2101
WARNING:
Donotinflatethisassembly whenitisunrestricted.
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.
INSTALLATION INSTRUCTIONS
Your kit includes separate inflation valves and air lines for
eachairhelperspring. Thiswillallowyoutolevelyourvehicle
fromsidetosideaswellasfromfronttoback. Ifyouwouldrather
haveasinglevalveinflationsystem, yourdealercansupplythe
required "T" fitting.
Congratulations - your new Air Helper Springs are quality
productscapableofimprovingthehandlingandcomfortofyour
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
identifythecomponentsandlearnwhereandhowtheyareused.
It is a good idea to start by comparing the parts in your kit with
the parts list below.
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
Springsareratedata maximuminflationpressureof100P.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.
The heart of the air helper spring kit is, of course, the air
helper springs. Rememberthattheairhelperspringsmustflex
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.Toinstalltherightsideassemblysimplyfollowthesame
procedures.
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.
PARTS LIST
267C AIR SPRING
6781
5157
5158
5159
1163
1004
2
1
1
2
2
1
4
4
12
2
2
4
3/8" LARGE FLAT WASHER
1/4" LOCK WASHER
1/4" HEX NUT
PUSH-TO-CONNECT
MALE AIR FITTING
PUSH-TO-CONNECT
INFLATION VALVE
5/16" FLAT WASHER
AIR LINE TUBING
NYLON TIE
4
2
2
UPPER BRACKET (RIGHT)
UPPER BRACKET (LEFT)
LOWER BRACKET
AXLE STRAP
HEAT SHIELD
3/8" -16 x 1" HEX BOLT
3/8" -16" x 3" CARRIAGE BOLT
3/8" -16 FLANGED LOCK NUT
3/8" -16 x 3/4" HEX BOLT
1/4" -20 x 1" HEX BOLT
1/4" FLAT WASHER
3046
3032
2
2
4
1
6
2
THERMAL SLEEVE
21-8156
12-03
NCD-5988-2
STEP 1-PREPARE THE VEHICLE
Remove the positive battery cable. With the vehicle on a solid, level surface
chockthefrontwheels. Raisethevehiclebytheaxleandremovetherearwheels.
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.
TWO-WHEEL
DRIVE VEHICLES
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.
FIGURE "B"
STEP 2 - PRE-ASSEMBLE THE KIT
SOME FOUR-WHEEL
DRIVE VEHICLES MAY
HAVE BOLTS, OTHERS
WILL HAVE RIVETS
Thiskitissuppliedwitharightandleftupperbracket. Beginbyinstallingthe
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
fittingintheairinflationhole. Tightentheairfittingsecurelytoengagetheorange
thread sealant.
FIGURE "C"
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
securedtothelowerbracketthroughtheforwardhole. Oncethecorrectmounting
holeforthelowerbrackethasbeenidentified,removethebracketfromtheaxleand
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
STEP 3-INSTALL THE ASSEMBLY TO THE VEHICLE
Set the assembly in place on the axle housing over the jounce pad. The lower
bracketshouldbuttagainsttheU-boltsontheleafspringseeFigure"E". Position
the assembly so that the upper bracket is aligned vertically against the outside
surface of the frame rail.
OVER-BENT
TAB
Onsomevehiclestheremaybearivetheadonthebottomofthebottomsurface
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
framerailseeFigure"A". Installationoftheflatwashersisonlynecessaryifyour
vehicle has a rivet head on the bottom of the frame rail. Insert a 1/4" -20 x 1" bolt
throughtheverticaltaboftheupperbracketandanexistingholeintheframerail.
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.
VIEW OF DRIVER’S SIDE ASSEMBLY
FROM INSIDE OF VEHICLE
FIGURE "D"
FRAME RAIL
UPPER BRACKET
LEAF
STACK
AIR SPRING
LOWER BRACKET
AXLE
The tabs on the bracket will be secured to the lower frame flange using 3/8"
flangedlocknutsand3/8"-16x1"hexboltsseeFigure"A". Note: onthedriver'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
BRAKE LINE
DRIVER'S SIDE
FRONT
SHOCK
BRACKET
BRACKET STRAP
FIGURE "E"
ontothecarriageboltsandsecurewith3/8"-16flangedlocknuts. Thisinstallation
willholdthelowerbracketinplace. Note: Wheninstallingtheleft-sideassembly,
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.
STEP 4-INSTALL THE PASSENGER'S SIDE ASSEMBLY
HEAT SHIELD
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
suspension compresses.
FIGURE "F"
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
OR KINK THE TUBING. Try to make the cut as square as possible. Insert one
endofthetubingintotheairfittinginstalledinthetopoftheairhelperspring. Push
the tubing into the fitting as far as possible.
AIR
SPRINGS
AIR HOSE
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
helperspringtotheinflationvalve,routingittoavoiddirectheatfromthe exhaust
pipe and away from sharp edges. Thermal sleeves have been provided for these
conditions. Ifathermalsleeveisrequiredsimplyslidethesleeveovertheairline
tubing to the location requiring protection. The air line tubing should not be bent
or curved sharply as it may buckle. Secure the tubing in place with the nylon ties
provided. Push the end of the air line tubing into the inflation valve as illustrated
see Figure "H".
INFLATION
VALVES
BUMPER
FIGURE "G"
AIR LINE
FLAT WASHER
STEP 6 - CHECK THE AIR SYSTEM
Oncetheinflationvalvesareinstalledinflatetheairhelperspringsto70P.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
outthetube. Ifaleakisdetectedwheretheairfittingscrewsintothespring,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
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
aroundtheairsprings. Withaloadonyourvehicleandtheairhelperspringsinflated,youmusthaveatleast1/2"clearancearound
theairsprings. Asageneralrule,theairhelperspringswillsupportapproximately50lbs.ofloadforeachP.S.I.ofinflationpressure
(perpair). Forexample,50P.S.I.ofinflationpressurewillsupportaloadof2500lbs.perpairofairhelpersprings. FORBESTRIDE
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.
NOTE:
Too much air pressure in the air helper springs will result in a firmer ride, while too little air pressure will allow the airhelper
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,resultingindamagetotheairhelpersprings. However,shoulditbecomenecessarytoraisethevehiclebytheframe,deflate
both air helper springs completely.
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