Part # 11380199 99-06 Silverado Level 1 Complete Air ... · 99-06 Silverado Level 1 Complete Air Suspension System ... 3/4" O.D. x 5/8 I.D. ... 2 90001082 Short bump stop

350 S. St. Charles St. Jasper, In. 47546 Ph. 812.482.2932 Fax 812.634.6632

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Part # 11380199 99-06 Silverado Level 1 Complete Air Suspension System

Front Components:

1 11381099 Front CoolRide System for OEM Control Arms

1 11380509 Front RQ Series Smooth Body Shocks

Rear Components:

1 11386799 Rear AirBar – Bolt-on 4 Link

1 11380809 Rear RQ Series Smooth Body Shocks

Compressor System:

1 30154000 3 gallon Analog Compressor Kit

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Part # 11381099 99-06 Silverado Front CoolRide

For Use w/ Stock Lower Arm Components:

2 90006873 224 double convoluted air spring

1 90000392 Drivers side lower air spring mount

1 90000393 Passenger side lower air spring mount

2 90000214 Upper air spring mount

2 90001083 Medium bump stop

Hardware:

2 99081001 8mm x 1.25” x 140mm Sway bar end link

2 99371001 3/8” x 3/4" USS bolt Air spring to lower plate

2 99373005 3/8” lock washer Air spring to lower plate

6 99373003 3/8” SAE flat washer Air spring mounting

4 99372002 3/8” USS Nylok nut Air spring to cup bracket

2 99373007 3/8” x 1” self tapping bolt Air spring plate to lower arm

2 99433002 7/16” SAE flat washer Cup bracket to frame

2 99435001 7/16” x 6” stud Cup bracket to frame

2 99432001 7/16” USS Nylok nut Cup bracket to frame

2 99621004 5/8 x 3” SAE bolts Air spring plate to lower arm

2 99622006 5/8” SAE thin Nylok jam nut Air spring plate to lower arm



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Installation Instructions

*** Must use RideTech Front Shock Kit ***

2. Install the lower air spring mounting plate into the lower control arm using the oem sway bar attachment hole as the primary locater. The remaining attachment holes will then be drilled so the plate can be securely fastened to the control arm. 3. The sway bar end link must be shortened by approx. 2”. A new shorter bolt is provided, but the

sleeve must be cut by the installer. Doing this will re-align the sway bar for proper clearance and effectiveness.

1. The upper coil spring bucket must be trimmed for air spring clearance. The trimmed piece will measure approx. 1 3/4 x 1 3/4. A die grinder and a cutoff wheel will do the job nicely. The objective here is to create clearance for the air spring. Check this area VERY carefully for abrasion against air spring.


9. Remove original bumpstop and replace with the shorter one supplied. Although, it is OK to let the suspension bottom out on the air spring. 10. Ride height on this air spring is around 4.5” - 5.5” tall. IT IS THE FINAL RESPONSIBILITY OF THE CUSTOMER / INSTALLER TO MAKE SURE THAT THE AIR SPRING DOES NOT RUB ON ANYTHING AT ANYTIME!!

4. Apply thread sealant onto an air fitting and screw it into the top of the air spring. 5. Place the upper cup bracket on top of the air spring and secure w/ the 3/8” Nylok nut and flat washers supplied. 6. Screw the 7/16” all thread into the nut in the bottom of the cup bracket. 7. Place the assembly into the upper coil spring pocket w/ the stud sticking through the factory shock hole. Secure w/ a 7/16” Nylok nut and flat washer. 8. Fasten the air spring to the lower arm using a 3/8” x 3/4 bolt, flat washer and lock washer.


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Part # 11380509 99-06 Silverado Front RQ Series Shock Kit

For Use with CoolRide Shock:

2 22449999 RQ Smooth Body Shock Cartridge

2 70011138 ¾” ID Shock Bushing

2 90002103 5/8” ID Inner Sleeve

Components:

4 70011140 Stem Bushings

4 70011141 Stem Washers

1 90000378 Drivers side upper shock mount

1 90000379 Passenger side upper shock mount

2 90000471 Aluminum shock spacer

2 90001619 Shock stud

Hardware:

2 99373007 3/8” x 1” self tapping bolt Shock mount to frame

8 99373003 3/8 SAE flat washer Shock mount to frame

4 99372002 3/8” USS Nylok nut Shock mount to frame

4 99371003 3/8” x 1” USS bolt Shock mount to frame

2 99372005 3/8”- 24 Nyloc Nut Upper Shock Stud



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Installation Instructions

1. The upper shock mount will bolt the rear upper control arm mounting bracket and to the side of the frame rail. It will use one existing hole in the control arm bracket. A 2nd 3/8” hole must be drilled in the control arm bracket. A 5/16” hole must be drilled into the frame rail for the 3/8” self tapping bolts. 2. Fasten the shock to the bracket using new bushings/hardware supplied. 3. The lower shock stud must be welded to the rear leg of the lower control arm. To determine it’s location; place a jack under the lower control arm and fully compress the air spring. Then fully compress the shock absorber. Swing the shock up to the center of the control arm and mark the center of the eye. Drill 5/8” hole in the arm and then weld in the stud. 4. Fasten the shock to the stud w/ hardware supplied.



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Part # 11386799

99-06 Silverado Rear AirBar Components: 2 90009000 Tapered sleeve air spring 1 90000304 Lower bridge assembly 1 90000307 Upper bridge assembly 2 90000311 C-notch spacer for 2000 & older trucks 1 90000209 Carrier bearing bracket 1 90000310 ¼” transmission spacer 2 90000070 Air spring roll plate 2 90000042 Upper axle bracket 1 90000308 Panhard bar axle bracket 1 90000207 Driver side c-notch frame section w/ shock mount 1 90000208 Passenger side c-notch frame section w/ shock mount 1 90000305 Driver side upper frame bracket 1 90000306 Passenger side upper frame bracket 2 90001038 Lower bar – WW 33.250” 2 90000987 Upper bar - TW 23.625” (C-C 25.375”) 1 90000971 Panhard bar - TW 20.500” (C-C 22.250”) 2 90000198 Inner bushing sleeve - 3/4" O.D. x 5/8 I.D. (installed in lower bar) 4 90001085 Poly bushing half - (installed in lower bar) 3 90001584 Threaded rod end - 5/8” x 3/4" (w/ rubber bushing pressed in) 8 90001942 Rubber bushing - Pressed into bars & rod ends 2 90001082 Short bump stop 2 90001617 .625” shock stud 1 99010008 Hardware kit



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Hardware Kit – Part # 99010008 4 3/8 x 3/4 uss bolts upper air spring mounting 6 3/8 lock washer air spring mounting 6 3/8 x 1 uss bolt air spring mounting & carrier bearing plate 4 3/8 nyloc nuts carrier bearing plate 10 3/8 sae flat washers carrier bearing plate & air spring mounting 6 7/16 x 1 1/4 uss bolt upper frame bar mount 12 7/16 uss flat washer upper frame bar mount 6 7/16 uss nyloc nuts upper frame bar mount 46 1/2 x 1 1/2 uss bolts C-notch to frame & upper bridge 92 1/2 sae flat washers C-notch to frame & upper bridge 48 1/2 uss nyloc nuts C-notch to frame, upper bridge & shocks 2 1/2 x 2 1/2 uss bolts lower shock mounting 1 5/8 lock washer (gr. 8) Heim end to axle cover brk. 8 5/8 x 2 3/4 sae bolts (gr. 8) rod ends to brackets & panhard bar axle bracket 7 5/8 sae nyloc jam nuts (gr. 8) rod ends to brackets 8 5/8 x 6 sae bolts (gr. 8) bridge to axle 8 5/8 sae nyloc nuts (gr. 8) bridge to axle 16 5/8 sae flat washers (gr. 8) bridge to axle 5 3/4 sae jam nuts lock nuts for rod ends 5 m8x40mm bolts panhard bar mount to axle cover 5 m8 flat washers panhard bar mount to axle cover 5 m8 lock washers panhard bar mount to axle cover

NOTE: oem spring hanger bolt is used for lower front bar to spring hanger!


99-01GM Sierra / Silverado rear AirBar installation 1. Raise truck to a comfortable working height and support safely with jackstands under the frame. Place these stands ahead of the leafspring mount and at the rear of the frame to support it when the C notch is installed.

This is the layout for cutting the frame for the C notch. Using a 1/2” drill to make the corners produces a rounded corner which is much less susceptible to a stress crack.

2. The C notch frame section will be installed first. Note that the front edge of the C notch is butted up to the round tube crossmember. Place the C notch against the framerail to scribe the outline for cutting the framerail. Be sure to “round” the corners of the cut to avoid any stress points.

6. After the C notches are installed, the jackstands placed at the rear of the truck can now be moved to support the axle housing. When this is done the leafsprings can be removed.

3. Using a saw or a cutoff wheel, trim the framerail on the marked lines.

4. Install the c notch onto the framerail. The C notch fits between the tube style crossmembers located in front of and behind the axle, so there is only one way they will fit. [NOTE: on 1999 and 2000 model trucks the framerail is approx. ¼” shorter in height than the later models. A spacer plate is provided to adapt our notches to these applications. It is installed between the bottom of the frame

and the C notch.] Using the holes in the C notch as a template, drill through the framerail and attach using the included hardware.

7. After the leafsprings are removed the lower axle bracket bridge can be installed. This will require an assistant to hold the assembly while the fasteners are installed. This piece has “ears” that will locate into the bottom of the oem leafspring pad on the axle tube. The axle brackets are contoured to fit around the axle tube very snugly. An excess of powdercoating or dirt on the axle tube may require cleaning or filing for best fit. The lower bridge assembly is combined with the upper axle brackets to “sandwich” the axle tube for maximum strength. Be sure to use the supplied grade 8 axle bolts. washers, and nyloc nuts.

9. The bottom 4 link bar [longer] is installed into the oem leafpring hangar. NOTE: This system is designed to use the OEM leafspring hangar. DO NOT use an aftermarket “dropped” leafspring hangar. It will affect the position of the lower bar resulting in poor bar angle, pinion angle and vibration. The shorter bars are installed into the upper frame and axle bar brackets. Be sure to use the supplied grease to lubricate these bushings during assembly.

10. Install the panhard bar axle bracket as shown. You MUST use the fasteners that are supplied with the system. The original bolts are too short and are not strong enough.

8. After the axle bridge assembly is installed, the upper bar frame brackets can be installed. These brackets will use 2 of the leafspring hangar rivit holes and one additional drilled hole for attachment. Grind the heads off of two of the leafspring hangar rivets and punch them out. You may have to run a drill through the rivets holes to clean them up. Use the bracket as a guide to drill the additional attachment hole.

11. The upper airspring crossmember can now be installed. It is bolted into the top flange of the C notch assemblies with the panhard bar bracket on the drivers side. This will position the airspring mounts behind the crossmember. The brakeline junction box may need to be relocated slightly. The panhard bar can now be installed.

14. This photo shows how the bed brace and the exhaust heat shield are trimmed for clearance. The bed will need to be reinstalled to mark the exact location of the cut.

13. The shocks are installed as shown to the left. [your upper shock mount may appear slightly different] Note the routing of the parking brake cable.

12. Install the airsprings into the mounts. Be sure to use the round roll down plate provided between the airspring and the lower bridge mount to avoid damage to the airspring when deflated.

20. The driveshaft carrier bearing will need to be relocated to optimize driveline angles at your new lower ride height. The oem carrier bearing bracket is sectioned as shown in the picture to the left. The new carrier bearing bracket is then bolted onto the remaining tabs. The carrier bearing mount is rotated 180 degrees and attached to the supplied bracket as shown in the picture on the right. Your AirBar installation is now basically complete. Recheck all fasteners for proper tightness and check the airsprings for abrasion throughout the full range of suspension travel. NOTE: If you are using an aftermarket wheel and tire combination, the overall height of your tires MUST be at least 28”. Shorter tires will allow the chassis to touch the ground at full deflation. This IS NOT an acceptable condition and MUST be resolved by either using taller tires or a taller bumpstop. Taller tires are recommended.

IT IS THE FINAL RESPONSIBILITY OF THE INSTALLER/CUSTOMER TO ENSURE THAT THE AIRSPRING DOES NOT RUB ON ANYTHING AT ANYTIME AND TO ENSURE THAT PROPER GROUND CLEARANCE IS MAINTAINED AT ALL TIMES!

15. The bed brace will also need to be trimmed for clearance of the C notch reinforcement. A cutoff wheel does a good job here.


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Part # 11370809 88-98 C1500 AirBar RQ Series Shock Kit

For Use w/Airbar

Shock:

2 22569999 RQ Smooth Body Shock Cartridge

4 70011138 3/4” ID Shock Bushing

2 90002103 5/8” ID Shock Sleeve

2 90002102 1/2” ID Shock Sleeve



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Part # 30154000 4000 Series RidePro 4 Way Compressor System

3 Gallon Tank – Analog Gauges

Components: 1 31920020 Thomas 319 Compressor 1 31194000 RidePro 4 Way analog control panel with rocker switches (Black Face) 1 31913100 3 gallon aluminum tank 1 31934001 RidePro 4 Way valve block 1 31980005 Pressure switch – 135 On / 150 Off Wiring: 1 31900022 30 amp relay 1 90001924 Fuse holder 1 90001922 20 Amp fuse 2 31900036 Wiring harness - Control panel to valve 3 99104001 10-24 x 1” phillips screw 3 99102002 10-24 Nylok nut 3 99103001 #10 SAE flat washer 1 90001916 #10 x 5/16 ring terminal 1 90001913 12-10 butt connector 2 90001918 Female spade connector Airline & Fittings: 2 31940002 1/4” DOT airline - 30 ft. roll - valve block to gauges 2 31940000 1/8” DOT airline - 25 ft. roll - valve block to gauges 1 31952150 1/8”npt x 1/4” tube female straight - compressor 1 31957003 2” Brass Nipple - compressor 6 31954201 1/4” npt x 1/4” tube Elbow airline fitting 7 31954000 1/4” npt x 1/4” tube Straight airline fitting 4 31952000 1/8” npt x 1/8” tube Straight fitting - manifold to gauge fitting 1 31957004 1/4” npt plug - plug unused supply port 1 31959301 1/4” npt check valve

THE CHECK VALVE SUPPLIED SCREWS INTO THE AIR TANK WITH AN AIR FITTING THREADING

INTO IT. THE COMPRESSOR LINE WILL FEED INTO THE CHECK VALVE.



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ARC4000 Compressor System Instructions These are some general guidelines to follow when installing your new RidePro air control system. Depending on the vehicle there are many different ways to plumb the system. Start out by planning a lay out of where you want everything to be mounted. Typically we try to keep the compressor, solenoids, tank, and sending units in a central location, but they can be separated to suit your needs.

Mounting the Compressor/ Pressure Switch Remove the negative battery cable before beginning installation.

All of our compressors are sealed for moisture and dust resistance so they can be mounted anywhere on the vehicle. Although it is best to mount it in a place out of direct contact with rain and snow. It is OK to mount it underneath the vehicle but keep it inside the frame rails away from water and debris thrown off the tire.

This is a dry compressor; therefore it is maintenance free and can be mounted in any position.

It is best if mounted to something solid to reduce vibration and noise. If mounting it to sheet metal or the bed of a truck, use sound deadening material between the compressor and the mounting surface.

Use the rubber grommets supplied on the feet of the compressor to reduce vibration.

A template is supplied to aid in drilling the holes. Check template with compressor before drilling the holes.

Apply thread sealant to the pressure switch and compressor T and screw into the tank.

One spade of the pressure switch will connect to power the other to the red wire on the compressor.

Mounting the Air Tank

The air tank can be mounted anywhere on the vehicle in any position.

A template is supplied to aid in drilling the holes. Check the template with the tank before drilling the holes.

If your air system is used frequently you may want to remove the tank once a season to drain any excessive accumulation of water.


Mounting the RidePro Air Valves The valves, like the compressor, are sealed and can be mounted in the same locations.

Although if the vehicle will be exposed to freezing temperatures it is a good idea to mount them in the engine bay if possible to reduce the possibility of freezing.

They can be mounted in any position.

Mount the valves higher than the tank to avoid moisture build up. This could cause the air pressure sensors to give a faulty reading.

Attach the ground strap to a good, clean ground (preferably the frame).

The exhaust port will be left open.

The valve is held closed with the pressure in the tank. If tank pressure drops below air spring pressure they will equalize deflating all 4 air springs.

Wiring Harness Red Wire- The red wire on the harness will connect to 12 volt switched.

Gray Wire- This power for the light in the switch- this wire goes to the light circuit(dash lights) of the vehicle. This wire needs 12 volt when the lights are on or the key is on. The gauge light should be hooked to the same circuit as this wire.

Black Wire- This wire is ground for the light in the switch. It goes to a good ground.

Routing the Airline and Fittings Make all airline cuts with a razor or tubing cutter. It must be clean and straight or it will not

seal.

All fittings are DOT approved push-to-connect style. They are very simple to use and are reusable. Firmly push the airline into the fitting to attach. To release the airline pull the collar on the fitting back towards the fitting and pull the airline out.

Use thread sealant on all fittings.

Do not over tighten the fittings. This could result in breaking the fitting or damaging the air spring.

All of our airlines are DOT approved so they are very strong. But keep them away from any sharp edges. Also when passing through a hole in the frame use a grommet.

Keep away from intense heat including mufflers and exhaust manifolds.

Use zip ties or other fasteners to secure the airline.

Illumination (Gray) - This wire provides power to the switch lights. It should be hooked up to a light circuit in the vehicle (dash lights) or it can be hooked up to a 12 volt switched source. +12V (Red) - This wire is the main power for the valves. It should be hooked up to a 12 volt switched circuit. It needs 12 volt with the key on and should have no power with the key off. Ground (Black) – This wire provides ground to the switch lights. It should be hooked up to a good ground source.

Note: The Illumination and Ground wires do not have to be hooked up for the switches to work. They do have to be hooked up for the lights in the switches to work.

ARC4000

Relay Wiring Diagram

Documents

Part # 11380199 99-06 Silverado Level 1 Complete Air ... · 99-06 Silverado Level 1 Complete Air Suspension System ... 3/4" O.D. x 5/8 I.D. ... 2 90001082 Short bump stop