User's Manual

ManualsBrandsAir Lift Performance ManualsBicyclesAir Lift Performance 39020 ECR 6107

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1-800-248-0892

Ext. 2

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

Checking Driveline Angles

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

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

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

Chevy 3500 Kit No. 39020

MN-564

(15704)

ECR 6107

Summary of content (18 pages)

PAGE 1
Chevy 3500 Kit No. 39020 MN-564 (15704) ECR 6107 by 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 ................
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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. 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”.
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Vehicle Requirements Vehicle Type Gross Vehicle Weight Rating (GVWR) Chevy 3500 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. NOTE: For 4WD crew cab models, use driveshaft spacer kit # 26029 (purchased seperately) in addition to kit # 39020.
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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 inflate the air springs until they have been properly secured to the vehicle. No Load in Truck Remove Wheel IMPORTANT: Measure and record the driveline angles in the chassis as first received (Figure 21). Remove Wheel Support the axle with jack stands and raise or lower to Normal Ride Height. 1.
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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.
PAGE 6
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 flange on the bracket to the frame flange using vise grips or welding clamps. Existing Frame Contact Overload Holes (If not equipped, drill out to ½") 2. a) If there are existing holes: Frame Trailer Hitch Cross Member Rivets b) If there are NO existing holes: Drill a ½” hole using the upper bracket as a template.
PAGE 7
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 flat washer, the bracket, the frame, a large flat washer and a nyloc nut. Push the bracket to the rear as far as possible and clamp both the frame and bracket flange together (Figure 9). Driver-Side View Panhard Rod Bracket (Front View) Existing Oval Hole in Side of Frame 2.
PAGE 8
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. No more than 1½" of thread showing on heim joint 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.
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Hardware List Hardware List Part No. 26537 26454 26332 07003 10046 10565 10466 18405 18411 21230 21233 21234 18509 18508 20086 18451 18484 18429 17219 18485 18480 13227 17269 18518 18470 58226 18011 17290 10008 17247 18460 26333 21745 17294 26393 18246 25435 10439 Description Quantity Driver-Side Beam Assembly 1 Passenger-Side Beam Assembly 1 Panhard Rod Assembly 1 Frame Bracket 2 Panhard Rod Bracket 1 5 /8”-18 x10.
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BB Ext. 2 LL Stock Spring Retainer O.E.M. M F N NN MM DD E T A T S EE CC P KK Q Q R R T DD DD C Y D M N X P X W B EE Installing the RoadTamer System 1-800-248-0892 Technical Support AA O.E.M. DD T T T NOTE: The beams in this image may appear different from the beams supplied with this kit.
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Installing the Rolling Lobe Air Sleeves Refer to Figure 14 for the following instructions. 1. Install the fitting into the large top stud of the rolling lobe air sleeve. Tighten the fitting finger-tight plus 11/2 turns, being careful to tighten on the metal hex nut only. NOTE: It may be necessary to raise the chassis to provide adequate space to install the rolling lobe air sleeves. Lock Washer 3.
PAGE 12
Installing the Air Lines 1. Choose a convenient location for mounting the inflation valves. Popular locations for the inflation valve are: the wheel well flanges, the license plate recess in the bumper, under the gas cap access door, or through the license plate itself. Air Line Cutting NOTE: Whatever the chosen location is, make sure there is enough clearance for an air chuck around the inflation valves. 2. Drill a 5/16 “ hole to install the inflation valves.
PAGE 13
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). 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).
PAGE 14
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.
PAGE 15
Installation Checklist This Installation Checklist must be completely filled out to ensure proper installation: RoadTamer Installation Checklist 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 specification? o Have the beam pivot bolts been torqued per the specification? o Was the suspension at ride height and even from side-to-side when the fasteners were torqued? o Have the upper bracket bolts been torqued per the specification? o
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Troubleshooting Guide Problem Possible Problem Check Procedure Air System leaks. • leaky airbag • leaky pneumatic fittings (i.e.: drain valve, Height Control Valve [HCV]) • cut or pinched air line • Spray air bag with a soapy water solution. • Spray fittings with a soapy water solution. • Conduct visual inspection. • If leaking, replace air bag. • Tighten fittings. • Repair or replace as necessary. Vehicle is not level sideto-side within 3/8". • OEM axle perch is not level side-to-side.
PAGE 17
Checking for Leaks 1. Spray all connections and the inflation valves with a solution of 1/5 liquid dish soap and 4/5 water to check for leaks. You should be able to spot leaks easily by looking for bubbles in the soapy water. 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.
PAGE 18
Maintenance Guidelines By following the steps below, vehicle owners will obtain the longest life and best results from their air springs. 1. Fulfill all Installer Responsibilities: This instruction manual includes specifications for fastener torques. Tighten fastening hardware as instructed by the specifications. Check driveline angles as shown in the section titled “Checking Driveline Angles.” 2.