VIGOR 57288 Air Spring Bags Suspension Kit Installation Guide

VIGOR 57288 Air Spring Bags Suspension Kit

Product Information

Product Specifications

• Compatible with: Chevrolet Silverado 1500 4WD & RWD 2019-2023, GMC Sierra 1500 4WD & RWD 2019-2023
• Kits Available: 57288, 88288, 89288
• Material: Zinc-plated steel, black powder-coated steel, stainless steel
• Air Lines: Nylon, braided stainless steel
• Installation: Single valve inflation system

Product Usage Instructions

Identifying the Differences Between Kits:
Each kit is distinguishable by the roll plates and airlines used. Refer to the following key differences:

• 7X 57288: Zinc-plated steel roll plates and black nylon air lines.
• 7X 88288: Black powder-coated roll plates and black nylon air lines.
• 7X 89288: Stainless steel roll plates, braided stainless steel air lines, stainless steel mounting hardware.

Installation Instructions:

Installation Diagram:
Refer to the provided diagram for a visual guide to the installation process.

Hardware and Tools Lists:
Ensure you have all the necessary tools and hardware listed before starting the installation.

Introduction:
Familiarize yourself with the product and the installation process before beginning.

Installing the System:

1. Getting Started: Prepare the workspace and gather all components.
2. Assembling the Air Springs: Follow the instructions to assemble the air springs correctly.
3. Installing the Air Springs: Mount the air springs ensuring proper alignment and clearance.
4. Attaching the Upper Brackets: Securely attach the upper brackets to complete installation.

Installing the Air Lines:
Choose between nylon air lines or braided stainless steel air lines based on your kit type.

• Installing Nylon Air Lines: Follow the provided steps for installing nylon air lines.
• Installing Braided Stainless Steel Air Lines: If applicable, follow the steps for installing braided stainless steel air lines.

Frequently Asked Questions (FAQ):

• Q: Can I install this kit on a different vehicle model?
  A: The kit is specifically designed for Chevrolet Silverado 1500 and GMC Sierra 1500 2019-2023 models. Installing it on other models may not be compatible.

• Q: How do I identify which kit I have purchased?
  A: You can identify your kit by examining the roll plates and airlines. The differences in materials and colours will indicate which kit you have (57288, 88288, or 89288).

Installation Manual
Thank you for purchasing the 7X 572 88 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 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.

IDENTIFYING THE DIFFERENCES BETWEEN KITS

Should you need to contact customer service, you will need to know which kit you are inquiring about standard 7X 57288, 7X 88288 or 7X 89288. The kits are easily identifiable by looking at the roll plates and airlines.

• 7X 57288— Zinc-plated steel roll plates and black nylon air lines.
• 7X 88288— Black powder-coated roll plates and black nylon air lines.
• 7X 89288.— Stainless steel roll plates, braided stainless steel air lines, stainless steel air spring mounting hardware.

• Offers two Ultimate Plus upgrade kits:
• Braided stainless steel air line and fittings.
• Stainless steel roll plates, air spring mounting hardware, braided stainless steel air lines and fittings.

Installation Diagram

Hardware and Tools Lists

Common Parts Included in All 3 Kits

• A. Upper bracket ……………………………………………… …… 2
• A. Upper bracket (Trail Boss/Sierra AT4) ………………… 2
• B Lower bracket ………………………………………………… 2
• C Forward clamp bracket ……………………………………. 2
• D Rear clamp bracket …………………………………………. 2
• G Brake line tab bracket ……………………………………… 2
• H Spacer……………………………………………………………. 2
• I U-bolt 3/8″-16 x 6 1/2″ …………………………………… 4
• J M8 -1.25 x 20 Hex-head cap screw ………………….. 2
• K M8 -1.25 x 50 Hex-head cap screw ………………….. 2
• L M8 Stainless steel flat washer ………………………….. 4
• M M8 x 1.25 Nylon lock nut …………………………………. 2
• N 3/8″-16 Serrated flange lock nut ……………………… 14
• O 3/8″-16 x 3″ Carriage bolt ………………………………… 6
• P 3/8″ x 1″ Thread cutting screw …………………………. 4
• W Zip ties ………………………………………………………….. 6
• X * 5/16″ Flat washer ……………………………………………..2

These parts are not shown in the Installation Diagram (Fig. A.1).

TOOLS LIST

• Description………………………………………………………………….. Qty
• Standard and metric open-end or box wrenches………………………………2
• Adjustable wrench…………………………………………………………………………1
• Ratchet with 10mm & 9/16″ deep-well sockets………………………………………….1
• 3/8″ Nut driver………………………………………………………………………………1
• T40 Torx bit…………………………………………………………………………………..1
• Torque wrench………………………………………………………………………………1
• Standard and metric hex head wrenches…………………………………………1
• Hose cutter, razor blade, or sharp knife……………………………………………1
• Hoist or floor jacks………………………………………………………………………..1
• Safety stands………………………………………………………………………………..1
• Safety glasses………………………………………………………………………………1
• Air compressor or compressed air source………………………………………..1
• Spray bottle with dish soap/water solution……………………………………….1

The photos in this manual show the 7X 57288 kit.

Unique Parts in Each Kit

7X 57288

• Item Description ……………………………………………….. Qty
• E Air spring ……………………………………………………….. .. 2
• E Air spring ext (Trail Boss/Sierra AT4) ………………….. 2
• F Roll plate (silver zinc plated) …………………………….. 4
• Q Airline assembly …………………………………………….. 1
• R 90-degree Swivel elbow fitting ………………………….. 2
• S 3/8″-24 x 3/4″ Flat-head socket cap screw ………… 4
• T 3/8″-24 x 7/8″ Hex-head cap screw ………………….. 4
• U 3/8″ Split lock washer ……………………………………… 4
• V 3/8″ Flat washer ……………………………………………… 4
• Y Valve cap ……………………………………………………….. 2
• Z 5/16″-32 Hex nut…………………………………………….. 4
• AA Rubber washer ……………………………………………….. 2
• BB Star washer …………………………………………………….. 2

7X 88288

• Item Description ……………………………………………….. Qty
• E Air spring w jounce bumper ……………………….. …… … 2
• E Air spring w jounce bumper (Trail Boss/Sierra AT4) 2
• F Roll plate (black powder coated) ………………………. 4
• Q Airline assembly …………………………………………….. 1
• R 90-degree Swivel elbow fitting ………………………….. 2
• S 3/8″-24 x 3/4″ Flat-head socket cap screw ………… 4
• T 3/8″-24 x 7/8″ Hex-head cap screw ………………….. 4
• U 3/8″ Split lock washer ……………………………………… 4
• V 3/8″ Flat washer ……………………………………………… 4
• Y Valve cap ……………………………………………………….. 2
• Z 5/16″-32 Hex nut…………………………………………….. 4
• AA Rubber washer ……………………………………………….. 2
• BB Star washer …………………………………………………….. 2

7X 89288

• Item Description ……………………………………………….. Qty
• E Air spring w jounce bumper ……………………………… 2
• E Air spring w jounce bumper (Trail Boss/Sierra AT4) 2
• F Roll plate (stainless steel) …………………………………. 4
• CC Stainless steel braided air line ………………………….. 2
• Q Airline assembly …………………………………………….. 1
• R AN-type fitting ………………………………………………… 2
• S 3/8″- 24 x 3/4″ Flat-head socket cap screw …… … 4
• T 3/8″- 24 x 7/8″ Hex-head cap screw ……………… … 4
• U 3/8″ Split lock washer …………………………………. … 4
• V 3/8″ Flat washer …………………………………………. ….4
• AA Rubber washer ……………………………………………….. 2
• BB M8 Flat washer……………………………………………….. 2
• CC Schrader valve with cap & nut ………………………….. 2
• DD AN to PTC fitting …………………………………………….. 2

Introduction

• The purpose of this publication is to assist with the installation and maintenance of the series air spring kits. All L kits utilize sturdy, reinforced, commercial-grade single or double, depending on the kit, convolute bellows.
• The air springs are manufactured like a tyre with layers of rubber and cords that control growth. kits provide up to 5,000 pounds (2,268kg) of load-levelling support with air adjustability from 5-100 PSI (.34-7BAR).
• It is important to read and understand the entire installation guide before beginning installation or performing any maintenance, service or repair.

NOTATION EXPLANATION
Hazard notations appear in various locations in this publication. The information that is highlighted by one of these notations must be observed to help minimize the risk of personal injury or possible improper installation which may render the vehicle unsafe. Notes are used to help emphasize areas of procedural importance and provide helpful suggestions. The following definitions explain the use of these notations as they appear throughout this guide.

• DANGER INDICATES IMMEDIATE HAZARDS THAT WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH.
• WARNING INDICATES HAZARDS OR UNSAFE PRACTICES THAT COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.
• CAUTION INDICATES HAZARDS OR UNSAFE PRACTICES THAT COULD RESULT IN DAMAGE TO THE MACHINE OR MINOR PERSONAL INJURY.

Installing the 7X 57288 Series System

GETTING STARTED

1. Raise and support the vehicle in a way, using safety stands or equivalent, that the axle can be safely dropped away from the frame. This will need to be done for the air spring assembly to be put into position between the axles and frame (Fig. D.1).
2. Remove the factory bolts that hold the upper brake line bracket in place. Reattach the bracket using the two new M8-1.25 x 50 hex-head cap screws (K), two new M8 flat washers (L), and two new spacers (H) (Figs. D.2 & D.3). Torque bolts to 10 lb.-ft. (14Nm).
3. Locate the jounce bumpers. Using a 10mm deep socket, remove the jounce bumpers (both sides) and discard them (Figs. D.4 & D.5).
4. For Trail Boss/Sierra AT4 models, unfasten 4 bolts and remove the spacer (Fig. D.6).
5. Using a T40-sized Torx bit, remove the two outermost Torx head screws on both wire harness guards, located on the front side of the axle (Fig D.7).
6. Remove the brake line bracket attached to the axle under the leaf spring on both sides of the vehicle. Set the bolt aside for reinstallation.
7. Attach the brake line tab bracket (G) using the factory hardware previously removed and tighten securely on both sides of the vehicle (Figs. D.8 & D.9).
8. Attach the brake line bracket to the brake line tab bracket using M8 hardware (J, L & M) on both sides of the vehicle (Fig. D.9). Torque bolts to 16 lb.-ft. (22Nm).
9. Position the forward clamp bracket (C) on the front side of the axle (Figs. D.10 & D.11).

ASSEMBLING THE AIR SPRINGS

1. Place a 3/8″-16 x 3″carriage bolt (O) through the innermost square hole on the rear side of each lower bracket (B) (Fig. D.12). NOTE
   The radiused (rounded) edge of the roll plate (F) will be toward the air spring so that the air spring is seated inside the roll plate.

2. Install a lower bracket (B) and roll plate (F) on each air spring (E) using two 3/8″-24 x 3/4″ flat-head socket cap screws (S) through the innermost mounting holes (Fig. D.13). Torque the flat-head screws to no more than 20 lb.-ft. (27Nm).

3. Install the 90 90-degreeivel elbow fitting (R) into the top of each air spring finger-tight. Tighten the swivel fittings with an additional one-and-a-half turns (Fig. D.13).

4. Attach the upper roll plates (F) and upper brackets (A) to the air springs (E) using two 3/8″-24 x 7/8″ bolts (T), two 3/8″ lock washers (U) and two 3/8″ flat washers (V) for each assembly (Fig. D.14). Torque bolts to no more than 20 lb.-ft. (27Nm). These brackets are left and right-hand specific (Fig. D.15).

5. With the bracket installed, ensure the swivel fitting is less than 7/8″ in height, and if not, tighten the fitting until this height is achieved (Fig. D.16).

INSTALLING THE AIR SPRINGS

CAUTION

1. Drop the frame to make room to put the assemblies into position.
   ENSURE THE VEHICLE IS PROPERLY SUPPORTED PRIBEFOREGINNING INSTALLATION.

2. Place the assemblies on the lower strike plate with the fitting side of the assembly to the outside (wheel side) of the vehicle. Align the tab on the forward clamp bracket (C) with the hole on the front of the lower bracket (B) (Fig. D.17).

3. Insert two carriage bolts (O) on the rear square holes and one carriage bolt on the front square hole of the lower bracket (B) (both sides) (Figs. D.17 & D.18).

4. Thread the 3/8″ flange nuts (N) onto the carriage bolts previously installed. Ensure the front and rear clamps align correctly under the axle jounce bumper strike plate. Torque all flange nuts evenly to 16 lb.-ft. (22Nm).

ATTACHING THE UPPER BRACKETS
There are two ways to attach the upper bracket.

For trucks that do not have a fifth-wheel hitch bracket alongside the frame:

1. Place U-bolts (I) over the frame as pictured on both sides of the vehicle (Fig. D.19).
2. Lower the vehicle or raise the axle while inserting the threaded portions of the U-bolts (I) through the corresponding holes in the upper brackets (A). Install flange nuts (N) finger-tight (Fig. D.20).
3. Adjust the upper bracket (A) as needed to vertically align the air spring with the frame (or as close to perpendicular as possible).
4. Torque all flange nuts (N) to 16 lb.-ft. (27Nm).

For trucks that have fifth-wheel hitch brackets alongside the frame rail:

1. There are holes in the middle of the bracket just forward and behind the jounce bumper mounting cups on the upper bracket (Fig. A.1). Once the upper brackets are in position, drill two 5/16″ holes through the bottom of the frame using the holes as a template and attach the upper brackets using the thread cutting screws (P). Torque all four fasteners to 15 lb.-ft. (20Nm).
2. Reattach the wire harness guards on the front side of the axle. Tighten securely (Fig. D.21).

Installing the Air Lines

CAUTION
KEEP AT LEAST 6″ (150) OF CLEARANCE BETWEEN ALL AIR LINES AND THE EXHAUST SYSTEM. AVOID SHARP BENDS AND EDGES.

INSTALLING NYLON AIR LINES

1. Cut the air line in half. Make clean, square cuts with a razor blade or hose cutter (Fig. E.2). Do not use scissors or wire cutters.
2. Use zip ties (W) to secure the airline to fixed points along the chassis. Do not pinch or kink the airline. The minimum bend radius for the airline is 1″ (25mm). Leave at least 2″ (50mm) of slack in the airline to allow for any movement that might pull on the airline.
3. Install the Schrader valve in the chosen location (Fig. E.3).

INSTALLING BRAIDED STAINLESS STEEL AIR LINES

CAUTION
KEEP THE AIRLINE AWAY FROM THE FUEL LINE, BRAKE LINES AND ELECTRICAL WIRES.

1. Use zip ties (W) to secure the airline to fixed points along the chassis every 6″ to 8″ (150-200mm). Leave at least 2″ (50mm) of slack to allow for any movement that might pull on the airline.
2. Tighten the airline hex nut finger-tight, then use 2 wrenches to turn 1 additional flat (1/6 of one full turn). Do not overtighten (Figs. E.4 or E.5). The easiest way to tighten the fitting is off the vehicle. Install the Schrader valve in the chosen location.
3. Coil and secure any excess airline in an area where it will not be susceptible to damage.

Air Line Setup Without Compressor System

Air Line Setup for Compressor Integration

The braided stainless steel airline cannot be trimmed.

Finished Installation

1. The images show the finished installation of both sides (Figs. F.1, F.2, F.3 & F.4).

NOTE
Finished installation images show the LoadLifter 5000 Ultimate Plus kit installed.

INSTALLATION CHECKLIST

• Clearance test — Inflate the air springs to 40-60 PSI (2.8-4.1BAR) and make sure there is at least 1/2″ (13mm) clearance from anything that might rub against each air spring. Be sure to check the tyre, brakes, frame, shock absorbers and brake cables.
• Leak test before road test — Inflate the air springs to 40-60 PSI (2.8-4.1BAR) and check all connections for leaks. All leaks must be eliminated before the vehicle is road-tested.
• Heat test — Be sure there is sufficient clearance from heat sources, at least 6″ (152mm) for air springs and airlines. If a heat shield was included in the kit, install it.
• Fastener test — Recheck all bolts for proper torque.
• Road test — The vehicle should be road tested after the preceding tests. Inflate the air springs to recommended driving pressures. Drive the vehicle 10 miles (16km) and recheck for clearance, loose fasteners and air leaks.
• Operating instructions — If professionally installed, the installer should review the operating instructions with the owner. Be sure to provide the owner with all of the paperwork that came with the kit.

Maintenance and Use Guidelines

1. Check air pressure weekly.
2. Always maintain normal ride height. Never inflate beyond 100 PSI (7BAR).
3. If the system develops an air leak, use a soapy water solution to check all air line connections and the inflation valve core before deflating and removing the air spring.

Minimum Recommended Pressure

• 5 PSI (.34BAR)

Maximum Air Pressure

• 100 PSI (7BAR)

CAUTION

• FOR SAFETY AND TO PREVENT POSSIBLE DAMAGE TO THE VEHICLE, DO NOT EXCEED THE MAXIMUM GROSS VEHICLE WEIGHT RATING (GVWR) OR PAYLOAD RATING, AS INDICATED BY THE VEHICLE MANUFACTURER.
• ALTHOUGH THE AIR SPRINGS ARE RATED AT A MAXIMUM INFLATION PRESSURE OF 100 PSI (7 BAR), THE AIR PRESSURE NEEDED IS DEPENDENT ON LOAD AND GROSS VEHICLE WEIGHT RATING.

References

• SOM - State of Michigan

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