DORMAN 949-527 Air Spring to Coil Spring Conversion Kit Instruction Manual

DORMAN 949-527 Air Spring to Coil Spring Conversion Kit

IMPORTANT INFORMATION

ATTENTION: Refer to the appropriate shop manual for your vehicle to obtain specific service procedures for this part. If you do not have a service manual or lack the skill to install this part, it is recommended that you seek the services of a qualified technician. Pay special attention to all cautions and warnings included in the shop manual. Read and follow all instructions carefully.

Air Suspension Conversion Kit
General Installation Instructions

When servicing any vehicle be sure to follow all safety procedures. First, make sure that when lifting the vehicle that you use an appropriate jack with a proper weight rating. Before going underneath any vehicle, make sure that it is properly supported with sturdy jack stands and on level ground so that the vehicle doesn’t fall or slide off of the jack and onto you. As with any automotive repair, make sure you have the appropriate tools to do the job so you don’t damage any parts on the vehicle. Safety glasses and mechanic’s gloves should also be worn for your protection.

Take care not to exceed the Gross Vehicle Weight Rating (GVWR), or the maximum load recommended by the manufacturer. It is important that all the vehicle owner manuals recommendations are followed for your own safety and to prevent damage to the vehicle.

Once you are ready to disable the ride light, you will need to disconnect the negative battery cable (-) to prevent electrical shock/malfunction.

Detailed instructions by application are available at: https://www.dormanproducts.com

If you have any further questions or concerns about this installation please give our Tech Support Line a call at 1-800-523-2492.

Parts included in this kit

• (2) fully assembled shocks

Tools needed for installation

• Metric socket set
• Floor jack
• Jack stands
• Metric wrenches
• Screw drivers (Phillips and flat head)
• Wire cutter/stripper/crimping tool
• Level work surface

Read instructions before attempting installation. If you have problems during the install, feel free to call our technical support line. Please have your invoice handy before calling for technical help

Front Removal Instructions

• Read the instructions sheet and any instructions printed on the parts package carefully prior to removing the strut from the vehicle.
• Do not grip polished rod with any tool. Nicks or scratches will cause decreased service life
• If this unit is gas pressurized, do not heat or open. Always wear safety glasses for eye protection. Use safety stands whenever a procedure requires you to under the vehicle.
• Raise the vehicle
• Support the lower control arm with a jack stand.

Front Removal

• Remove the 30 amp RTD fuse.

• Remove the front wheels.

• Disconnect the electrical connector from the shock.

• Grasp the connector lock tabs (1,2). Rotate the connector tabs counterclockwise until the connector unlocks.

• Disengage the connector from the tenon by firmly pulling the connector up.
  

• Remove the upper shock mount.
  

• Remove all original parts.
  

• Remove the lower shock mounting bolt.

• Remove shock.
  

Front Installation Instructions

• Install the shock absorber. Insert the stem through the hole in the shock bracket on the frame.

• Install the lower shock mount and bolt.

• Tighten all bolts to factory specifications.

• Cut the electrical connector from the vehicle harness.

• Install the supplied resistors.
  

• Reinstall the wheels and safely set vehicle on the ground.

Rear Kit

Parts included in this kit

• (2) Rear shocks with bushings

• (2) Rear coil springs

• (2) Bypass units for the shocks electrical connectors
  

• (1) Bypass unit for the vent solenoid valve
  

Tools needed for installation

• Metric socket set
• Floor jack
• Jack stands
• Metric wrenches
• Screw drivers (Phillips and flat head)
• Wire cutter/stripper/crimping tool
• Level work surface
• Spring compressor (if applicable)
• Allen wrenches

Rear Removal Instructions

• Raise and support the vehicle. Caution: Make sure the vehicle is properly supported.

• Support the rear axle.
  

• Remove the electrical connector.

• Remove the air-line.
  

• Remove the upper shock bolt.
  

• Remove the lower shock bolt.
  

• Remove the shock.

• Install and tighten the upper shock mount only.

Rear Spring Removal

• Remove the brake line bracket from the rear differential, to prevent stretching the brake line.
  

• Remove the ABS wire from the frame clip to prevent stretching the wire.
  

• Remove the ride height sensor bracket.
  

Rear Spring Removal

• Work on one side at a time

• Remove the stabilizer shaft link retaining nut from the frame.

• Remove the stabilizer link.
  

• Lower the axle until the coil spring is fully unloaded.

• Remove the coil spring.

• Retain both rubber isolators they will be reused in the installation of the new spring.
  

Rear Spring Installation

• Install the new coil spring.

• Reinstall the factory isolators.
  

• Raise the axle and install the lower shock bolt.

• Install the stabilizer link.

• Install the ride height sensor bracket.

• Attach the ABS line.

• Attach brake line to differential.

•  Tighten all fasteners completely.
  

Air Suspension Light Disarm Instructions

• Install the supplied resistors to the shock’s electrical connector.

• The factory connector will need to be removed and the wires butt connected (there is no polarity with this connection). Either wire from the bypass resistor can be connected to either wire from the vehicle’s harness.
  

• Should your vehicle have issues with the vent solenoid valve then you will want to proceed to the next procedure. Make sure to disconnect the negative battery cable, or remove the RTD 30amp fuse. Replace fuse after repair.
  
  

• Splice the resistors blue wire into the dark blue wire at the vehicle harness.

• Splice the resistor white wire into the tan wire in the vehicle harness.

• Splice the resistor black wire into the grey wire of the vehicle harness.

• Wire the resistor up to the vehicle harness at the compressor to eliminate the “Check Suspension” message.

• Leave the compressor unplugged.

• Locate the compressor and unplug the electrical connector.

• Remove the wire insulation.
  

• Locate and cut the dark blue wire, the tan wire, and the grey wire.
  

• Splice the blue wire from our resistor to the dark blue wire in the vehicle harness.

• Splice the white wire to the tan wire.

• Splice the black wire to the grey wire.
  

• Leave the compressor unplugged. Installation is now complete
  

• Reinstall the 30 amp fuse.

• Fuse designation is RTD fuse.
  

Disclaimer

Even though every attempt is made to ensure this information is complete and accurate, it is impossible to account for all possible circumstances or situations. Please consult with a qualified auto technician before attempting to perform any work you are not qualified to do. Automobiles can be hazardous to work on; be sure to take all necessary safety precautions. Failure to do so may result in property damage or personal injury. Certain motor vehicle standards and performance requirements may apply to your motor vehicle (such as Federal Motor Vehicle Safety Standards by the National Highway Traffic Safety Administration). Be sure that your work is performed in accordance with such standards and that you do not disable any motor vehicle safety feature.

©2018 Dorman Products, Inc.
No reproductions in whole or in part without prior written approval.

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