VIGOR 2001 Air Spring Bag Suspension Kit Installation Guide

Air Helper Spring Kit For
2001 – 2007 GMC Sierra 2500 HD Classic
2007 – 2007 Chevrolet Silverado 2500 HD Classic
2001 – 2010 GMC Sierra 2500 HD (2WD & 4WD)
2001 – 2010 Chevrolet Silverado 2500 HD (2WD & 4WD)
2007 – 2010 Chevrolet Silverado 3500 HD (2WD & 4WD)
2001 – 2010 GMC Sierra 3500 HD (2WD & 4WD)Sway Bar
Installation Manual

Thank you for purchasing the 7X 1233 Kit! Please kindly be advised to read the instructions carefully before installing the air spring kit.
Please take safety precautions accordingly during installation.
The installation instructions are based on the left side or based on the driver’s side of the vehicle, and the structure on the right side can refer to the same method on the left side.
The retrofit kit you purchased is a single valve inflation system.
Please note that the air spring will bend and expand under working conditions. Ensure there is enough space for it to work properly and avoid friction between the air spring and other chassis parts.

INSTALLATION INTRODUCTION

IMPORTANT!
For your own safety and in aim to prevent possible damage to the vehicle, don’t exceed the maximum load recommended by the vehicle manufacturer. Your air bag helper springs are rated at a maximum inflation pressure of 150 PSI. You are allowed to carry a greater load on some vehicles with this pressure.
It is best to have your vehicle weighed once it is completely loaded and compare that weight to the maximum allowed.
Check your vehicle’s owner’s manual or data plat on your driver’s side door for maximum loads listed for your car.
When inflating your airbag helper springs, add air pressure in small quantities, checking pressure frequently during inflation. Each air spring requires much less air volume than a tire and inflates much quicker.

HARDWARE LIST

Minimum pressure 5psi
Normal pressure (light load) 60-80psi
Max pressure (heavy load) 150psi
Burst pressure 550psi

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ASSEMBLING AIR SPRING BAGS & BRACKETS

Step 1- Add thread sealant to the 90°elbow fitting and install it on the top of the air spring. Tighten finger tight plus 1 1/2 turns. Do not over tighten.
Step 2- Install the upper bracket (B) onto the below assembly. Attach using two 3/8″ bolts. Leave the bolts loose at this time (Fig. 2 & Fig. 3)
Drivers Side Only: Insert a 5/16″ bolt into the small hole on the lower bracket (C) before attaching the lower bracket to  the air spring assembly.
2500 HD Models Only: Install a 3/8″ bolt and lock nut through the hole in the lower bracket (Fig. 2) with the head of the bolt facing down.
Tighten securely.
Step 3- Insert two 3/8″ carriage bolts (I) through the large holes and into the square holes of the legs in the lower bracket.
Step 4- Attach the lower bracket (C) to the bottom of the air bag assembly using a 3/8″ flat head screw. Tighten securely.

REMOVING THE JOUNCE BUMPER

Step 5- Jack up the rear of the vehicle and support the frame with jack stands. Drop the axle to gain clearance to install the assembly.
Step 6- Remove both jounce bumpers under the frame rail and discard them.

POSITIONING THE ASSEMBLY ON THE AXLE

On the 2500 HD models only, the driver side axle may have a small bracket with a nut that has nothing attached to it. This bracket must be trimmed off of the axle in order to install the assembly. (Fig. 4)

2500 HD Models:
Set the assembly that has the cinch bolt onto the driver’s side. It will be necessary to index the lower legs under the jounce bumper strike plate. With the lower bracket parallel to the strike plate, hook one leg under the side of the strike plate and turn the assembly until the other leg is under the strike plate on the other side (Fig. 4B).
Once the legs are under the strike plate, proceed with the upper bracket instructions.

3500 Models:
Set the assembly on the strike plate so that the legs of the lower bracket are forward and behind the axle (Fig. 5).

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INSTALLING THE HEAT SHIELD

Find the closest point between the exhaust pipe and the air bag. Mount the hear shield in this spot.

ATTACHING THE UPPER BRACKET

Step 7

1. The elbow fitting points toward the rear of the vehicle on the driver’s side and toward the front of the vehicle on the passenger side.
2. Insert two 3/8″ bolts and flat washers through the existing jounce bumper holes and the slotted holes in the upper bracket (Fig. 6). It may be helpful to raise the axle at this point so that the upper bracket touches the frame.
3. Attach the upper bracket using two flat washers and nyloc nuts on each previously installed bolt (Fig. 6).
4. Push the bracket inboard and tighten both upper bolts.

ALIGNING AND ATTACHING THE
ASSEMBLY AND LOWER BRACKET

Step 8

1. Bring the axle all the way up and remove the jack stand previously used to support the frame when removing the jounce bumper. The upper bracket is slotted for forwarding and backward adjustment. The bottom adjusts by moving the bracket on the axle  in or out (Fig. 7).
2. Adjust the assembly so that the air spring is perpendicular to the bottom and top mounting brackets.
3. Tighten the top mounting bolts to 20 lb.-ft.
4. Attach the axle strap to both lower bracket carriage bolts using two flat washers and two nyloc nuts. Torque evenly to 16 lb.-ft. (Fig. 8).

INSTALLING THE EMERGENCY BRAKE
LINE BRACKET AND CLIP

Step 9

1. Attach the brake line bracket to the lower bracket using the previously installed 5/16″ bolt with one flat washer and nyloc nut (Fig. 9).
2. Attach the brake line clip to the emergency brake line bracket (Fig. 9).
3. Attach the clip assembly to the brake line bracket using a 5/16″ bolt, two flat washers, and a nyloc nut (Fig. 9).
4. Align the brake line bracket and clip assembly so that the two do not bind to the cable.
   Tighten all mounting hardware in this assembly securely. Be sure the cable does not rub against the bellows when it is fully inflated. If it does, adjust the assembly accordingly.

CAUTION
WHEN CUTTING OR TRIMMING THE AIR LINE, USE A HOS CUTTER, A RAZOR BLADE, OR A SHARP KNIFE. A CLEAN, SQUARE CUT WILL ENSURE AGAINST LEAKS. DON’T USE WIRE
CUTTERS OR SCISSORS TO CUT THE AIR LINE. THESE MAY FLATTEN OR CRIMP THE AIR LINE CAUSING IT TO LEAK AROUND THE O-RING SEAL INSIDE THE ELBOW FITTING.

PUSH-TO-CONNECT (PTC) FITTINGS
Air lines should be pushed into the push-to-connect fittings firmly, with a slight side-to-side rotational twist. Check the connection by pulling on each line to verify a robust connection.
To release the air line from the connection, first release all air from the system. Push in on the air line (step 1), push the collar in (step 2 ), and with the collar depressed, pull the air line out of the fitting (step 3).

GUIDE LINE FOR ADDING AIR

1. Start with the vehicle level or slightly above.
2. When In doubt, always add air.
3. If the front of the vehicle dives while braking, increase the pressure Si the front air bag if equipped.
4. If it Is ever suspected that the at bags have bottomed out Increase the pressure.
5. Adjust the pressure up and down to find the best ride.
6. It may be necessary to maintain different pressures on each side of the vehicle Loads such as water, fuel, and appliances will cause the vehicle to be heavier on one side. As much as a 50 PSI difference is not uncommon.

By following the steps below, vehicle owners will obtain the longest life and best result from their air springs.

1. Check the air pressure weekly.
2. Always maintain normal ride height.
3. If you develop an air leak In the system, use a soapy water solution (1 part dish soap. 4 parts water) to check all air fine connections and the Inflation valve core before deflating and removing the air spring.
4. When increasing load. always adjust the air pressure to maintain the normal ride height. Increase or decrease pressure from the system as necessary to attain normal ride height for optimal ride and handling. Remember that loads carried behind the aide (including tongue loads) require more levelling force (pressure) than those carried directly over the axle.

CAUTION
FOR YOUR SAFETY AND TO PREVENT POSSIBLE DAMAGE TO YOUR VEHICLE, DO NOT EXCEED THE MAXIMUM GROSS VEHICLE WEIGHT RATING (GVWR). AS INDICATED BY THE VEHICLE MANUFACTURER.

IMPORTANT SAFETY NOTICE :
The installation of this kit does not alter the Gross Vehicle Weight Rating (GVWR) or payload of the vehicle. Check your vehicle’s owner’s manual and do not exceed the maximum load listed lot your vehicle.

Gross Vehicle Weight Paling:
The maximum allowable weight of the fully-loaded vehicle (including passengers and cargo). This number — along with other weight limits. as well as tire, rim size and inflation pressure data — Is shown on the vehicle’s Safely Compliance Certification Label.

If you have any questions about this product, please contact us below:
Phone：+1-604-636-8654 (Monday – Friday, 8 am – 6 pm PST)
Email：support@vigorairride.com
Thank you very much!

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