actiontrucks Ford F150 4WD Air Spring Kit Instruction Manual
- June 15, 2024
- actiontrucks
Table of Contents
actiontrucks Ford F150 4WD Air Spring Kit
Product Information
Specifications
- Product Name: Air Spring Kit
- Compatible Vehicle: Ford F150 (4WD)
- Part Number: L6497
- Revision: REV7_02.22.2023
Description
The Air Spring Kit is designed to eliminate sag, sway, and bottoming out in your Ford F150 (4WD) vehicle. It is equipped with advanced air springs that provide added support and level the truck’s stance, ensuring a smooth and safe ride. Please note that the application guide should be referred to for proper fitment.
Usage Instructions
Important Safety Information
Please read and follow the instructions, safety recommendations, and maintenance suggestions provided in this manual to prevent serious personal injury or accidents due to improper installation or air spring pressure operation or maintenance. Inflating an unsecured air spring can be dangerous and may result in serious personal injury or death. Always ensure that the air spring is securely attached to the vehicle before inflating it. Removing and replacing air springs should only be done by a qualified service professional with proper training, tools, and equipment.
Kit Contents
The following components are included in the Air Spring Kit:
- 2 x HP10000
- 1 x HP1590
- 1 x HP1591
- 2 x HP1594
- 1 x HP1592
- 1 x HP1593
- 4 x HP1623
- 4 x HP10054
- 2 x HP1341
- 4 x HP1149
- 8 x HP1332
- 20 x HP1000
- 8 x C10464
- 8 x HP1002
- 30 x C18006
- 8 x C18007
- 4 x HP0123
- 2 x HP1100
- 1 x HP1344
- 6 x C11618
- 2 x HP1440
Before Starting the Installation
- Ensure that the application information matches the make, model, and year of your vehicle.
- Check with the manufacturer if your vehicle is equipped with a rear wheel brake proportioning valve, as it may affect braking performance when installing the air spring kit.
- Apply a good quality anti-seize on all fasteners to prevent corrosion and facilitate future removal, if necessary.
Please note that this kit contains push-to-connect fittings. Do not use scissors or wire cutters to cut the nylon airline, as it may cause distortion and leakage. Use the nylon hose cutter provided in the kit or a sharp utility knife to cut the airline squarely.
FAQ
Q: Will this air suspension kit increase the vehicle’s Gross Vehicle Weight Rating (GVWR)?
A: No, this air suspension kit will not increase the GVWR, as it is determined by the vehicle manufacturer. Do not exceed the maximum capacity listed by the vehicle manufacturer.
Q: What should I do to prevent contact between the air bag and surrounding components?
A: To prevent any contact when the air bag is inflated or compressed, ensure that there is clearance between the air bag and surrounding components. Additionally, trim off excess bolt length to ensure no contact with the bag or other suspension components can be made once installed.
WARNING: This product can expose you to the chemical Hexavalent Chromate, which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov
IMPORTANT
This air suspension kit will not increase the GVWR (Gross Vehicle Weight
Rating), as the GVWR is determined by the vehicle manufacturer. Do not exceed
the maximum capacity listed by the vehicle manufacturer.
PLEASE NOTE: The air bag must have clearance between itself and the
surrounding components to prevent any contact when bag is infl ated or
compressed. Trimming off excess bolt length is also required to ensure no
contact with the bag or other suspension components can be made once
installed.
Safety Warnings!
- Serious personal injury or death may result from an air spring failure or accident due to improper installation or air spring pressure operation or maintenance. Please read and abide the instructions, safety recommendations and maintenance suggestions throughout this manual.
- Infl ating an unsecured air spring is dangerous. If it bursts, it could be hurled into the air with explosive force resulting in serious personal injury or death. Never infl ate an air spring unless it is secured to the vehicle.
- Removing and replacing air springs can be dangerous. This is only a job for a qualifi ed service professional. Never perform air spring service procedures without proper training, tools, and equipment.
KIT CONTENTS
Reference the kit explosion diagram on the following page for part assembly.
KIT CONTENTS QTY PART #
A Air Spring| 2| HP10000
B ** Upper Frame Bracket (Driver Side)| 1| HP1590
C ** Upper Frame Bracket (Passenger)| 1| HP1591
D Upper Airbag Bracket| 2| HP1594
E ** Lower Bracket, Driver| 1| HP1592
F ** Lower Bracket, Passenger| 1| HP1593
G Leaf Spring Clamp Bar| 4| HP1623
H ** Roll Plate| 4| HP10054
I ** M10 x 1.5 x 45 mm Bolt| 2| HP1341
J ** 3/8”– 16 x 1.25” Carriage Bolt| 4| HP1149
K ** 3/8”– 16 x 3.50” Carriage Bolt| 8| HP1332
L ** 3/8”– 16 Nylon Locknut| 20| HP1000
M 3/8”– 16 x 1.25” Hex Cap Bolt| 8| C10464
N 3/8”– 24 x 7/8” Hex Cap Bolt| 8| HP1002
O 3/8” Flat Washer| 30| C18006
P ** 3/8” Lock Washer| 8| C18007
Q Carriage Bolt Lock Bracket| 4| HP0123
R ** 90° Swivel Air Fitting| 2| HP1100
S ** Air Line Assembly (not shown)| 1| HP1344
T ** Tie Strap (not shown)| 6| C11618
U** Bolt Leader Tool (not shown)| 2| HP1440
REQUIRED TOOLS
- Hoist or Floor Jack
- Safety Stands
- Safety Glasses
- Torque Wrench
- Standard Combination Wrenches
- 7/32” Hex Allen Wrench
- 1-1/8” Wrench or Deep Socket
- Ratchet
- Metric & Standard Sockets
- Hose Cutter (included) or Sharp Utility Knife Pipe Thread Sealant
- Spray Bottle with Dish Soap/Water
- Air Compressor/Compressed Air Source (to test/fill air springs)
Please make sure all the items shown in this explosion diagram are provided in your kit before starting the installation.
ASSEMBLY
DRIVER SIDE ASSEMBLY SHOWN:
BEFORE STARTING THE INSTALLATION:
- Ensure the application information is correct for the make, model and year of the vehicle you are installing the kit on.
- Some vehicles are equipped with a rear wheel brake proportioning valve. Check with the manufacturer before installing the air spring kit, as it may affect braking performance.
- It is recommended to use a good quality anti-seize on all fasteners. This will reduce the chance of corrosion on the fasteners and will help facilitate removal, if required at a later date.
PLEASE NOTE:
This kit contains push-to-connect fittings; using scissors or wire cutters to cut the nylon airline will distort the line and cause the connection to leak. THE AIRLINE MUST BE CUT OFF SQUARELY WITH THE NYLON HOSE CUTTER PROVIDED IN THIS KIT OR A SHARP UTILITY KNIFE.
-
MEASURE STOCK RIDE HEIGHT
Park the vehicle on a level surface. Using a measuring tape, measure the distance between the center of the wheel hub and the bottom of the fender well (as shown in Figure 1) this will give you your ride height. Note the ride height for all four corners. -
REMOVE REAR WHEELS
Place wheel chocks in front of and behind both front wheels. Raise the rear of the truck high enough to remove both wheels and attain a comfortable working height. Place two jack stands under rear axle (shown in Figure 2). Lower the vehicle until the axle is supported by the jack stands. Remove rear wheels. -
REMOVE THE JOUNCE BUMPER
The jounce bumper assembly ( shown in Figure 3) consists of a cup and a bumper. It is bolted to the frame with a single bolt running through the center of the jounce bumper. Remove the bolt holding the jounce bumper to the frame with a 13 mm socket. A socket extension may be required to reach the bolt. -
ATTACH THE UPPER BRACKET TO THE FRAME
Assemble the upper bracket (B) as shown in Figure 4A. Place the upper frame bracket on the frame rail and position by inserting the M10 x 1.5 x 45 mm bolt (I) through the locating hole in the bottom of the bracket into the jounce bumper bolt hole. Torque the M10 bolt to 30 ft-lbs (41 N-m). Insert a 3/8” – 16 x 1.25 carriage bolt (J) through a carriage bolt locking bracket (Q). Insert the bolt and bracket combination through the oval hole on the rear side of the frame and align with the mounting holes. Fishing wire may be needed to pull the bolt and bracket combination through the frame. Secure the bracket to the frame using two 3/8” – 16 nylock nuts (L) and two 3/8” flat washers (O). Torque the nylock nuts to 20 ft-lbs (27 N-m). A correctly attached bracket should appear as shown in Figure 4B. Repeat on opposite side
-
ASSEMBLE THE AIR SPRINGS AND BRACKETS
Set the roll plate (H) over the over the bottom of the air spring (A).
Set the lower spring bracket (E) onto the air spring ensuring that the holes in the air spring, roll plate and lower bracket all line up. Fasten the assembly together using two 3/8”– 24 x 7/8” hex cap bolt (N), two 3/8” lock washers (P) and two 3/8” flat washers (O). Torque the mounting hardware to 20 ft-lbs (27 N-m). Turn the assembly over and set the roll plate (H) over the top of the air spring. Fasten the swivel fitting (R) into the top of the air spring. It is recommended to use Teflon tape or some form of thread sealant to prevent air leaks. Finger tighten the swivel fitting and turn an extra 1.5turns to tighten Set the upper airbag bracket (B) onto the air spring ensuring that the holes in the air spring, roll plate and bracket all line up. Fasten the assembly together using two 3/8”– 24 x 7/8” hex cap bolt (N), two 3/8” lock washers (P) and two 3/8” flat washers (O). Torque the mounting hardware to 20 ft-lbs (27 N-m). Repeat for the other air spring. -
INSTALL THE AIR SPRING ASSEMBLIES
Note: It may be necessary to raise the frame of the truck a few inches to allow more clearance to install the air spring assemblies. Place the air spring assembly onto the truck with the lower bracket sitting on the leaf spring and the upper airbag bracket between the extended arms of the upper frame bracket (shown in Figure 6). Attach the upper airbag bracket to the upper frame bracket using four 3/8” – 16 hex bolts (M), four 3/8” flat washers (O) and four 3/8” – 16 nylock nuts (L). Torque the mounting hardware to 20 ft- lbs (27 N-m). Repeat for the opposite side
-
ATTACH LOWER BRACKETS TO LEAF SPRINGS
Insert four 3/8” – 16 x 3.50” carriage bolts (K) into the mounting holes in the lower bracket (as shown in Figure 7). Clamp the lower bracket to the leaf spring using the leaf spring clamp bar (G). Secure using four 3/8” – 16 nylon locknuts (L) and four 3/8” flat washers (O). Torque the locknuts to 20 ft-lbs (27 N-m). Repeat on opposite side -
INSTALL AIR LINE
PLEASE NOTE: This kit contains push-to-connect fittings; using scissors or wire cutters to cut the nylon airline will distort the line and cause the connection to leak. THE AIRLINE MUST BE CUT OFF SQUARELY WITH THE NYLON HOSE CUTTER PROVIDED IN THIS KIT OR A SHARP UTILITY KNIFE
Provided in air spring kit are two fill valves. The most common place to install is in place of license plate fasteners. Alternatively, two 5/16” holes can be drilled in a convenient location. Cut air line assembly into two equal lengths with hose cutter. Install one air line, route the nylon air line to an air spring fitting and cut the hose. Moisten the end of the air line prior to inserting it into the fitting and push it in until it stops. Repeat with the other fill valve. Secure airlines using the tie-straps, away from moving items and heat sources. Place a 5 ⁄16” nut on the air valve. Leave enough of the inflation valve in front of the nut to extend through the hole, install a flat washer, and 5 ⁄16” nut and cap (reference Figure 8 for assembly). There should be enough valve exposed after installation—approximately ½”—to easily apply a pressure gauge or an air chuck. If an in-cab inflation kit is being installed, follow the instructions provided with that kit now. -
CHECK SYSTEM FOR LEAKS
Inflate both air springs to 90 psi and then use a mixture of dish soap and water on all air line connections to detect any air leaks. Large, expanding bubbles indicate a leak (as shown in Figure 9). Repair as necessary and retest. Inflate air springs to a predetermined value and on following day recheck pressure. If one or both of air springs have lost pressure, an air leak is present. Leak must be repaired, and then retested until no leaks exist. -
AFTER COMPLETING THE INSTALLATION
PLEASE REMEMBER:
Install wheels and torque fasteners to manufacturer’s specifications. Re- torque all fasteners after first 500 miles of driving. For safe and proper operation, never operate the vehicle under minimum of 10 psi or over maximum of 100 psi in air springs. Staying within pressure limit will ensure maximum air spring life. Failure in doing so may result in a void warranty (see Note below).
NOTE: Do not exceed maximum vehicle payload. Failure to do so my result in failure of the air suspension kit and/or damage to your vehicle.
Thank you again, and congratulations on the installation of the air suspension kit.
OPTIONAL ACCESSORIES
Optional dual needle air gauges are available to monitor pressure in each spring from vehicle cab, as well as a full line of air compressors, air tanks, and solenoids built to work with and control your air spring system.
OPERATING YOUR VEHICLE WITH AIR SUSPENSION
Air springs have minimum and maximum pressure requirements. Never operate your
vehicle with less than 10 psi in air spring and never infl ate air springs
over 100 psi. Damage to air springs will result.
Check air pressure in air springs daily for fi rst couple of days to ensure a
leak has not developed. Air springs are designed to maintain the vehicles
stock ride height with a load. Do not use the air springs as a means to lift
vehicle with no load. This will result in a harsh ride.
SERVICING YOUR VEHICLE WITH AIR SUSPENSION
When lifting the vehicle with a fl oor jack or hoist on the frame, never allow the air spring to limit the travel of the axle. Try to always jack the vehicle on the axle. Suspending the axle with the air spring limiting the axle travel will damage the air spring and void the air spring warranty.
WARRANTY
The owner’s warranty will be void if air springs are run with less than the minimum of 10 psi. See additional warranty for details.
