RAS 4611-TD and 4611TD-HD 1999-2021 Toyota Tundra Instruction Manual

RAS 4611-TD and 4611TD-HD 1999-2021 Toyota Tundra

Item# 4611-TD & 4611TD-HD 1999 – 2021 TOYOTA TUNDRA

IMPORTANT

The RoadActive Suspension kit must NEVER be fitted while the vehicle is standing with the rear wheels on the ground. In this position the rear leaf springs will be under load and the RoadActive coil spring settings cannot be achieved, resulting in the RAS not working correctly. Always install with the rear axle and leaf springs hanging free.

• ALWAYS CHECK THE LEAF SPRINGS FOR ANY EXCESS WEAR, FATIGUE, CRACKED OR BROKEN BLADES OR WORN BUSHINGS -ESPECIALLY OLDER SPRINGS, THESE MUST BE REPLACED WHERE NECESSARY.
• IF THE VEHICLE THE RAS KIT WILL BE INSTALLED ON, IS FITTED WITH OVERLOAD LEAF SPRINGS, LOCATED ABOVE THE LEAF SPRINGS, THE OVERLOAD LEAF SPRINGS MUST FIRST BE REMOVED BEFORE THE KIT CAN BE INSTALLED.

ANY DEVIATION FROM THESE INSTRUCTIONS WILL VOID THE WARRANTY. THIS KIT WILL NOT BE WARRANTIED IF INSTALLED ON ANY VEHICLE USED FOR RACING, SIMILAR ACTIVITIES OR FITTED TO VEHICLES WHERE THE REAR SUSPENSION HAS BEEN MODIFIED IN ANY WAY

COMPONENTS INCLUDED

1. COIL SPRING 2
2. AXLE BRACKETS 2
3. EYE BRACKETS 2
4. THREADED ROD 2
5. CAP SCREW 14mm X 80mm 2
6. ROLLER 2
7. BOLT 12mm X 90mm 2
8. BOLT 8mm X 90mm 2
9. TUBE 13mm X 65mm 2
10. TUBE 9mm X 65mm 2
11. NUTS 12mm NYLOC 4
12. NUTS 8mm NYLOC 2
13. CUP BEARING 2
14. TUBE 13mm X110mm 2
15. BOLT 12mm X 120mm 2
16. 14mm HEX NUTS 10

IMPORTANT INSTALLATION NOTES

When Removing From The Packing Box

• There are two gold colored threaded rods that come with approx. six inches screwed into the end of the coiled springs, this is for packing purposes only.
• You may need to screw each of the threaded rods out of the coil springs, to lengthen kit to fit your vehicle.

When Setting Or Adjusting Tension On Coil Spring

• The axle should be hanging free & leaf springs should be in the maximum arch position.
• If not using a lift, jack stands should be placed under the front leaf spring eye.
• To be sure, any support (lift or jack), should only be utilized by placing within an inch of, but should not be supporting axle or differential

If You Require Removal Of RoadActive Suspension Kit

• The Axle should be hanging free and leaf spring in maximum arch position.
• Loosen the two nuts at the rear of the spring, turn the spring to screw the threaded rod out of the spring to completely eliminate the tension on the spring.
• Once the tension is eliminated (and kit is loose), remove front bolt to free kit

PLEASE NOTE

When installing this kit on a 1999 to PRESENT Toyota Tundra the rear shocks are located very close to the leaf springs, the two axle connecting bracket assemblies as shown below must be installed so that the brackets do not interfere with the shocks or other brackets on this pickup.

INSTALLATION INSTRUCTION

1. Before starting the installation make sure the vehicle is on a level surface, then place wheel chocks on both side of the front wheels

2. Loosen all the rear wheel lug nuts just one turn, but don’t remove at this stage.

3. Position a floor jack of (the correct capacity for your vehicle) under the differential housing

4. Next raise the rear of the vehicle with the jack sufficiently to place jack stands on both sides of the vehicle. As the vehicle has rear leaf springs, the ideal place to position the stands is under the front eye of the leaf springs, connected to the fixed shackles, as illustrated. With the floor jack still under the differential, next remove the rear wheels. With the lug nuts now loosened, this will make the removal a lot easier.

5. Next raise the rear of the vehicle with the jack sufficiently to place jack stands on both sides of the vehicle. As the vehicle has rear leaf springs, the ideal place to position the stands is under the front eye of the leaf springs, connected to the fixed shackles, as illustrated. With the floor jack still under the differential, next remove the rear wheels. With the lug nuts now loosened, this will make the removal a lot easier.

6. The RAS kit comes fully assembled out ofthe box. Remove one side and place it on top of the rear leaf spring witl1 the eye bracket hook (C) facing the rear of the vehicle. Next position the eye bracket over the rear wrap eye of the leaf spring, as illustrated.

7. If installing to vehicle on the ground, make sure the vehicle is well supported now remove the tow nuts from the rear shackle as shown in the illustrations
   NOTE: When fitting to a vehicle while using a lift, utilize a lift that lets the axle hang free. With the vehicle supported at the frame, simply remove the two nuts without removing the bolts. Remove the one side (outside) of the shackle

8. IMAGE SHOWING ONE SIDE OF THE SHACKLE REMOVED

9. Now position the eye bracket (C) over the eye of the leaf spring and replace the eye of the shackle that was removed and secure the two nuts. Repeat on the other side leaf spring

10. Before resuming installation of kit, once again make sure rear of vehicle is well supported and both rear wheels are removed for convenience. Review page 2 with illustration showing correct side for each bracket. This will avoid interference with the shocks or any brake lines or wiring (this should not be applicable on the majority of vehicles). Next place the one side kit (as shown in step 10) directly on top of the leaf springs, with the two arms of the bracket astride the leaf springs and two U bolts.

11. Next remove from the end hole in the Axle Connecting Bracket the nylon insert nut, tube spacer, bolt and two spacers washers (not shown in illustration 10). With these items removed set them aside.
    Note: This kit has two 1” diameter spacer washers as illustrated. (Not Shown In Image 11)

12. With the axle bracket no astride the leaf spring, relocate the tube spacer long bolt and two spacer washers

13. Attach the nyloc nut and tighten.
    VERY IMPORTANT : The bolt with spacer must be located directly below the leaf spring as shown.
    Note: This kit has two 1” diameter spacer washers as illustrated. These center the bracket on the leaf spring.(Not Shown in Image 13)

14. With both the axle connecting bracket and the eye bracket in place, tum the spring with one hand and hold the threaded rod with the other until the coil spring is supported
    HOW TO TENSION THE COIL SPRING.
    WITH THE REAR OF THE VEHICLE STILL SUPPORTED, THE LEAF SPRINGS STILL IN THEIR MAXIMUM ARCHED POSITION AND THE AXLE HANGING FREE

15. Position the two nuts on the threaded rod as shown. Then use a ratchet fitted with a 12 mm socket on the head of the cap screw, and a 22 mm wrench on the lock nuts closest to the eye bracket at the end of the threaded rod. The two nuts come locked together when the kits are assembled at our factory. By holding the threaded rod stationary and turning the coil spring the gap between the coils will start opening.

16. We have included with this kit two small discs that are to be used as a gauge to adjust the tension setting of the variable rated tension coil springs. These can be adjusted to two different settings depending on the vehicle’s requirement. For improved handling and 25% additional load carrying the correct adjustment between the coils is reached when the white disc (1mm thick) is used as a gauge and can just pass between the coils. For improved handling and 40% additional load carrying the correct adjustment is reached when the black disc (2mm thick) is used as a gauge and can just pass between the coils. the additional load carrying as stated above can vary depending on the vehicle.

17. Finally, tighten one of the two nuts located in the center of the threaded rod hard against the rear of the coil spring while holding the nut in the front of the spring, then tighten the second nut at the rear of the coil spring against the first while still holding the nut at the front of the spring.

18. With the one side now installed, check all the fasteners to See that they are secure. Now continue the installation on the opposite side. Once the installation on both sides is complete, raise the rear of the vehicle, replace the wheels, remove the two jack stands, lower the vehicle and remove the wheel chocks. Once you have taken the vehicle for a spin, we are sure that you will immediately feel the improvement in handling.

Should you require technical support please call us at
800-398-5036 or Email us at sales@activesuspension.com

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