Install Instructions

Air
Ride
Conversion
System
Installation
Instructions
800 334-6150
KLM14619
www.keldermanairride.com
kelderman air ride
“The difference in the ride is like night and day”
Inside this manual:
Tools required for
2
installation
Preliminary and
2
safety
2001 & newer Chevy Rear Four-Link
This system was developed to
improve the ride of the 2001
Chevy 3500 2&4 wheel drive
pickups. There are many
advantages to equipping your
truck with air ride suspension:
instructions,
installation steps
•
Improves the ride of the truck
1-3
•
Automatic leveling is available
•
Dump option available
•
Increases load carrying
Parts location,
3
installation steps
4-6
Installation steps
4
7-13
Installation steps
5
Chevy 3500
capacity
•
Keeps truck bed at the same
height whether empty or
loaded
14-19
Installation steps
6
20-21
Self-leveling kit
7
plumbing detail
Contact
Information
8
Warranty Disclaimer Notice
Read Before Beginning Installation
Some Kelderman Air
any threaded portion of
threaded fasteners,
Ride kits contain both
the Air Ride, check to
fittings and air bags
fine thread and course
be sure the threads are
caused by improper
thread fasteners,
the same size and
size. Thread count or
fittings and air bag
thread count before
misalignment are not
mountings. Before
attempting to tighten.
covered by warranty.
attempting to tighten
Damaged or cross-
Note: Exhaust system will have to be modified.
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kelderman air ride
2001 & up Chevy
Tools Required for Installation of the Air Ride Unit
Before removing anything, Tools and equipment required:
measure the pinion angle
and rear bumper height.
Record this measurement
as you will need to put the
axle back to this angle to
Reciprocating saw or cutting
wheel
Welder (exhaust modifications)
Jack
prevent driveline vibration. (2) Jack Stands
The rear bumper height
Wheel Chocks
1.1
will get you an idea of
Combination Wrench Set (up to
vehicle ride height after
1 5/16”)
the air ride is installed.
Socket Set
**When raising or lowering
Figure A
(1 5/16” torque wrench)
the truck, keep jack stands in
figure A
Hammer
place to prevent the truck
Pinion Angle Finder
from falling, which could
DANGER
Tape Measure
cause severe personal injury
or death**
Installing the Air Ride
Step 1. Jack up the truck
Step 3. Remove the leaf
from the frame in front of
springs. Set the bolts
the rear leaf springs just
high enough that the tires
trailing arm mounts. Use the
aside. The front bolt will be bolts that held the front
used to hold the upper front overload pads to fasten the
are off the ground. Place a trailing arm in place.
jack stand under the frame
or under the rear hitch.
Step 5. Locate the front
Step 4. Remove the
trailing arm mount in place.
Also use the bolt that held
overload pads. NOTE: ON the front eye of the leaf
spring in position. Tighten all
Step 2. Remove the tailpipe THE FRONT PADS, USE
from the muffler back. Use WIRE OR ZIP TIES TO KEEP bolts. (Fig. 1.1) NOTE: Short
the instructions at the end
to reinstall exhaust.
THE BOLTS FROM FALLING box trucks will require
INSIDE THE FRAME. All the trimming of the box mount.
factory bolts will be used to
fasten the air ride brackets.
Page 3
Installation Instructions (continued)
Step 6. Locate the upper airbag mount. Use the bolts that held the rear overload pad in
place. Tighten all the bolts. (Fig. 1.2)
Step 7. Locate the lower air bag mounts and place them on the axle pad. It may be necessary to bend the brake lines around the bracket. Locate factory lower axle clamp and
fasten the two brackets together with the 5/8” x7 1/2” bolts.
Step 8. Locate the four trailing arms and the 7/8” x5 1/2” bolts and 7/8x5” bolts. Put the
trailing arms in place and use the 5” bolts on the links (insert so the nuts are on the outside) and use the 5 1/2” bolts on the bottom of the air bag mount (insert so nuts are on
the inside). Use the 7/8” washers on the bolts/nuts. Locate the lower support brace (the
1/2” x2” bar with holes on each end) and slide on place over the 7/8x5 1/2” lower bolt and
use the 3/4x2” bolt to fasten the rear to the lower bag bracket. (Fig. 1.5) Tighten all
bolts. NOTE: WHEN INSERTING THE TRAILING ARMS, TRY AND KEEP THE PINION ANGLE CLOSE TO THE FACTORY SETTING. ALSO TRY AND KEEP THE UPPER ARMS CLOSE
TO THE SAME LENGTH AS WELL AS THE LOWER ARMS CLOSE TO THE SAME LENGTH.
(Fig. 1.4)
1.2
1.3
Recommended torque ratings on
bolts: 1/2” - 95ft. lbs
5/8” - 195ft. lbs
factory shackle bolts - 170 ft. lbs.
7/8” - 460 ft. lbs
Step 9. Locate the air bags. Fas- the bottom of the frame. This is where the
ten into place using the 1/2” lock
support gusset attaches. Tighten the bracket
washer and nut on the top stud
and gusset in place.
and use the 3/4” lock washer and
nut on the bottom stud. (Fig. 1.5)
1.4
Step 10. Locate the pan hard bar
bracket. This fastens to the passengers side frame. It will be necessary to drill two 1/2” holes in
1.5
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kelderman air ride
Step 11. Locate the pan hard bar. Fasten into place using the spacers to center up the
heim end in the middle of the brackets. Once the install is complete, the pinion angle is
set, the axle is centered in the wheel, and the truck is set at ride height, adjust the pan
hard bar so the axle is centered side to side. (Fig. 1.6)
Step 12. Locate the accumulator tanks. These are the small tanks with two air ports.
They mount up to the rear leaf spring perch using the original leaf spring shackle bolt.
The accumulator tank plumbs up to the air bag with the 1/2” air line. The 1/4” air line
goes from the tank out to the height control valve. The accumulator tanks change the
spring rate of the air bag which allows the truck to ride better. (Fig. 1.7)
Step 13. Locate the drivers side shock relocation brackets. Use the spacers to move
and fasten the shock towards the right of the original mounts.
Step 14. Plumbing of the system. Mount the air compressor on the inside of the frame
on the drivers side in the area under the drivers seat. You can mount the compressor in
any direction except upside down. Use the supplied instructions on how to wire up the
compressor, relay and height control system. The air tank can be mounted on the
outside of the side of the frame. (Fig. 1.9)
Step 15. Locate the tailpipe. If the spare tire is going to be kept in the stock location it
is going to require the exhaust to be rerouted in front of the rear wheels. If the spare is
removed, there will be enough room to route the exhaust out the stock location.
1.6
1.7
NOTE: When adjusting the trailing arms, make sure the arms on the top and the arms on
the bottom are the same length. On the final alignment, they may be off up to a 1/4”, but
to start the alignment process have them the same. If the arms get over 3/8” different, it
will cause them to bind and the arms will be difficult to turn.
Page 5
2001 & up Chevy
Step 16. Final Alignment. Set the truck so the airbags are between 7-8”. Also refer to
the original bumper height measurement as to what height to run the bag at. Find a
hole on the side of the frame about half way up the truck. Use this point to square up
the axle. Measure from the axle to the hole in the frame. It is easier to turn the trailing arms if you place a jack stand under the rear hitch at ride height, then remove the
air lines off the bags so that there is no pressure on the rear axle.
Step 17. Test drive the truck. If the steering wheel is off, that means the rear axle is
not square. If the truck pulls to the right or left, the axle is not square. If the truck vibrates between takeoff and 10 mph then the pinion angle is off. Continue to make adjustments until the truck drives straight and true. If you have any questions, you can
call the factory at 641-673-0468.
Step 18. Once the distance is the same on both sides between the tire and the frame,
adjust the heim-end so the holes line up and the panhard bar will fit properly. Tighten
bolts on both ends.
2.0
1.8
2.1
1.9
2.2
2.3
**NOTE: the purpose of the panhard is to set and maintain proper side-to-side
axle alignment. It is critical to measure the distance between the inside of the tire
and the outside of the frame. This distance should be the same on both sides.
Page 6
kelderman air ride
Page 7
Self-Leveling Kit
Top - Exhaust
Middle - Out to Bags
Air Compressor
Bottom - In From Tank
Tank
Height-Control Valve
Optional Dump Valve
would plumb in here
Air Bag
Air Bag
Page 8
kelderman air ride
Contact Information
Kelderman Air Ride appreciates your business.
We strive to meet the needs of our customers
by providing the highest quality products. If you
have any questions concerning this system,
please call or email us at the following:
2686 Highway 92
Oskaloosa, Iowa 52577
Phone: 800 334-6150
Fax: (641) 673-4168
Email: [email protected]
www.keldermanairride.com
“The difference in the ride is like night and day”
Page 9
Exhaust rerouting
Crush here.
Place in a vise
and egg shape
the tube. Make
it one inch narCut factory tail
pipe and weld to
the end of the 90
3. this is what the tailpipe should look like
when its ready to reinstall.
1. Cut the factory exhaust off right above the
axle about 9 inches from the hanger.
Heat wrap
optional
2. slide the 90 degree bend over the stock
tailpiple. Put the clamp on but don't tighten,
just snug. You will need to adjust it.
4. Put the tailpipe in position. Make sure
you have enough clearance between the
pan hard bar mount and the air bag. You
may need to redo the rear hanger at the
same time in order to hold up the tailpipe
level with the ground.
For best results, cut off the factory
rear hanger and weld it to the side of
the pan hard bar drop.
Sway bar installation
1. Locate sway bar, blue bushings, u bolts and mounting brackets and “D” rings. Connect the
sway bar to the bottom of the axle using the u bolt and sway bar mounting brackets.
2. Locate the end links and end link mounting brackets. You can drill or weld the end link mounting
brackets to the bottom of the truck frame. If you are going to drill the holes, you will need to
loosen the fuel tank and slide it over to get clearance for a drill. Locate the endlink mounts so the
endlinks are straight up and down.
3. Once the sway bar is fastened to the axle, connect the end links to the end link mounts. On the
drivers side you will need to bend the emergency brake cable loop so it doesn't rub on the endlink.
Passengers side “D” ring goes
close to shock clamp Endlink
should be straight up and down
Drivers side “D” ring and endlink