PACBRAKE HP10 Series Air Suspension Kit Installation Guide

HP10 Series Air Suspension Kit

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Specifications:

• Product: Air Suspension Kit

• Compatible Vehicles: Chevrolet Silverado 4500HD/5500HD/6500HD
  (2WD/4WD) International CV Class 4/5 Trucks (2WD/4WD)

• Load-Leveling Capacity: Up to 7500 lbs

• Application: Towing/hauling big loads regularly

Product Usage Instructions:

Important Safety Information:

This air suspension kit is designed to eliminate sag, sway, and
bottoming out while providing added support for a smooth and safe
ride. It is crucial to follow the safety guidelines and
recommendations provided in this manual to ensure proper
installation and operation of the kit.

Safety Warnings:

• Read and abide by all instructions in the manual, paying close
  attention to warning icons.

• Do not exceed the maximum load capacity specified by the
  vehicle manufacturer.

• Do not exceed a maximum of 100 PSI in the air springs for safe
  operation.

Installation Tips:

• Ensure correct application information for the vehicle.

• Check for rear wheel brake proportioning valve presence before
  installation.

• Use anti-seize on fasteners to prevent corrosion.

Air Line Cutting Note:

When cutting the nylon air line, use the hose cutter provided in
the kit or a sharp utility knife to ensure a proper connection and
avoid leaks. Using scissors or wire cutters may distort the line
and void the warranty.

FAQ:

Q: Can this air suspension kit increase the Gross Vehicle

Weight Rating (GVWR) of my vehicle?

A: No, the GVWR is determined by the vehicle manufacturer and
cannot be increased by this kit. Always adhere to the
manufacturer’s specified limits to avoid damage or warranty
void.

Q: What is the maximum load capacity of this air suspension

kit?

A: The kit is rated for up to 7500 lbs of load-leveling
capacity, making it suitable for towing or hauling heavy loads
regularly.

Q: Is it safe to inflate the air springs above 100 PSI?

A: No, for safe operation and maximum air spring life, do not
exceed a maximum of 100 PSI in the air springs. Exceeding this
limit can lead to damage or safety hazards.

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version française

AIR SUSPENSION KIT

Chevrolet Silverado 4500HD/5500HD/6500HD (2WD/4WD) International CV Class 4/5 Trucks (2WD/4WD)
Eliminate your vehicle’s sag, sway and bottoming out while providing added support for an overall smooth and safe ride with this extreme duty air suspension kit. Rated for up to 7500 lbs of load-leveling capacity +, this kit is ideally suited for those towing/ hauling big loads on a regular basis.

• See application guide for proper fitment. + Applications vary. Never exceed manufacturer’s recommended Gross Vehicle Weight Rating

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Chevrolet Silverado 4500HD / 5500HD / 6500HD & International CV Class 4/5 Trucks L6517
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IMPORTANT
This air suspension kit will not increase the GVWR (Gross Vehicle Weight Rating), as the GVWR is determined by the vehicle manufacturer. Do not exceed the maximum capacity listed by the vehicle manufacturer. For safe and proper operation of the vehicle, never exceed a maximum of 100PSI in the air springs. Staying under the pressure limit will ensure maximum air spring life. Failure in doing so may result in damage to your vehicle and/or a void warranty.

SAFETY WARNINGS!

Please read and abide the instructions found in this manual, paying close attention to the helpful, cautionary or dangerous warning icons highlighting important safety recommendations and maintenance suggestions throughout this manual.

HELPFUL INSTALL TIP Additional information that could potentially make the job a little easier.
PLEASE USE CAUTION Unsafe practices could result in damage to you or your vehicle, or others.
DANGER WARNING Hazards which could result in severe personal injury or death.

Serious personal injury or death may result from an air spring failure or accident due to improper installation or air spring pressure operation or maintenance.
Inflating an unsecured air spring is dangerous. If it bursts, it could be hurled into the air with explosive force resulting in serious personal injury or death. Never inflate an air spring unless it is secured to the vehicle.
Removing and replacing air springs can be dangerous. This is only a job for a qualified service professional. Never perform air spring service procedures without proper training, tools, and equipment.

BEFORE STARTING THE INSTALLATION
Ensure the application information is correct for the make, model and year of the vehicle you are installing the kit on.
Some vehicles are equipped with a rear wheel brake proportioning valve. Check with the manufacturer before installing the air spring kit, as it may affect braking performance.
It is recommended to use a good quality anti-seize on all fasteners. This will reduce the chance of corrosion on the fasteners and will help facilitate removal, if required at a later date.
PLEASE NOTE: This kit contains push-to-connect fittings; using scissors or wire cutters to cut the nylon air line will distort the line and cause the connection to leak. The air line must be cut off squarely with the hose cutter provided in this kit, or a sharp utility knife. Failure to do so may void the warranty.

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Chevrolet Silverado 4500HD / 5500HD / 6500HD & International CV Class 4/5 Trucks L6517

KIT CONTENTS
Please confirm the items below are provided in your kit before starting the installation. Reference the kit explosion diagram on the following page for part assembly.

XTREME DUTY KITS
A Double Convoluted XD Spring

QTY PART #
2 HP10438

XTREME DUTY JOUNCE BUMPER KITS QTY PART #
A Double Convoluted XD Spring w/ Jounce Bumper 2 HP10438J

KIT CONTENTS
B Roll Plate, 4.5″ Diameter C Fitting, 1/4″ NPT Brass Straight D Upper Bracket, Driver Side Air Spring E Upper Bracket, Drivers Side Frame F Upper Bracket, Passenger Side Frame G Upper Bracket, Passenger Side Air Spring H Bracket, Lower I Plate, Lower Bracket Adjustment J Extension, Lower Bracket K Axle Strap L Round Strap, Axle M Spacer, Sleeve N Bolt, 3/8″ – 24 x 3/4″ Countersunk O Bolt, 3/8″ – 24 x 1″ Hex Head P Bolt, 3/8″ – 16 x 1.25″ Carriage Q Bolt, 3/8″ – 16 x 7″ Carriage R Bolt, 3/8″ – 16 x 10″ Carriage Bolt S Bolt, M10 x 1.5 x 35mm Button Head T Washer, 3/8″ Split Lock U Washer, 3/8″ Flat V Nut, 3/8″ Nylon Lock W Nut, M10 x 1.5mm Clip-On Barrel X Heat Shield Y Worm Gear Ring Clamp 2.5″ to 3.5″

QTY
4 2 1 1 1 1 2 2 2 3 1 1 4 4 8 1 7 2 4 16 6 2 1 2

PART #
HP10054 HP1099 HP1418 HP1417 HP1424 HP1425 HP1419 HP1423 HP1426 HP1383 HP0009 HP1422 HP1008 HP1183 HP1149 HP1409 HP1329 HP1414 C18007 C653 HP1000 HP1421 HP0012 HP1001

HP10438

HP10438J

KIT LAYOUT

REQUIRED TOOLS
· Hoist or Floor Jack · Safety Stands · Safety Glasses · Torque Wrench · Standard Combination Wrenches · 7/32″ Hex Allen Wrench · Ratchet · Metric & Standard Sockets · Hose Cutter (included) or Sharp Utility Knife · Pipe Thread Sealant · Spray Bottle with Dish Soap/Water · Air Compressor/Compressed Air Source
(to test/fill air springs)

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Chevrolet Silverado 4500HD / 5500HD / 6500HD & International CV Class 4/5 Trucks L6517

KIT EXPLOSION DIAGRAM
DRIVER SIDE ASSEMBLY SHOWN
R D V

K N

I O
W

C S

H

B

A

XD Springs (HP10438)

XD Springs w/ Jounce Bumper (HP10438J)

M I

O

E

G

F

S

Q

J

U

L
P T
4

Chevrolet Silverado 4500HD / 5500HD / 6500HD & International CV Class 4/5 Trucks L6517
KIT EXPLOSION DIAGRAM
DRIVER SIDE ASSEMBLY SHOWN Assembled onto simplified frame and axle for representation
5

Chevrolet Silverado 4500HD / 5500HD / 6500HD & International CV Class 4/5 Trucks L6517

INSTALLATION INSTRUCTIONS

1 MEASURE STOCK RIDE HEIGHT & CLEARANCE
Park the vehicle on a level surface and remove any unnecessary weight from the vehicle to attain a “Normal Ride Height”.

Using a measuring tape, measure the distance between the center of the wheel hub and the bottom of the fender well (see Figure 1A for reference) this will give you your stock Normal Ride Height.

Note the ride height for all four tires.

Check the clearance between the outside of the frame and the inside

of the rear tires (as shown in red in Figure 1B), a minimum of 5″ is

1A

required for adequate air spring clearance.

2 REMOVE REAR WHEELS
PLEASE NOTE: This step is optional for this installation but will make the install easier to complete.

Place wheel chocks in front of and behind both front wheels.

Raise the rear of the truck high enough to remove both wheels and

attain a comfortable working height.

1B

Place two jack stands under rear axle (as shown in Figure 1B).

Lower the vehicle until the axle is supported by the jack stands.

Remove rear wheels.

3 PRE-ASSEMBLE SPRING AND FRAME BRACKET
Install the air fitting into the port on the top of the air spring.
Tighten the fitting finger tight plus an additional 1.5 turns. The use of Teflon tape or thread sealant is recommended.
Set a roll plate and the upper frame bracket on the top surface of the air spring.
Ensure all holes are aligned and install two 3/8″ ­ 24 x 3/4″ countersunk bolts.
Torque bolts to 20 ft-lbs (27 N·m)

3
6

Chevrolet Silverado 4500HD / 5500HD / 6500HD & International CV Class 4/5 Trucks L6517

4 PRE-ASSEMBLE SPRINGS AND LOWER BRACKETS
Insert two 3/8″ ­ 16 x 7″ carriage bolts through the square holes in the lower bracket. Place a roll plate on the bottom surface of the air spring, followed by the bracket with carriage bolts. Align the holes in the air spring and roll plate with the pair of holes in the lower bracket (See Figure 4A & 4B for reference).
Take note of the bracket orientations as this defines which assembly is for the driver and passenger side. Secure with two 3/8″-16 x 7/8″ hex head bolts, two 3/8″ flat washers and two 3/8″ lock washers Torque bolts to 20 ft-lbs (27 N·m)
5 UNBOLT FRAME BRAKE LINE BRACKETS
Remove the bolt securing the upper brake line bracket to the frame. Gently pull the brake lines away from the frame to allow clearance for upper bracket installation.
Brake lines omitted for clarity in images
Repeat on the other side of the vehicle
6 RELOCATE AXLE BRAKE LINES
Remove the bolt securing the brake lines to the axle and gently pull the brake lines rearward and away from the mounting hole. Secure the brake line relocation bracket to the axle as shown using the previously removed bolt.
Brake lines omitted for clarity in images Attach the axle brake line bracket to the brake line relocation bracket using a ¼” ­ 20 x 0.75″ bolt, two ¼” flat washers and a ¼” nylon lock nut. Torque hardware to 76 in-lbs (8.6 N·m)
Repeat on the other side of the vehicle

DRIVER SIDE

PASSENGER SIDE

4A

4B

5
6A
6B
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Chevrolet Silverado 4500HD / 5500HD / 6500HD & International CV Class 4/5 Trucks L6517
7 REMOVE FACTORY STRIKE BLOCK BOLTS
Remove the four bolts and retaining nuts securing the factory strike block to the frame. As each bolt is removed, replace it with a ½” ­ 13 x 2″ bolt and ½” flat washer (as shown in Figures 7A & 7B). Discard the removed hardware.
Repeat on the other side of the vehicle 7A

7B

8 INSTALL FRAME SUPPORT BRACKET
Install the upper support bracket into the vehicle (as shown in Figure 8 on the following page) by placing the bracket onto the previously inserted strike block bolts.

Ensure the upper brake line bracket sits above the installed bracket and no brake lines are pinched or under the frame support bracket.

Brake lines omitted for clarity in images

Secure the bracket with four ½” serrated nuts. Thread the nuts until

they contact the bracket. Do NOT fully tighten at this time.

8

Repeat on the other side of the vehicle

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Chevrolet Silverado 4500HD / 5500HD / 6500HD & International CV Class 4/5 Trucks L6517
9 INSTALL SPRING ASSEMBLY
Place the previously assembled air spring in the vehicle (as shown in Figure 9). Secure the spring assembly to the frame support bracket with four 3/8″ ­ 16 x 1.5″ bolts, eight 3/8″ flat washers and four 3/8″ nylon lock nuts. Do NOT fully tighten at this time. Repeat on the other side of the vehicle
9
10 TORQUE SPRING INSTALLATION HARDWARE
Adjust the spring assembly to place the upper frame bracket plate flat against the underside of the vehicle frame. It may be necessary to raise the axle or lower the vehicle frame to achieve the required placement.
PLEASE NOTE: The upper frame bracket MUST rest flat against the underside of the vehicle frame (as shown in Figure 10) before torquing any hardware. Not resting the bracket flat may result in kit failure or vehicle damage during use. When proper bracket placement is achieved, torque hardware as follows: · Torque the four ½” ­ 13 x 2″ bolts to 80 ft-lbs (108.5 N·m).
10 · Torque the four 3/8″ ­ 16 x 1.5″ bolts to 31 ft-lbs (42 N·m). Repeat on the other side of the vehicle
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Chevrolet Silverado 4500HD / 5500HD / 6500HD & International CV Class 4/5 Trucks L6517
11 INSTALL AXLE STRAP
Secure the spring assembly to the vehicle axle with an axle strap and two 3/8″ serrated flange nuts (see Figure 11A on following page). Adjust the lower bracket on the axle to achieve the proper spring alignment (as per Figure 11B on the following page). Torque the serrated flange nuts to 16 ft-lbs (21.7 N·m)
11A

11B
12 SECURE UPPER BRAKE LINE BRACKET
Attach the upper brake line bracket to the frame support bracket (as shown in Figure 12).
Secure the bracket using a ¼” ­ 20 x .75″ bolt, two ¼” flat washers and a ¼” nylon lock nut.
Torque hardware to 76 in-lbs (8.6 N·m)

Repeat on the other side of the vehicle 12

13 SECURE EMERGENCY BRAKE LINE
On the driver’s side of the vehicle, the E-brake cable must be relocated to prevent interference with the air spring.

Attach the E-brake cable to the upper bracket using an adel clamp (as shown in Figure 13).

Secure the cable and clamp using a ¼” ­ 20 x .75″ bolt, two ¼” flat washers and a ¼” nylon lock nut.

Torque hardware to 76 in-lbs (8.6 N·m)

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Chevrolet Silverado 4500HD / 5500HD / 6500HD & International CV Class 4/5 Trucks L6517

INSTALL AIR LINE
Two fill valves are provided in this kit. The most common place to install them is in place of the license plate fasteners. Alternatively, two 5/16″ holes can be drilled in a location of your choosing.
Cut the air line assembly into two equal lengths with the hose cutter provided in this kit or a sharp utility knife.
PLEASE NOTE: This kit contains push-to-connect fittings; using scissors or wire cutters to cut the nylon air line will distort the line and cause the connection to leak. The air line must be cut off squarely with a hose cutter or a sharp utility knife.
Install one air line at a time starting at the fill valve location. Place a 5 /16″ nut on the air valve. Leave enough of the inflation valve in front of the nut to extend through the hole, install a flat washer, and 5 /16″ nut and cap (reference Figure A for assembly). There should be enough valve exposed after installation ­ approximately ½” ­ to easily apply a pressure gauge or an air chuck.
Route the air line back to the NPT fitting on the air spring, then cut the hose to length. Moisten the end of the air line prior to inserting it into the fitting and push it in until it stops.
Repeat with the other fill valve. A
Secure the air lines using the provided tie-straps, away from any moving items and heat sources.
CHECK SYSTEM FOR LEAKS
Inflate both air springs to 90 psi and then use a mixture of dish soap and water on all air line connections to detect any air leaks. Large, expanding bubbles indicate a leak (as shown in Figure B). Repair as necessary and retest.
Inflate air springs to a predetermined value and on following day recheck pressure. If one or both of air springs have lost pressure, an air leak is present.
Leak must be repaired, and then retested until no leaks exist.

CONGRATULATIONS! You have completed the install

*Air Spring & NPT Air Fitting may differ between kits

B

After Installation continues on the following page.

11

Chevrolet Silverado 4500HD / 5500HD / 6500HD & International CV Class 4/5 Trucks L6517
Thank you again, and congratulations on the installation of your Air Suspension kit.
AFTER COMPLETING THE INSTALLATION
The air spring must have clearance between itself and the surrounding components to prevent any contact when spring is inflated or compressed. Trimming off excess bolt length may also be required to ensure no contact with the spring or other suspension components can be made once installed.
If removed, re-install the wheels and torque fasteners to the manufacturer’s specifications. Re-torque all fasteners after the first 500 miles of driving.

OPERATING YOUR VEHICLE WITH AIR SUSPENSION
Air springs have minimum and maximum recommended pressure requirements:

PART #
HP10189 HP10560 HP10001 HP10173 HP10199 HP10083 HP10083J HP10000 HP10000J HP10068 HP10438 HP10438J

SPRING STYLE
In-Coil
Sleeve Style
Single Convoluted Double Convoluted Large Double Convoluted Double Convoluted

SPRING TYPE

MIN PSI MAX PSI

STANDARD DUTY STANDARD DUTY

5 PSI

70 PSI

STANDARD DUTY

STANDARD DUTY

10 PSI

100 PSI

STANDARD DUTY

HEAVY DUTY

5 PSI

100 PSI

HEAVY DUTY with JOUNCE BUMPER

0 PSI* / 5 PSI

100 PSI

HEAVY DUTY

5 PSI

100 PSI

HEAVY DUTY with JOUNCE BUMPER

0 PSI* / 5 PSI

100 PSI

HEAVY DUTY

5 PSI

100 PSI

EXTREME DUTY

5 PSI

100 PSI

EXTREME DUTY with JOUNCE BUMPER

0 PSI* / 5 PSI

100 PSI

• Springs with a jounce bumper can be run at zero PSI when vehicle is unloaded only

For safe and proper operation, never operate the vehicle over the maximum listed PSI in the air springs. Staying under the pressure limit will ensure maximum air spring life. Failure in doing so may result in damage to your vehicle and/or a void warranty.

It is recommended to check the air pressure in your air springs daily for first couple of days to ensure a leak has not developed.

Air springs are designed to maintain the vehicle’s stock ride height with a load. Do not use the air springs as a means to lift vehicle with no load. This will result in a harsh ride.

SERVICING YOUR VEHICLE WITH AIR SUSPENSION
When lifting the vehicle with a floor jack or hoist on the frame, never allow the air spring to limit the travel of the axle. Try to always jack the vehicle on the axle. Suspending the axle with the air spring limiting the axle travel will damage the air spring and void the air spring warranty.

WARRANTY
See additional warranty included with this kit for details.

12

References

• P65Warnings.ca.gov

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