VIGOR TR2525 Air Spring Bags Suspension Kit Installation Guide

VIGOR TR2525 Air Spring Bags Suspension Kit

Product Information

Specifications:

• Min. Pressure (Unloaded): 5 PSI
• Max Pressure (Loaded): 100 PSI

Product Usage Instructions

Step 1 – Preparation:

With the vehicle on a solid, level surface, chock the front wheels. Raise the vehicle by the rear axle and set it on jackstands rated for your vehicle’s weight. Remove the rear wheels and the jounce bumpers from the underside of the frame rail. The jouncebumper will not be re-used with the kit, but the bolt will be replaced.

Step 2 – Attach the Upper Bracket:

Attach the upper bracket to the air spring.

Step 3A – Attach the Lower Bracket (4WD):

Select the left lower bracket and fasten it to the air spring with a 3/8-16 x 3/4 flange bolt (finger tight).

Step 3B – Attach the Lower Bracket (2WD):

Select the left lower bracket and spacer and attach them to their spring with a 3/8-16 x 2 flange hex bolt (finger tight). Ensure that the open end of the spacer is mounted towards the lower bracket.

Step 4 – Attach the Frame Bracket to the Frame:

Attach the left frame bracket to the bottom of the frame reusing the jounce bumper bolt. Insert hex head bolts through the left frame bracket and into the holes on the outside of the frame. Secure with frame hole brackets inserted through the hole on the inside of the frame. Do not over-tighten (max 20 FT/LBS).

Step 5 – Installing the Assembly to the Vehicle:

Place the assembly on the leaf stack over the spring retainer and align the holes in the upper bracket with the lower four holes in the left frame bracket. Install four hex head bolts and fastening flange nuts in the lower mounting holes. Secure the left lower bracket to the leaf stack using bail clamps and flange nuts. Tighten the bolt holding the bottom of the air spring to the lower bracket.

Step 6 – Installation to the Passenger’s Side Assembly:

Reverse any orientations when assembling and installing the right (passenger) side of the vehicle.

FAQ

• Q: Can I inflate the air springs beyond 100 psi?
  • A: No, inflating beyond 100 psi can cause property damage orsevere personal injury. Stick to the recommended pressure range.
• Q: What should I do if I encounter difficulties during installation?
  • A : If you face challenges during installation, refer back to the user manual for detailed instructions or seek professional assistance.

Thank you for choosing our Air Spring kit. It will improve the overall handling and comfort of your truck and provide trouble-free service with proper installation. Please take a few minutes to read through and follow the instructions to identify the components by comparing the parts in your kit with the parts list below.

Please keep in mind that the air springs must expand during operation, so be sure that there is enough clearance to do so without rubbing against any other part of the vehicle. Air springs are the most important part in this kit so be sure that they have enough space and are properly installed. Be sure to take all applicable safety precautions during installation. The instructions listed in this document and the illustrations show the left or driver’s side of the vehicle. To install the passenger side simply follow the same procedures. Your kit includes two sets of inflation valves and air lines for each air spring. This will allow you to level your vehicle from side to side as well as from front to back.

IMPORTANT!

• Do not exceed the maximum load recommended by the vehicle manufacturer (GVWR). Maximum inflation pressure of 100 psi may allow you to carry a load that might exceed this causing possible damage to your vehicle and jeopardizing your safety. We recommend you to have your vehicle weighed once it is completely loaded and compare that weight to the maximum allowed. Check your vehicle owner’s manual or data plate on the driver’s side door for the maximum loads listed for your vehicle. When inflating your AirSprings, add air pressure in small quantities and check the pressure frequently during inflation. The air springs inflate much quicker since they require much less air volume than a tire.
• Do not inflate the air springs without restricting/securing the whole kit. The kit assembly must be restricted by the suspension or other adequate structure.
• Do not inflate beyond 100 psi. Improper use or over-inflation may cause property damage or severe personal injury.

PARTS LIST

• AIR SPRING (A):2

• UPPER BRACKET (B):2

• LEFT FRAME BRACKET (C):1

• RIGHT FRAME BRACKET (D):1

• LEFT LOWER BRACKET (E):1

• RIGHT LOWER BRACKET (F):1

• SPACER 1.25″ (G):2

• FRAME HOLE BRACKET (H):4

• BAIL CLAMP 4.5 X 2.5 X 2.0 (I):4

• AIRLINE TUBING (J):1

• INFLAT ION VALVE (K):2
  

• ELBOW FITTING (L):2
  

• 3/8″-16 FLANGE LOCK NUT (M):22
  

• 3/8″-16 X 1″ HEX HEAD BOLT (N):12
  

• 3/8″-16 X 3/4″ FLANGE BOLT (O):2
  

• 3/8″-16 X 2″ FLANGE BOLT (P):2
  

• 5/16″ FLAT WASHER (Q):4
  

• THERMAL SLEEVE (R):2
  

• NYLON TIE STRAP (S):6
  

• M10 FLAT WASHER (T):2

PRODUCT  OVERVIEW

INSTALLATION   INSTRUCTIONS

STEP 1 – PREPARE THE VEHICLE

With the vehicle on a solid, level surface, chock the front wheels. Raise the vehicle by the rear axle and set it on jack stands rated for the weight of your vehicle. Remove the real wheels. Remove the jounce bumpers from the upper side of the frame rail. The jounce bumper will not be re-used with the kit, but the bolt will be re-used.

STEP 2— ATTACH THE UPPER BRACKET

Select one air helper spring and one upper bracket from your kit. Insert the studs of the air spring into the mounting holes of the upper bracket. Make sure the air inlet is visible through the large access hole. Fasten the upper bracket to the air spring using the 3/8″-16 flange nuts, see Figure “A”. Install the elbow fitting into the air spring through the largeaccess hole in the upper bracket. Tighten the air fitting securely to engage the orange thread sealant. Position the fitting to point to the anticipated location of the air inflation valves.

STEP 3A— ATTACH THE LOWER BRACKET (4WD)

Select the left lower bracket and fasten it to the air spring with a 3/8″-16x 3/4″ flange bolt (finger tight). Figure “B”.

STEP 3B— ATTACH THE LOWER BRACKET (2WD)

Select the left lower bracket and spacer and attach them to the air spring with a 3/8″-16 x 2″ flange hex bolt (finger tight). The open end of the spacers should be mounted towards the lower bracket. See Figure “C”.

STEP 4— ATTACH THE FRAME BRACKET TO THE FRAME

Attach the left frame bracket to the bottom of the frame reusing the jouncebumper bolt in the hole from the jounce bumper removal. Next, insert the 3/8″-16 x 1″ hex head bolts through the left frame bracket and into the holes on the outside of the frame. Secure with frame hole brackets inserted through the hole on the inside of the frame. See Figure “A”.

DO NOT OVER TIGHTEN! 20 FT/LBS Max

STEP 5— INSTALLING THE ASSEMBLY TO THE VEHICLE

Place the assembly on the leaf stack over the spring retainer and alignthe holes in the upper bracket with the lower four holes in the left frame bracket. Install four, 3/8″ x 1″ hex head bolts and fasten using 3/8″-16flange nuts in the lower mounting holes.Secure the left lower bracket tothe leaf stack using bail clamps and 3/8″-16 flange nuts. Once aligned, tighten the bolt holding the bottom of the air spring to the lower bracket.See Figures “A”, “B” & “C”.

STEP 6 — INSTALLATION TO THE PASSENGER SIDE ASSEMBLY

Reverse any orientations when assembling and installing the right, or passenger, side of the vehicle.

STEP 7—INSTALL THE AIRLINE AND THE INFLATION VALVE

Uncoil the airline tubing and cut it into two equal lengths. DO NOT FOLD OR KINK THE TUBING. Try to make the cut as square as possible. Insert one end of the tubing into the elbow fitting installed in the top of the air helper spring. Push the tubing into the fitting as far as possible. Select a location on the vehicle for the air inflation valves. The location can be the bumper or the body of the vehicle, as long as it is in a location so the valve will not be damaged, but maintain accessibility for the air chuck, see Figure “E”. Drill a 5/16″ hole and install the air inflation valve using two 5/16″ flat washers per valve as supports, see

Figure “D”.Run the tubing from the air helper spring to the inflation valve, routing it to avoid direct heat from the engine, and exhaust pipe, and away from sharp edges. Thermal sleeves have been provided for these conditions. If the athermal sleeve is required simply slide the sleeve over the air line tubing to the location requiring protection. The airline tubing should not be bent or curved sharply as it may buckle. Secure the tubing in place with the nylon ties provided. Push the end of the airline tubing into the inflation valve as illustrated, see Figure “D”.

STEP 8— CHECK THE AIR SYSTEM

Once the inflation valves are installed, inflate the air helper springs to 70 psi and check the fittings for air leaks with an applied solution of soap and water. If a leak is detected at a tubing connection then check to make sure that the tube is cut as square as possible and that it is pushed completely into the fitting. The tubing can easily be removed from the fittings by pushing the collar towards the body of the fitting and then pulling out the tube. If a leak is detected where the fitting screws into the spring, screw the fitting into the air spring until the leak stops. Reinstall the tubing reinflate the air springs and check for leaks as noted above.

This now completes the installation. Install the wheels and torque the lug nuts to the manufacturer’s specifications. Raise the vehicle by the rear axle and remove the jack stands and lower the vehicle back onto the ground. Re- attach the negative battery cable and remove the wheel chocks from the wheels. Before proceeding, checkonce again to be sure you have proper clearance around the air springs. With a load on your vehicle and the airhelper springs inflated, you must have at least 1/2″ clearance around the air springs. As a general rule, the air helpersprings will support approximately 40 lbs. of load for each psi of inflation pressure (per pair). For example, 50 psi of inflation pressure will support a load of 2000 lbs. per pair of air helper springs. FOR BEST RIDE use only enough air pressure in the air helper springs to level the vehicle when viewed from the side (front to rear). This amount will vary depending on the load, location of load, condition of existing suspension and personal preference.

NOTE:

Too much air pressure in the air helper springs will result in a firmer ride, while too little air pressure will allow the helper spring to bottom out over rough conditions. Too little air pressure will also not provide the improvement in handling that is possible. TO PREVENT POSSIBLE DAMAGE MAINTAIN A MINIMUM OF 5 psi IN THE AIRHELPER SPRINGS AT ALL TIMES.

Once the air helper springs are installed, it is recommended that the vehicle not be lifted by the frame, as over-extension may occur, resulting in damage to the air helper springs. However, should it become necessary to raise the vehicle by the frame, deflate both air helper springs completely

CUSTOMER SERVICE:

If you have any questions about this product, please contact us below:

• Email： [email protected]

Thank you very much!

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