PACBRAKE HP10 Series Air Suspension Kit Installation Guide
- August 15, 2024
- Pacbrake
Table of Contents
- HP10 Series Air Suspension Kit
- Specifications:
- Product Usage Instructions:
- Important Safety Information:
- Safety Warnings:
- Installation Tips:
- Air Line Cutting Note:
- Q: Can this air suspension kit increase the Gross Vehicle
- Q: What is the maximum load capacity of this air suspension
- Q: Is it safe to inflate the air springs above 100 PSI?
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
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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.
2
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)
3
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
7
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
8
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
9
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)
13
10
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
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