INSTALLATION INSTRUCTIONS
2101
WARNING:
Do not inflate this assembly when it is unrestricted.
The assembly must be restricted by the suspension
or other adequate structure. Do not inflate beyond
100 P.S.I. Improper use or over inflation may cause
property damage or severe personal injury.
Congratulations - your new Air Helper Springs are quality
products capable of improving the handling and comfort of your
vehicle. As with all products, proper installation is the key to
obtaining all of the benefits your kit is capable of delivering.
Please take a few minutes to read through the instructions to
identify the components and learn where and how they are used.
It is a good idea to start by comparing the parts in your kit with
the parts list below.
The heart of the air helper spring kit is, of course, the air
helper springs. Remember that the air helper springs must flex
and expand during operation, so be sure that there is enough
clearance to do so without rubbing against any other part of the
vehicle.
Be sure to take all applicable safety precautions during the
installation of the kit. The instructions listed in this brochure
and the illustrations all show the left, or driver’s side of the
vehicle. To install the right side assembly simply follow the same
procedures.
PARTS LIST
Your kit includes separate inflation valves and air lines for
each air helper spring. This will allow you to level your vehicle
from side to side as well as from front to back. If you would rather
have a single valve inflation system, your dealer can supply the
required "T" fitting.
IMPORTANT!
For your safety and to prevent possible damage to your
vehicle, do not exceed the maximum load recommended by the
vehicle manufacturer (GVWR). Although your Air Helper
Springs are rated at a maximum inflation pressure of 100 P.S.I.,
this pressure may allow you to carry too great a load on some
vehicles. Check your vehicle owner’s manual for maximum
loads listed for your vehicle.
When inflating your Air Helper Springs, add air pressure
in small quantities, checking pressure frequently during
inflation. The air spring requires much less air volume than
a tire and, therefore, inflates much quicker.
267C AIR SPRING 6781 2
UPPER BRACKET (RIGHT) 5157 1
UPPER BRACKET (LEFT) 5158 1
LOWER BRACKET 5159 2
AXLE STRAP 1163 2
HEAT SHIELD 1004 1
3/8" -16 x 1" HEX BOLT 4
3/8" -16" x 3" CARRIAGE BOLT 4
3/8" -16 FLANGED LOCK NUT 1 2
3/8" -16 x 3/4" HEX BOLT 2
1/4" -20 x 1" HEX BOLT 2
1/4" FLAT WASHER 4
21-8156 12-03 NCD-5988-2
3/8" LARGE FLAT WASHER 4
1/4" LOCK WASHER 2
1/4" HEX NUT 2
PUSH-TO-CONNECT
MALE AIR FITTING 3046 2
PUSH-TO-CONNECT
INFLATION VALVE 3032 2
5/16" FLAT WASHER 4
AIR LINE TUBING 1
NYLON TIE 6
THERMAL SLEEVE 2
2101
KIT ASSEMBLY
FIGURE "A"
NOTE: Both illustrations are of the left, or drivers
side, of the vehicle. Reverse any orientations when
assembling and installing the right, or passenger, side
of the vehicle.
1/4” -20 x 1”
HEX BOLT
1/4” FLAT
WASHER
3/8” -16
FLANGED
HEX NUT
3/8” LARGE
WASHER
(SEE NOTE 1)
KIT TO FRAME ASSEMBLY
FRAME
1/4” FLAT
WASHER
1/4” LOCK
WASHER
1/4” -20
HEX NUT
3/8” LARGE
WASHER
(SEE NOTE 1)
AIR LINE
3/8” -16”
FLANGED
HEX NUT
UPPER BRACKET
AIR SPRING
3/8” -16
FLANGED
HEX NUT
FITTING
AIR
USE THIS HOLE
FOR 2WD
VEHICLES
USE THIS
HOLE FOR
4WD VEHICLES
3/8” -16 x 3”
CARRIAGE BOLT
WHEEL
3/8” -16 x 1”
HEX BOLT
AXLE STRAP
FRONT
3/8” -16 x 3”
CARRIAGE
BOLT
3/8” -16 x 1”
HEX BOLT
LEAF STACK
AXLE
LOWER
BRACKET
3/8” -16 x 3/4”
HEX BOLT
NOTE 1:
Use 3/8 large flat washer
between upper bracket and
frame rail only if rivet head is
present on bottom of frame.
Rivet head will prevent flush
mounting of the upper bracket
to the frame rail.
3/8” -16
FLANGED LOCK NUT
TWO-WHEEL
DRIVE VEHICLES
FIGURE "B"
SOME FOUR-WHEEL
DRIVE VEHICLES MAY
HAVE BOLTS, OTHERS
WILL HAVE RIVETS
FIGURE "C"
STEP 1 - PREPARE THE VEHICLE
Remove the positive battery cable. With the vehicle on a solid, level surface
chock the front wheels. Raise the vehicle by the axle and remove the rear wheels.
After the removal of the wheels lower the vehicle so the axle rests on jack stands
rated for your vehicles weight.
This installation assumes that there is no load in the truck.
NOTE:
This kit is designed to fit both two-wheel and four-wheel drive vehicles. The
jounce bumper and brackets must be removed for installation of this kit. The
jounce bumper and bracket on the two-wheel drive can be unbolted and removed
see Figure "B". The jounce bumper and bracket on the four-wheel drive may be
bolted or riveted in place, depending on model year. Simply unbolt the jounce
bumper bracket and remove from the frame see Figure "C". On older models,
remove the jounce bumper by drilling out two rivets that fasten the bracket to the
frame. Complete the removal by cutting off the heads with a cold chisel. The
completion of the kit installation is the same for the two-wheel and four-wheel
drive.
STEP 2 - PRE-ASSEMBLE THE KIT
This kit is supplied with a right and left upper bracket. Begin by installing the
left (driver's side) upper bracket. This bracket will have the "over-bent tab" see
Figure "D". The lower bracket is the same for both sides. Align the studs on the
top of one of the air springs with the mounting holes in the upper bracket while
ensuring that the air hole is visible through the slot in the upper bracket. Insert
the studs into the holes and secure the air spring to the upper bracket with 3/8"
-16 flanged lock nuts see Figure "A". Next, install the male push-to-connect air
fitting in the air inflation hole. Tighten the air fitting securely to engage the orange
thread sealant.
To attach the lower bracket to the air spring, first position the bracket on the
axle housing over the jounce pad see Figures "A" & "E". Position the bracket so
that the narrow end is toward the center of the vehicle. The air spring must be
secured to the lower bracket through the forward hole. Once the correct mounting
hole for the lower bracket has been identified, remove the bracket from the axle and
fasten to the air spring using a 3/8" -16 x 3/4" hex bolt (finger tight). Note that
this bolt will be tightened in Step 3.
FRONT
OVER-BENT
VIEW OF DRIVER’S SIDE ASSEMBLY
FROM INSIDE OF VEHICLE
FIGURE "D"
UPPER BRACKET
LEAF
STACK
DRIVER'S SIDE
FRONT
SHOCK
BRACKET
BRACKET STRAP
FIGURE "E"
TAB
FRAME RAIL
AIR SPRING
LOWER BRACKET
AXLE
BRAKE LINE
STEP 3 - INSTALL THE ASSEMBLY TO THE VEHICLE
Set the assembly in place on the axle housing over the jounce pad. The lower
bracket should butt against the U-bolts on the leaf spring see Figure "E". Position
the assembly so that the upper bracket is aligned vertically against the outside
surface of the frame rail.
On some vehicles there may be a rivet head on the bottom of the bottom surface
of the frame rail that will prevent the upper bracket from being mounted flush
against the frame. To assure that the upper bracket clears the rivet head, install
four large flat washers between the upper bracket and the bottom surface of the
frame rail see Figure "A". Installation of the flat washers is only necessary if your
vehicle has a rivet head on the bottom of the frame rail. Insert a 1/4" -20 x 1" bolt
through the vertical tab of the upper bracket and an existing hole in the frame rail.
Secure with washers and a nut see Figure "A". On some models, a hole must be
drilled in the frame rail for the bolt to pass through. Using the upper bracket as
a template, drill a 5/16" hole though the frame rail. Make sure that all electrical,
brake, and fuel lines are cleared from the path of the drill.
The tabs on the bracket will be secured to the lower frame flange using 3/8"
flanged lock nuts and 3/8"-16 x 1" hex bolts see Figure "A". Note: on the driver's
side of the vehicle the 1/4" bolt will also hold a clip (on some models) used to
hold brake and fuel lines. Secure the clip to the 1/4" bolt to secure the lines.
Align the lower bracket against the U-bolts over the leaf spring stack see
Figure "E". After the bracket has been squared with the U-bolts, tighten the
3/8" hex bolt to secure the lower bracket to the air spring. Next, insert two
3/8" -16 x 3" carriage bolts into the square holes on the lower bracket. Install one
axle strap on the bottom of the axle housing see Figure "A". Slide the axle strap
on to the carriage bolts and secure with 3/8" -16 flanged lock nuts. This installation
will hold the lower bracket in place. Note: When installing the left-side assembly,
it will be necessary to tie the parking brake line to the sway bar to prevent it from
contacting the air spring in normal operation. There must be at leat 1/2" of
clearance between the inflated air spring and any other part of the vehicle.
HEAT SHIELD
STEP 4 - INSTALL THE PASSENGER'S SIDE ASSEMBLY
Follow steps 1 - 4 for assembly and installation of the passenger's side
assembly. On the passenger's side it will be necessary to install a heat shield
between the upper bracket and the air spring to protect the air spring from the
exhaust pipe heat see Figure "F". Position the heat shield so that it will reflect
radiant heat from the point on the exhaust pipe closest to the air spring. The heat
shield should be positioned so that it does not contact the axle housing as the
FIGURE "F"
suspension compresses.
STEP 5 - INSTALL THE AIR LINE AND THE INFLATION VALVE
Uncoil the air line tubing and cut it into two equal lengths. DO NOT FOLD
AIR
SPRINGS
AIR HOSE
OR KINK THE TUBING. Try to make the cut as square as possible. Insert one
end of the tubing into the air fitting installed in the top of the air helper spring. Push
the tubing into the fitting as far as possible.
Select a location on the vehicle for the air inflation valves. The location can
be on the bumper or the body of the vehicle, as long as it is in a protected location
so the valve will not be damaged, but maintain accessibility for the air chuck see
Figure "G". Drill a 5/16" hole and install the air inflation valve using two 5/16"
flat washers per valve as supports see Figure "H". Run the tubing from the air
helper spring to the inflation valve, routing it to avoid direct heat from the exhaust
pipe and away from sharp edges. Thermal sleeves have been provided for these
conditions. If a thermal sleeve is required simply slide the sleeve over the air line
tubing to the location requiring protection. The air line tubing should not be bent
BUMPER
FIGURE "G"
INFLATION
VALVES
or curved sharply as it may buckle. Secure the tubing in place with the nylon ties
AIR LINE
FLAT WASHER
provided. Push the end of the air line tubing into the inflation valve as illustrated
see Figure "H".
STEP 6 - CHECK THE AIR SYSTEM
PUSH-TO-CONNECT
INFLATION VALVE
BODY OF
VEHICLE
HEX NUT
VALVE CAP
FIGURE "H"
tubing and reinflate the air springs and check for leaks as noted above.
This now completes the installation. Install the wheels and torque the lug nuts to the manufactures specifications. Raise the
vehicle by the rear axle and remove the jack stands and lower the vehicle back onto the ground. Re-attach the positive battery
cable and remove the wheel chocks from the wheels. Before proceeding, check once again to be sure you have proper clearance
around the air springs. With a load on your vehicle and the air helper springs inflated, you must have at least 1/2" clearance around
the air springs. As a general rule, the air helper springs will support approximately 50 lbs. of load for each P.S.I. of inflation pressure
(per pair). For example, 50 P.S.I. of inflation pressure will support a load of 2500 lbs. per pair of air helper springs. FOR BEST RIDE
use only enough air pressure in the air helper springs to level the vehicle when viewed from the side (front to rear). This amount
will vary depending on the load, location of load, condition of existing suspension and personal preference.
Once the inflation valves are installed inflate the air helper springs to 70 P.S.I.
and check the fittings for air leaks with an applied solution of soap and water. If
a leak is detected at a tubing connection, check to make sure that the tube is cut
as square as possible and that it is pushed completely into the fitting. The tubing
can easily be removed from the fitting by first releasing the pressure from the air
spring, then by pushing the collar towards the body of the fitting and then pulling
out the tube. If a leak is detected where the air fitting screws into the spring, release
the air pressure, then remove the tubing as described above, then screw the brass
fitting into the air spring one additional turn or until the leak stops. Reinstall the
NOTE:
Too much air pressure in the air helper springs will result in a firmer ride, while too little air pressure will allow the air helper
spring to bottom out over rough conditions. Too little air pressure will also not provide the possible improvement in handling.
TO PREVENT POSSIBLE DAMAGE MAINTAIN A MINIMUM OF 5 P.S.I. IN THE AIR HELPER SPRINGS AT ALL TIMES.
NOTE:
Once the air helper springs are installed, it is recommended that the vehicle not be lifted by the frame, as over-extension may
occur, resulting in damage to the air helper springs. However, should it become necessary to raise the vehicle by the frame, deflate
both air helper springs completely.
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