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Ext. 2

MN-643

(02511)

ECR 5461

Kit No. 39205

Read all maintenance guidelines on page 7 before operating the vehicle.

Item P/N Description Quantity

A 26391 Driver-Side Beam Assembly 1

B 26414 Passenger-Side Beam Assembly 1

C 26380 Panhard Rod Assembly 1

D 07138 Upper Bracket (Right) 1

E 07137 Upper Bracket (Left) 1

F 58201 Bellows 2

G 17247 1/2” - 13 x 1.75” Bolt GD8 14

H 18485 1/2” Flat Washer 28

I 18460 1/2” - 13 Nylock Nut 16

J 17268 10mm Bolt GD8.8 8

K 18495 10mm Nylock Nut 4

L 13228 Spacer 2

M 10308 U-Bolt 2

N 18509 Washer .65ID x 1.25OD 4

O 18508 5/8” - 18 Nut 4

P 18451 3/4” - 16 Jam Nut 2

Q 18484 1/2” - 20 Hex Nut GD8 4

R 18429 1/2” - Lock Washer 6

S 21745 1/4” MNPT x 1/4” Tube Straight 2

T 18480 9/16” Nylock Nut 1

Y 17219 9/16” - 12 x 5 Bolt GD8 1

Z 13034 Spacer 2

AA 20086

sub Air Line Assembly 1

Item P/N Description Quantity

BB 10466 8” Zip Tie 6

CC 21230 Poly Cap 2

DD 18405

/16" Flat Washer 2

EE 21234 Rubber Washer 2

FF 18411

/16" Star Washer 2

GG 21233

/16" Hex Nut 4

HH 17269 3/4” - 16 x 4” Bolt GD8 1

II 18518 3/4” Flat Washer GD8 2

JJ 18470 3/4” - 16 Nylock Nut GD8 1

KK 18435 3/8"-16 Nylock Nut 2

LL 10195 Flat Washer, 2.5" OD x .53 ID x .19 4

MM 17271 1/2"-13 X 3, Hex Cap Screw 2

NN 17307 5/8” - 18 x 6.5 Bolt 4

OO 18509 1.25” OD Flat Washer 8

PP 18536 5/8” Nyloc Nut 4

QQ 17305 22mm Bolt 1

RR 18535 22mm Flat Washer 2

SS 18534 22mm Nyloc Nut 1

TT 10513 Axle Bracket 1

UU 17286 Centering Pin 1

VV 10642 Spring Retainer 1

WW 10445 Limiting Strap 1

Parts List

Please read these instructions completely before proceeding with installation

Summary of content (8 pages)

PAGE 1
MN-643 (02511) ECR 5461 Kit No. 39205 Please read these instructions completely before proceeding with installation Parts List Item A B C D E F G H I J K L M N O P Q R S T Y Z AA P/N 26391 26414 26380 07138 07137 58201 17247 18485 18460 17268 18495 13228 10308 18509 18508 18451 18484 18429 21745 18480 17219 13034 20086sub Description Quantity Driver-Side Beam Assembly 1 Passenger-Side Beam Assembly 1 Panhard Rod Assembly 1 Upper Bracket (Right) 1 Upper Bracket (Left) 1 Bellows 2 1/2” - 13 x 1.
PAGE 2
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. I. Getting Started Remove Frame Contact Overload Upper Bracket 1. Elevate the rear of the vehicle and secure the frame with jack stands. Remove Bolts 2. Remove both of the leaf springs. NOTE: Retain the front nuts and bolts to be reused. Remove Gas Tank Cover Rivet Driver-Side Only 3.
PAGE 3
III. Attaching the Frame Brackets 1/2" Bolts 1. Install the passenger-side frame bracket (D) using the existing holes from the previously removed frame contact overload bracket. Attach using four bolts (G), eight flatwashers (H), and four nylock nuts (I). Tighten securely. Drill 1/2" Hole 10mm Bolts NOTE: Be sure the bracket flange is tight to the bottom frame flange. Clamp tightly using a pair of vice grips. 2. Attach the driver-side frame bracket (E) following the instructions in the previous step. 3.
PAGE 4
V. Installing the Rolling Lobe Air Sleeves Driver-Side Shown 1. Install the fitting (S) 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 air sleeves. 2. Insert the studs of both rolling lobe air sleeves into the bottom mounting hole of the beam assemblies on both sides of the vehicle.
PAGE 5
VII. Installing the Air Lines Vehicle body or bumper 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 bumper, under the gas cap access door, or through license plate itself. DD NOTE: What ever the chosen location is, make sure there is enough clearance around the inflation valves for an air chuck. Air Line to Bellows GG FF CC 2. Drill a 5/16 " hole to install the inflation valves.
PAGE 6
IX. Checking for Leaks 1. Inflate the air spring to 25 p.s.i. 2. 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. After the test, deflate the springs to the minimum pressure required to restore the Normal Ride Height, but not less than 10 p.s.i. 4. IMPORTANT: Check the air pressure again after 24 hours. A 2 to 4 p.s.i.
PAGE 7
XII. Maintenance and Operations Minimum Air Pressure Maximum Air Pressure 10 p.s.i. 100 p.s.i. Failure to maintain correct minimum pressure (or pressure proportional to load), bottoming out, over-extension, or rubbing against another component will void the warranty. By following these steps, vehicle owners will obtain the longest life and best results from their air springs. 1. Check the air pressure weekly. 2. Always maintain Normal Ride Height. Never inflate beyond 100 p.s.i. 3.
PAGE 8
Thank you for purchasing Air Lift Products Mailing Address: AIR LIFT COMPANY P.O. Box 80167 Lansing, MI 48908-0167 Street Address: AIR LIFT COMPANY 2727 Snow Rd. Lansing, MI 48917 Local Phone: (517) 322-2144 Fax: (517) 322-0240 For Technical Assistance call 1-800-248-0892 Technical Support “The Choice of the Professional Installer”1010 1-800-248-0892 8 Ext.