Air Lift Performance ECR 6107, 39020 -15704, 39020, MN-564 User Manual

Please read these instructions completely

before proceeding with installation

Failure to read these instructions can result in mis-installation

Introduction to the RoadTamer System

What You Need to Know About RoadTamer ...................... 2

Vehicle Requirements ........................................................ 3

RoadTamer Warranty and Return Policy............................ 3

Installing the RoadTamer System

Getting Started ................................................................... 4

Inspecting Axle Spring Perch Uniformity ............................ 5

Attaching the Axle Beams .................................................. 5

Attaching the Frame Brackets ............................................ 6

Attaching and Adjusting the Panhard Rod.......................... 7

Hardware List ..................................................................... 9

*Kit Installation Diagram .................................................... 10

Installing the Rolling Lobe Air Sleeves .............................. 11

Installing the Air Lines ....................................................... 12

Reattaching the Brake Cables ........................................... 13

Final Adjustments .............................................................. 13

MN-564
(15704)

ECR 6107

by

Checking Driveline Angles

Checking Driveline Angles................................................. 14

Checking Angles in Various Conditions............................. 14

Chevy 3500 Kit No. 39020

Installation Checklist

Installation Checklist .......................................................... 15

Troubleshooting Guide

Troubleshooting Guide ...................................................... 16

Checking for Leaks ............................................................ 17

Fixing Leaks ...................................................................... 17

Maintaining and Servicing the System

Maintenance Guidelines .................................................... 18

Servicing the RoadTamer System ..................................... 18

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Ext. 2

1

What You Need to Know About RoadTamer

About RoadTamer

The RoadTamer suspension system and your
vehicle’s original equipment steel spring suspension
operate differently. RoadTamer allows your vehicle to
ride “on air.” It lowers air pressure for lighter loads,
meaning you will have a softer ride when you don’t
need the heavy factory springs.

RoadTamer lowers your vehicle to be approximately
level with the front suspension. The result is a vehicle
altitude very similar to that of a fully loaded vehicle.
The air management system then maintains that rear
suspension height regardless of the load you carry.

Ride Height

RoadTamer gives you optimum ride performance,
regardless of the load. RoadTamer’s air management
system will maintain the vehicle’s ride height within ½”.
You will enjoy a much more comfortable, controllable
and safer ride. The design of RoadTamer is carefully
considered to give you “The Ultimate Suspension

Upgrade.”

Vehicle Leveling, Side-to-Side

Vehicles are not always level when they are delivered
from the factory. Installing RoadTamer on your vehicle
does not correct this non-level condition. Before you
install RoadTamer, measure for vehicle levelness on
a fl at surface. After the factory springs have been
removed, use a level to verify that the axle spring
perches are level from side-to-side. If the perches
are not level, you will need to apply a wedge shim
to one side or the other to correct this condition. The
wedge shim is provided with each RoadTamer kit.
More information is provided later in the instruction
manual.

Install your RoadTamer kit and make sure the axle
is level and square with the vehicle frame. Snug, but
DO NOT TORQUE, all fasteners per the directions
provided in this installation manual. Check again to
see if the vehicle is level. If it is not close to as level
as its factory levelness, re-read the installation manual
concerning the use of the wedge shim. You may also
have to loosen all beam connecting bolts, u-bolts,
etc. Re-level the axle to the frame before re-torquing
all fasteners.

Introduction to the RoadTamer System

Driveline Angles

Driveline angles are factory-set to cancel vibrations
caused by the u-joints. RoadTamer takes this into
consideration when lowering the vehicle to a level
height. However, the factory does not set up all vehicles
to be identical. Many different axle, suspension, and
wheelbase combinations are possible. You will need to
measure the driveline angles and make a calculation
to verify that the driveline cancels correctly. See the
section Checking Driveline Angles toward the back of
the installation manual.

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2

Vehicle Requirements

Vehicle Type

Chevy 3500

NOTE:
spacer kit # 26029 (purchased seperately) in
addition to kit # 39020. If you do not already have
spacer kit # 26029, you can purchase it by calling
Air Lift’s Customer Service Department at 800-248­0892, extension 1.

For 4WD crew cab models, use driveshaft

Vehicle Years

See the application guide for specifi c years.

5th Wheel Hitch

The installation of this RoadTamer kit will fi t onto most
vehicles with a fi fth wheel hitch. Some fi fth wheel
hitches may require modifi cations to make the kit fi t
properly.

See page 5 for further instructions.

Muffl er Modifi cations

Modifi cations will need to be made to the muffl er after

the completion of this kit.

Gross Vehicle Weight Rating
(GVWR)

IMPORTANT: The installation of this kit does not
alter the GVWR or payload of the vehicle. Check
your vehicle 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.
It is GVWR minus the Base Curb Weight.

Introduction to the RoadTamer System

Air Lift Company recommends taking your vehicle
to a muffl er repair shop upon completion of the kit

installation.

RoadTamer Warranty and Return 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. 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 [phone] ext 2 for
an RGA (Returned Goods Authorization) 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.

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3

Getting Started

DANGER: Compressed air can cause injury and
damage to the vehicle and parts if it is not handled
properly. For your safety, do not try to infl ate the air
springs until they have been properly secured to the

vehicle.

No Load in Truck

Remove Wheel Remove Wheel

IMPORTANT: Measure and record the driveline angles
in the chassis as fi rst received (Figure 21).

1. Elevate the rear of the vehicle and secure the frame
with jack stands or a frame-contact hoist. Support
the axle (Figure 1).

2. Remove the spare tire, both leaf springs, and the
rear frame contact overload brackets, if equipped,
from the frame (Figure 2).

NOTE: It will be necessary to cut the driver side

bolt out of the spring retainer because of how
the gas tank is positioned. A replacement 16
mm bolt is supplied for reinstallation. Retain
the front spring eye bolt from the passenger side
and nuts for later use.

NOTE: It may be necessary to remove the trailer

hitch in order to remove the bolts from the spring
hanger.

NOTE: After removing the factory steel springs,

check the axle spring perches for side-to-side
angle uniformity. Refer to the Inspecting Axle
Spring Perch Uniformity section for information
on installing the supplied 1° wedge shim.

Support the axle with jack

stands and raise or lower

to Normal Ride Height.

Driver-Side View

REMOVE

Leaf Spring.

Driver-Side View

Figure 1

Axle

Figure 2

REMOVE Frame

Contact Overload

Upper Bracket

if equipped.

REMOVE

Spare Tire.

Installing the RoadTamer System

3. Cut off the tailpipe behind the muffl er and remove.
Leave enough room on the muffler to install a
replacement pipe (Figure 3).

4. Remove the bolts securing the brake cables to the
rear end (Figure 4).

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Axle

Top Rear End

Cover Bolt

Remove bolt and

discard bracket.

REMOVE

excess tailpipe.

Figure 3

Figure 4

CUT OFF tailpipe behind

muffler. Leave enough

room to attach a

replacement pipe.

Remove
Bolt

Driver Side
Emergency Brake Cable

4

Inspecting Axle Spring Perch Uniformity

1. After removing the factory steel springs, check
the axle spring perches for side-to-side angle
uniformity. Without disturbing the axle position,
place a magnetic angle protractor on one perch and
note the angle. Next, place the angle protractor on
the other perch and note the angle there as well.
A difference of less than 1° is normal and does
not require a shim. If the difference between the
two angles exceeds 1°, use the supplied 1° wedge

shim to correct the difference.

2. Place the 1° wedge shim on one axle spring perch
and re-measure the angles to verify that they equal
less than 1°. Use the centering pin to attach the
wedge to the correct beam and install the beams
as directed in the section titled Attaching the Axle
Beams. DO NOT TIGHTEN FASTENERS until you
have checked the driveline angles as instructed in

Attaching the Axle Beams

NOTE: For 4WD crew cab models, refer to the
manual provided with the driveshaft spacer kit
# 26029 (purchased seperately) at this time. You
must have this spacer kit before proceeding. If you
do not already have spacer kit # 26029, you can
purchase it by calling Air Lift’s Customer Service
Department at 800-248-0892, extension 1.

1. Attach the centering pins through each beam with
the round head facing down. Tighten the centering
pin nut securely (Figure 5).

the section dealing with that topic toward the back of
this manual.

NOTE: You must check the driveline angles for

cancellation before completing the installation
(see the Driveline Angles section toward the back
of the manual). It may be necessary to reverse the
shim and place it on the opposite side to maintain
correct driveline angles.

3. Measure from the top of each frame rail (at the rear of
the frame) to the ground. The measurement must be
made at vehicle ride height with the vehicle on level
ground and with equal tire pressures. The vehicle
levelness is acceptable if the two measurements from
side-to-side are within 3/8”. If the vehicle is not level
within 3/8”, check that the 1° shim is placed properly.

For 4WD crew cab models, refer to the manual
provided with the driveshaft spacer kit # 26029
(purchased seperately) at this time. You must
have this spacer kit before proceeding. If you
do not already have spacer kit # 26029, you can
purchase it by calling Air Lift’s Customer Service
Department at 800-248-0892, extension 1.

Driver-Side Shown

Stock Spring

Retainer

Centering

Pin

Beam

Installing the RoadTamer System

2. Attach the driver-side beam assembly to the front
spring eye hanger using the supplied 16 mm bolt
(stock bolt on passenger side) and washer and the
previously removed stock nut (Figure 5). Be sure
to index the centering pin into the spring perch in
order to properly locate the axle and the beam.
Leave loose.

NOTE: The emergency brake cable should go

over the beam assembly.

3. Attach the beam assemblies to the axle with the
hardware shown in Figure 5. Secure snugly, but
do not completely tighten at this time.

NOTE: It will be necessary to use the stock

spring retainer between the u-bolts and the
beams.

NOTE: Draw the nuts down evenly on the

retainer by using a criss-cross tightening
pattern.

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Ext. 2

U-bolt

A 16mm bolt and washer
are supplied for the driver
side only. Use the stock
bolt on the passenger side.

Figure 5

Axle

5

/8"

Flat

Washer

5

/8" Nut

5

Attaching the Frame Brackets

1. Install the driver-side frame bracket. Line up the
lower crossmember rivet with the lower, forward
hole in the upper bracket. Clamp the bottom of the
fl ange on the bracket to the frame fl ange using vise
grips or welding clamps.

2. a) If there are existing holes:

Line up the upper bracket holes with the

existing contact overload bracket holes in the
frame (Figure 6). Attach the bracket to the
frame with four ½” bolts, eight washers and
four nyloc nuts. Leave loose at this time.

b) If there are NO existing holes:

Drill a ½” hole using the upper bracket as a

template. Attach the bracket with one ½”
bolt, two fl at washers and one nyloc nut.
Tighten just until snug. Do not overtighten.

3. Drill two ½” holes through the frame fl ange using the
top hole in the bracket as a template. Attach the
upper bracket using two ½” bolts, four fl at washers
and two nyloc nuts. Tighten just until snug. Do not
overtighten.

Existing Frame Contact

Overload Holes

(If not equipped,

drill out to ½")

Cross Member Rivets

FORWARD

Driver-Side Shown

Figure 6

½" Flat Washer

½" Bolt

Frame

Trailer Hitch

Installing the RoadTamer System

4. Drill the remaining holes through the side, if needed,
using the bracket holes as a template. Attach the
remaining ½” hardware shown in Figure 7, starting
with the bottom ½” bolts. Torque all hardware to 107
ft.lbs.

5. Repeat steps 1-4 for the passenger side.

6. Reinstall the spare tire.

Cross member rivet

must be in forward

hole in upper bracket.

FORWARD

Frame

Trailer Hitch

½" Flat Washer

½" Bolt

Driver-Side Shown

Figure 7

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6

Attaching and Adjusting the Panhard Rod

1. Attach the panhard rod bracket to the driver side
frame. Use the oval hole in the side of the frame
shown in Figure 8 as your starting point. Insert a ½”
bolt through a fl at washer, the bracket, the frame, a
large fl at washer and a nyloc nut. Push the bracket
to the rear as far as possible and clamp both the
frame and bracket fl ange together (Figure 9).

2. Drill out the remaining holes, even through the frame
fl ange, to ½” (Figure 8, Figure 9). Attach with three
more ½” bolts, six fl at washers and three nyloc nuts
(Figure 10). Starting with the bottom fl ange, tighten
all hardware to 107 ft.lbs.

3. Attach the panhard rod assembly to the panhard rod

9

bracket to the frame rail using one

/16” bolt, two fl at

washers and one nyloc nut (Figure 10). Leave loose
at this time.

NOTE: Insert the bolt front-to-rear so the nyloc

nut is in the back towards the rear of the vehicle
(Figure 10).

Driver-Side View

Existing
Oval Hole
in Side of
Frame

Drill out ½" holes in

frame using the

bracket as a template.

Panhard Rod

Bracket

(Front View)

REAR

Figure 8

Inner View of Frame Flange

Frame

Installing the RoadTamer System

Drill out a ½" hole in the

frame flange using the

bracket as a template.

Figure 9

Driver-Side View

Inner View of Frame Flange Outer View of Frame

½" Washer

½" Nut

½" Washer

½" Nut

½" Bolt

2.5" Washer

Panhard Rod

Bracket

(Back View)

Figure 10

½" Bolt

Existing

Oval Hole
in Side of
Frame

9

/16" Bolt

Panhard Rod

Bracket

(Front View)

½" Washer

Panhard

Rod

9

/16" Washer

REAR

9

/16" Nut

Panhard Rod

Bracket

(Back View)

Frame

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7

Attaching and Adjusting the Panhard Rod

4. Raise or lower the axle to create a space of 12.5
inches between the rolling lobe upper and lower
mounting brackets (Figure 14). Adjust the heim,
using a pry bar if necessary, so both passenger­side and driver-side beam-to-frame distances are
equal.

CAUTION: There must be no more than 1½” of

thread showing on the heim joint (Figure 11).

5. Attach the heim to the passenger side beam
assembly. Refer to Figure 12 for an installation
diagram. Tighten both ends of the panhard rod
securely. Turn the heim joint so the cage is parallel
with the bracket to prevent suspension travel from
interfering. Tighten the jam nut on the heim.

CAUTION: The panhard rod heim joint jam nut

must be torqued to 150 ft/lbs and the heim must
be lubricated.

6. Refer to Figure 21 and the Checking Driveline Angles
section at this time. If angles are acceptable, proceed
with torquing the U-bolts and pivot bolts.

Flat Washer

No more than 1½" of thread

showing on heim joint

Bottom View Passenger-Side

¾"

¾" Bolt

0-1½"

Figure 11

¾"

Jam Nut

Installing the RoadTamer System

¾"

Flat Washer

¾" Nut

7. Tighten the beam U-bolts to 170 ft/lbs. using a criss­cross pattern to tighten evenly (Figure 13). Using a
hacksaw, grinder, or cut-off wheel, trim off the excess
U-bolt so it is 1” above the retaining nuts. Torque
the front stock beam pivot bolts to 110 ft/lbs.

1

4

Criss-Cross Tightening Pattern:

Tighten 1 until snug. Then tighten 2, 3
and 4, in that order, until snug but not
tight. Continue tightening in increments
following the same pattern until all U-bolt
nuts are torqued to 170 ft./lbs.

3

Bottom View

of

U-Bolt Bracket

2

¾" Spacers

Beam Assembly

Figure 12

Axle

Torque to 170 ft/lbs.

Figure 13

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8

Hardware List

Hardware List

Item Part No. Description Quantity

A 26537 Driver-Side Beam Assembly 1
B 26454 Passenger-Side Beam Assembly 1
C 26332 Panhard Rod Assembly 1
D 07003 Frame Bracket 2
E 10046 Panhard Rod Bracket 1
F 10565
G 10466 8” Zip Tie 6
H 18405
I 18411
J 21230 Poly Cap 2
K 21233 Hex Nut 4
L 21234 Rubber Washer 2
M 18509 1.25” Flat Washer 8
N 18508
O 20086 Air Line Assembly 16 ft.
P 18451 ¾”-16 Jam Nut 2
Q 18484 ½”-20 Hex Nut 4
R 18429 ½” Lock Washer 4
S 17219 9/16”-12 x 5 Bolt 1
T 18485 ½” Flat Washer 26
U 18480 9/16”-12 Nyloc Nut 1
V 13227 ¾” x 1/2” Spacer 2
W 17269 ¾”-16 x 4 Bolt 1
X 18518 ¾” Flat Washer 2
Y 18470 ¾”-16 Nyloc Nut 1
Z 58226 Rolling Lobe Sleeve 2
AA 18011 M16 Flat Washer 1
BB 17290 M16-2 x 120 Bolt 1
CC 10008 2.5” x 9/16” x .19” Flat Washer 1
DD 17247 ½”-13 x 1.75 Bolt 16
EE 18460 ½”-13 Nylock Nut 16
FF 26333 Frame Clamp 1
KK 21745 ¼” x ¼” Male Connector 2
LL 17294 Centering Pin 2
MM 26393 Double Tube Clamp 1
LL 18246
25435 Automatic Leveling System 1
10439 1° Wedge Shim 1

5

/8”-18 x10.25” U-Bolt 4

5

/16” Flat Washer 2

5

/8” Lock Washer 2

5

/8”-18 x .85 Nut 8

5

/8”-18 Jam Nut 1

Installing the RoadTamer System

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Ext. 2

9

Kit Diagram

Z

D

EE

NOTE: The beams in this image may appear

different from the beams supplied with this kit.

EE

T

EE

CC

R

Q

T

T

DD

B

W

X

P

X

Y

C

DD

T

N

M

D

DD

T

Q

R

KK

P

S

T

E

R

Q

A

Installing the RoadTamer System

O.E.M.

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Ext. 2

DD

F

O.E.M.

Stock Spring Retainer

AA

BB

MM

NN

N

M

LL

10

Installing the Rolling Lobe Air Sleeves

Refer to Figure 14 for the following instructions.

1. Install the fi tting into the large top stud of the rolling
lobe air sleeve. Tighten the fi tting fi nger-tight plus

1

/2 turns, being careful to tighten on the metal hex

1
nut only.

NOTE: It may be necessary to raise the chassis

to provide adequate space to install the rolling
lobe air sleeves.

2. Insert the bottom studs of both rolling lobe air sleeves
into the lower mounting hole of the beam assemblies
on both sides of the vehicle. Attach fi nger-tight using
a ½” lock washer and nut.

3. Lower the frame while guiding both top studs on
the rolling lobe air sleeves through the holes in the
upper mounting bracket.

4. Attach the air sleeves using a ¾” jam nut on the large
stud. Use a lock washer and ½” nut on the smaller
stud. Tighten the top mounts securely. Leave the
bottom loose at this time.

Installing the RoadTamer System

Lock

Washer

½" Nut

Inside of Beam

GUIDE rolling lobe bottom stud through

hole in center of beam. Attach with

hardware shown.

Driver-Side View

¾" Jam Nut

Large

Stud

Beam

Air Fitting

GUIDE rolling lobe top studs through

holes in upper mounting bracket

while lowering frame. Attach

½" Nut

Lock Washer

Small

Stud

Raise or lower axle to create

between mounting brackets.

with hardware shown.

Figure 14

12.5"

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11

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.

5

2. Drill a

/16 “ hole to install the infl ation valves.

Air Line Cutting

3. Cut the air line assembly in two equal lengths.

CAUTION: When cutting or trimming the air line,

use a razor blade or a very 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 fl atten or crimp
the air line, causing it to leak around the O-ring
seal inside the elbow fi tting (Figure 15).

4. Refer to Figure 16 to assist with air valve
installation.

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 (Figure

17). 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).

Good Cut

Flat
Washer

Valve

Cap

Exhaust Pipes

Air
Lines

Figure 15

Vehicle body

or bumper

Rubber

Washer

Hex Nut

Figure 16

Keep air lines
secured at least 6"
away from all
heat sources

Frame Rail

Installing the RoadTamer System

Poor Cut

Air Line to

Bellows

Hex Nut

Star

Washer

Muffler

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Tie Straps

Figure 17

12

Reattaching the Brake Cables

1. Reattach the passenger side emergency brake cable
to the top of the rear end using the new hanger
supplied and the stock rear end cover bolt. Tighten
securely (Figure 18).

Stock Bolt

New Supplied Brake

Cable Bracket

Figure 18

2. Reattach the driver side brake line to the shock
bracket using the existing hardware. Attach the
driver-side emergency brake cable to the inside,
rear U-bolt using the double tube clamp and the
supplied 5/8” - 18 jam nut (Figure 19).

Installing the RoadTamer System

Figure 19

Final Adjustments

1. Infl ate both rolling lobe air sleeves to 20 p.s.i and

check for leaks.

2. Tighten both bottom rolling lobe mounts securely
at this time. Torque to 50 ft/lbs.

3. An Air Lift SmartAir system must be installed with this
kit. Follow the instructions in the SmartAir manual
to install the system. Once the SmartAir system is
installed it will automatically maintain the rolling lobe
air springs’ installed height of 12 - 13 inches within
their mounts (Figure 20).

4. Routing the exhaust out of the side of the vehicle
in front of the rear wheel on the passenger side is
recommended.

NOTE: It may be necessary to have a custom-bent

pipe made if routing the exhaust out the back
behind the rear wheels is desired.

5. IMPORTANT: Check and re-torque all mounting
hardware, especially the beam U-bolts, after 150
miles and every 10,000 miles.

Driver-Side Shown

12 - 13 inches

Keep a distance of 12 - 13

inches for operation of vehicle.

Figure 20

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13

Checking Driveline Angles

1. After the RoadTamer kit is installed, the following
conditions must be true for the driveline angles, both
at unloaded and fully loaded ride heights:

a. Condition #1: The operating angle at any individual

joint must be between 0.1° and 4°. The preferred
maximum angle is 2°.

b. Condition #2: When added together, the

operating angles throughout the driveline MUST
cancel. The operating angles at either end of a shaft
should be within 1° of each other or at least satisfy
the following formula in order to provide adequate
cancellation (Figure 21).

angle-a

2. Wedge shims may be placed between the beams
and axle to correct driveline angles that fall
outside this requirement. Re-check all driveline
angles after installing the shims.

3. A minimum operating angle of 0.1° at each
universal joint is required to prevent dents from
forming on the bearing surfaces.

Checking Driveline Angles

DRIVESHAFT

angle-b

SIDE VIEW

For a 3-joint, 2-shaft driveline:

(as shown above)

Figure 21

Checking Angles in Various Conditions

1. Measure and record the driveline angles in each of
the following conditions for later comparison:

a. The chassis as fi rst received (note that the driveline

angles may not conform exactly to this bulletin in this
incomplete condition).

b. The completed vehicle, unloaded.

c. The completed vehicle loaded to Gross Vehicle

Weight Rating (GVWR) with maximum front
Gross Axle Weight Requirement (GAWR).

d. The completed vehicle loaded to GVWR with

maximum rear GAWR.

angle-c

22 2

a - b + c 4.0˚

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14

Installation Checklist

This Installation Checklist must be completely fi lled out to ensure proper installation:

o Have you checked the mounted height of the air springs and is it correct?
o Have the axle U-bolts been torqued per the specifi cation?
o Have the beam pivot bolts been torqued per the specifi cation?
o Was the suspension at ride height and even from side-to-side

when the fasteners were torqued?

RoadTamer Installation Checklist

o Have the upper bracket bolts been torqued per the specifi cation?
o Does the heim joint have the proper amount of thread showing?
o Have you tightened the heim joint jam nut?
o Was the axle centered in the chassis within

3

/8”?

o Have all remaining fasteners and fi ttings been torqued per the specifi ca-

tion?

o Have the pinion angles been checked and are they within specifi cation?
o Has the panhard bar heim joint been properly greased?
o Is there adequate clearance around all parts of the panhard bar?
o Is there a minimum clearance of ½” around all parts of the air spring?
o Has the system been leak checked and found free of leaks?
o Are all wires and hoses routed correctly and away from heat sources?
o Has the vehicle been road tested?
o Has the owner been informed of the maintenance requirements?
o Has the owner been informed of the operation of the system?
o Does the owner have the correct instruction manual?

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Troubleshooting Guide

Problem Possible Problem Check Procedure Solution

Air System leaks.

Vehicle is not level side­to-side within 3/8".

Truck sits too low or too
high.

Suspension rides rough.

Rear end "jacks" when
vehicle is accelerated.

Pneumatic Control System

Problem

Compressor doesn't run.

Compressor runs all the
time.

System will not kneel.

SmartAir Control System

Problem

Compressor doesn't run.

Compressor runs all the
time.

System will not kneel.

• leaky airbag

• leaky pneumatic fittings
(i.e.: drain valve, Height
Control Valve [HCV])

• cut or pinched air line

• OEM axle perch is not
level side-to-side.

• Air spring mounting height
is not correct.

• Air bag is mounted too
high or too low.

• OE shocks are too stiff or
worn out.

• Shocks are not compatible
with air suspension.

• Spray air bag with a soapy
water solution.

• Spray fittings with a soapy
water solution.

• Conduct visual inspection.

• Refer to Inspecting Axle
Spring Perch Uniformity in
the manual.

• Measure the distance
between the upper and
lower air bag mounting
surfaces.

• Measure the mounted height.

• Bounce the rear of the truck.
If there are more than two
oscillations, the shocks are
too worn. If less than two
oscillations, shocks are too stiff.

• Truck lurches when
accelerating.

Possible Problem Check Procedure Solution

• blown fuse

• loose wire or ground

• bad pressure switch

• HCV or height sensor is
mounted incorrectly.

• Bad pressure switch

• Stuck or clogged solenoid

• Damaged or improperly
connected switch.

• Check fuse.

• Inspect wiring connections.

• Jumper pressure switch.

• Check manual for mounting
location and adjustment
instructions.

• Disconnect switch.

• Inspect the exhaust port or
energize the solenoid.

• Ensure that switch wiring is
correct by referencing the
wiring diagram in the Smart­Air manual.

Possible Problem Check Procedure Solution

• blown fuse

• loose wire or ground

• Relay/ECU

• Magnet to ECU distance

• Magnet direction/180˚ off

• Possible major leak. • Check system for leaks.

• Stuck or clogged solenoid

• Damaged or improperly
connected switch.

• Check fuse.

• Inspect wiring connections.

• Ground terminals #85 if
compressor runs.

• Magnet may be too close or
too far from ECU

• Magnet not facing ECU
properly.

• Inspect the exhaust port or
energize the solenoid.

• Ensure that switch wiring is
correct by referencing the
wiring diagram in the Smart­Air manual.

• If leaking, replace air bag.

• Tighten fittings.

• Repair or replace as
necessary.

• Add a 1˚ shim per the

Inspecting Axle Spring Perch
Uniformity section.

• Change the ride height as
necessary to within
specifications given in the
manual for rolling lobe
mounting heights.

• Adjust mounted height as
necessary.

• Install Air Lift Select-A-Ride
shocks.

• Install Air Lift Select-A-Ride
shocks.

• Replace fuse.

• Tighten loose wires or grounds.

• If compressor runs, replace
switch.

• If compressor does not run,
replace compressor.

• Move HCV or height sensor
further towards the pivot
bushing.

• If compressor stops, replace
switch.

• Replace solenoid.

• Replace switch if found faulty.

• Replace fuse.

• Tighten loose wires or grounds.

• If compressor runs, replace ECU

• If compressor does not run,
replace compressor.

• Refer to SmartAir manual for
proper distance between magnet
and ECU

• Make sure dot on magnet
points towards the ECU

• Repair as necessary.

• Replace solenoid.

• Replace switch if found faulty.

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Checking for Leaks

1. Spray all connections and the infl ation valves with
a solution of
check for leaks. You should be able to spot leaks
easily by looking for bubbles in the soapy water.

2. After the test, defl ate the springs to the minimum
pressure required to restore the Normal Ride
Height, but not less than 10 p.s.i.

1

/5 liquid dish soap and 4/5 water to

Fixing Leaks

1. If there is a problem with the air fi tting:

a. Check the air line connection by defl ating the

spring and removing the line by pulling the
collar against the fi tting and pulling fi rmly on
the air line. Trim 1” off the end of the air line.
Be sure the cut is clean and square. Reinsert

Minimum Air Pressure

the air line into the push-to-connect fi tting.

b. Check the threaded connection by tightening

the swivel fi tting another 1/2 turn. If it still leaks,
defl ate the air spring, remove the fi tting, and re-
coat the threads with thread sealant. Reinstall
by hand tightening as much as possible, then
use a wrench for an additional two turns.

3. IMPORTANT: Check the air pressure again

after 24 hours. A 2 to 4 p.s.i. loss after initial
installation is normal. Retest for leaks if the
loss is more than 5 lbs.

2. If there is a problem with the infl ation valve:

a. Check the valve core by tightening it with a valve

core tool.

b. Check the air line connection by removing the

air line from the barbed fi tting. CAUTION: Do

not cut it off. This will usually nick the barb
and render the fi tting useless. Cut air line off

a few inches in front of the fi tting and use a pair
of pliers or vise-grips to pull/twist the air line off
the fi tting.

3. If the preceding steps have not resolved the problem,
call Air Lift Technical Service at 1-800-248-0892 for
assistance.

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Maintenance Guidelines

By following the steps below, vehicle owners will obtain the longest life and best results
from their air springs.

1. Fulfi ll all Installer Responsibilities:

The installer is solely responsible for checking the

installation for safe operation before the vehicle
is placed in service. This includes all fastener
torques, proper control system operation, and
driveline angles.

This instruction manual includes specifi cations for

fastener torques. Tighten fastening hardware as
instructed by the specifi cations.

Retorque the fasteners in intervals as specifi ed

Check driveline angles as shown in the section titled

2. If you develop an air leak in the system, use a soapy

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): the beam front hardware
and pivot bolts, the axle U-bolts, and the panhard
rod pivot bolts.

2. Every 3,000 miles:

Check the air spring install height and adjust the

height control valve as necessary.

Check all fittings for air leaks and reseal if

necessary.

Grease the panhard rod end fi tting.

Check the compressor air fi lter and replace as

3. Perform DAILY maintenance by releasing the

below under “Servicing the RoadTamer System.”

“Checking Driveline Angles.”

water solution to check all air line connections
and the infl ation valve core before defl ating and
removing the air spring.

necessary.

moisture from the air tank. To do this, pull on the
release cable attached to the drain valve. Excess
moisture in the system can lead to component
failure or freeze up in cold weather.

Maintaining and Servicing the System

Thank you for purchasing Air Lift Products

Mailing Address: Street Address:
AIR LIFT COMPANY AIR LIFT COMPANY
P.O. Box 80167 2727 Snow Rd.
Lansing, MI 48908-0167 Lansing, MI 48917

Local Phone: [phone]

Fax: [phone]

www.airliftcompany.com

For Technical Assistance call 1-800-248-0892

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