to 65 ft/lbs. 6. Repeat on the other side. 7. Install the control system at this time. ATTACHING THE ELECTRONIC HEIGHT SENSOR (EHS) UNITS AND MAGNETS It will be necessar to obtain the two EHS units, magnets and mounting hardware from the control kit supplied with this suspension. CAUTION THE MAGNET HAS A STRONG PULL. USE CARE WHEN HANDLING SO AS NOT TO PINCH FINGERS OR SKIN. 1. Install the magnets to both magnet brackets on the left and right spring beam/axle assemblies using the two, long 3/16 machine screws, large fl at washers and nyloc nuts. Leave loose at this time. NOTE Be sure the orange dot on the magents face the frame where the EHS units will be installed (fi g. 27).
2. Set the suspension so that there is a mounting distance of 11½” between the upper and lower bracket. 3. Set the magnet in the middle of the mounting slot as a starting point for later adjustment (fi g. 27). 4. Set the EHS units onto the frame in correspondance to the magnets. Line up the dotted line on the EHS unit so that it is centered to the magnets. Mark the frame using the EHS mounting holes as a template. Use the ¼” self tapping screws to mount the EHS (fi g. 28). NOTE It may be necessary to drill a pilot hole for the self tappers. CAUTION BE AWARE OF THE FUEL AND BRAKE LINES. PROTECT THESE LINES WHEN DRILLING. AFTER EHS UNITS ARE INSTALLED, KNEEL THE SUSPENSION TO NOTE TRAVEL OF THE MAGNETS/BRACKETS. DO NOT MOUNT OR INSTALL ANYTHING THAT WILL IMPEDE THE TRAVEL OF THESE COMPONENTS. DO NOT MOUNT ANY STEEL OR MAGNETIC COMPONENTS AROUND OR NEAR THE EHS UNITS MOUNTED TO THE FRAME. EHS Magnet bracket Magnet must be aligned with the center of the 3/16” Large #10-24 x 1” EHS and centered with flat washer Screw the dotted line.
THIS END UP
Magnet
ALIGN DOTTED Orange dot faces LINE WITH CENTER the frame. OF MAGNET 3/16” Nyloc nut fi g. 28 Frame fi g. 27
14 MN-664 RoadTamer Before Operating INSTALLATION CHECKLIST Have you checked the mounted height of the air springs and is it correct?
Have the axle U-bolts been torqued per the specifi cation?
Have the beam pivot bolts been torqued per the specifi cation?
Was the suspension at ride height and even from side-to-side when the fasteners were torqued?
Have the upper bracket bolts been torqued per the specifi cation?
Was the axle centered in the chassis within 3/8”? Has the pan hard rod CAM bolt been torqued properly?
Have all remaining fasteners and fi ttings been torqued per the specifi cation?
Have the pinion angles been checked and are they within specifi cation?
Is there adequate clearance around all parts of the panhard bar?
Is there a minimum clearance of ½” around all parts of the air spring?
Has the system been leak checked and found to be free of leaks?
Are all wires and hoses routed correctly and away from heat sources?
Has the vehicle been road tested?
Has the owner been informed of the maintenance requirements?
Has the owner been informed of the operation of the system?
Does the owner have the correct instruction manual?
Technician’s Signature ______Date ______Vin # ______Milage______
MN-664 15 RoadTamer Troubleshooting Guide
Problem Possible Problem Check Procedure Solution Air System leaks. • leaky airbag • Spray air bag with a soapy • If leaking, replace air bag. • leaky pneumatic fittings water solution. • Tighten fittings. (i.e.: drain valve, Height • Spray fittings with a soapy • Repair or replace as Control Valve [HCV]) water solution. necessary. • cut or pinched air line • Conduct visual inspection. Vehicle is not level side- • OEM axle perch is not • Refer to Inspecting Axle • Add a 1˚ shim per the to-side within 3/8". level side-to-side. Spring Perch Uniformity in Inspecting Axle Spring Perch the manual. Uniformity section. Truck sits too low or too • Air spring mounting height • Measure the distance • Change the ride height as high. is not correct. between the upper and necessary to within lower air bag mounting specifications given in the surfaces. manual for rolling lobe mounting heights. Suspension rides rough. • Air bag is mounted too • Measure the mounted height. • Adjust mounted height as high or too low. necessary. • OE shocks are too stiff or • Bounce the rear of the truck. • Install Air Lift Select-A-Ride worn out. If there are more than two shocks. oscillations, the shocks are too worn. If less than two oscillations, shocks are too stiff. Rear end "jacks" when • Shocks are not compatible • Truck lurches when • Install Air Lift Select-A-Ride vehicle is accelerated. with air suspension. accelerating. shocks. Pneumatic Control System Problem Possible Problem Check Procedure Solution Compressor doesn't run. • blown fuse • Check fuse. • Replace fuse. • loose wire or ground • Inspect wiring connections. • Tighten loose wires or grounds. • bad pressure switch • Jumper pressure switch. • If compressor runs, replace switch. • If compressor does not run, replace compressor. Compressor runs all the • HCV or height sensor is • Check manual for mounting • Move HCV or height sensor time. mounted incorrectly. location and adjustment further towards the pivot instructions. bushing. • Bad pressure switch • Disconnect switch. • If compressor stops, replace switch. System will not kneel. • Stuck or clogged solenoid • Inspect the exhaust port or • Replace solenoid. energize the solenoid. • Damaged or improperly • Ensure that switch wiring is • Replace switch if found faulty. connected switch. correct by referencing the wiring diagram in the Smart- Air manual. SmartAir Control System Problem Possible Problem Check Procedure Solution Compressor doesn't run. • blown fuse • Check fuse. • Replace fuse. • loose wire or ground • Inspect wiring connections. • Tighten loose wires or grounds. • Relay/ECU • Ground terminals #85 if • If compressor runs, replace ECU compressor runs. • If compressor does not run, replace compressor. • Magnet to ECU distance • Magnet may be too close or • Refer to SmartAir manual for too far from ECU proper distance between magnet • Magnet not facing ECU and ECU • Magnet direction/180˚ off properly. • Make sure dot on magnet points towards the ECU Compressor runs all the • Possible major leak. • Check system for leaks. • Repair as necessary. time. System will not kneel. • Stuck or clogged solenoid • Inspect the exhaust port or • Replace solenoid. energize the solenoid. • Damaged or improperly • Ensure that switch wiring is • Replace switch if found faulty. connected switch. correct by referencing the wiring diagram in the Smart- Air manual.
16 MN-664 RoadTamer Maintenance and Servicing MAINTENANCE GUIDELINES NOTE By following the steps below, vehicle owners will obtain the longest life and best resultsfrom their air springs.
1. Fulfi ll all Installer Responsibilities: a. The installer is solely responsible for checking the installation for safe operation before the vehicle is placed in service. This includes all fastener torques. b. This instruction manual includes specifi cations for fastener torques. Tighten fastening hardware as instructed by the specifi cations. c. Retorque the fasteners in intervals as specifi ed below under “Servicing the RoadTamer System.” 2. If you develop an air leak in the system, use a soapy water solution to check all air line connections and the infl ation valve core before defl ating and removing the air spring. SERVICING THE ROADTAMER SYSTEM 1. At 150 miles and every 10,000 miles thereafter, check and retorque (per the fastener torques specifi ed in this manual). 2. Every 3,000 miles: a. Check the air spring install height. b. Check all fi ttings for air leaks and reseal if necessary. Warranty and Returns Policy Air Lift Company warranties its RoadTamer product against quality and workmanship defects to the original retail purchaser as follows; Main Structural components defi ned as; beams, brackets, and links for 24 months or 24,000 miles, whichever occurs fi rst. All other components for 12 months or 12,000 miles, whichever occurs fi rst. Air Lift Company provides no warranty on the vehicle’s original equipment or other aftermarket products. This warranty does not apply to products that have been improperly applied, installed, used in racing applications or maintained in accordance with installation instructions furnished with the product.
This warranty gives you specifi c legal rights and you may also have other rights that may vary from state to state. Some states do not allow limitations on how long an implied warranty lasts or allow the exclusion or limitation of incidental or consequential damages. The above limitation or exclusion may not apply to you. There are no warranties, expressed or implied including any implied warranties of merchantability and fi tness, which extend beyond this warranty period. There are no warranties that extend beyond the description on the face hereof. Seller disclaims the implied warranty of merchantability. Dated proof of purchase required.
A $10.00 minimum shipping and handling charge will apply to all warranty claims. Before returning any defective product, you must call Air Lift Company at (800) 248-0892 for a Returned Materials Authorization (RMA) number. Product failures resulting from abnormal use or misuse are excluded from this warranty. The loss of use of the product, loss of time, inconvenience, commercial loss, or consequential damages is not covered. The Air Lift Company reserves the right to change the design of any product without assuming any obligation to modify any product previously manufactured. Dated proof of purchase is required.
MN-664 17 RoadTamer Replacement Information If you need replacement parts, contact the local dealer or call Air Lift customer service at (800) 248-0892. Most parts are immediately available and can be shipped the same day. Contact Air Lift Company customer service at (800) 248-0892, fi rst if: • Parts are missing from the kit. • Need technical assistance on installation or operation. • Broken or defective parts in the kit. • Wrong parts in the kit. • Have a warranty claim or question. Contact the retailer where the kit was purchased: • If it is necessary to return or exchange the kit for any reason. • If there is a problem with shipping if shipped from the retailer. • If there is a problem with the price. Contact Information If you have any questions, comments or need technical assistance contact our customer service department by calling (800) 248-0892, Monday through Friday, 8 a.m. to 5 p.m. Eastern Time. For calls from outside the USA or Canada, our local number is (517) 322-2144.
For inquiries by mail, our address is PO Box 80167, Lansing, MI 48908-0167. Our shipping address for returns is 2727 Snow Road, Lansing, MI 48917.
You may also contact us anytime by e-mail at [email protected] or on the web at www.airliftcompany.com.
18 MN-664 Need Help? Contact our customer service department by calling (800) 248-0892, Monday through Friday, 8 a.m. to 5 p.m. Eastern Time. For calls from outside the USA or Canada, our local number is (517) 322-2144.
Register your warranty online at www.airliftcompany.com/warrantyreg.htm
Thank you for purchasing Air Lift products — the professional installer’s choice!
Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or PO Box 80167 • Lansing, MI 48908-0167 Toll Free (800) 248-0892 • Local (517) 322-2144 • Fax (517) 322-0240 • www.airliftcompany.com
Printed in the USA