Network Computing Devices Automobile Parts NCD 5988 2 User Manual

2101  
WARNING:  
Donotinflatethisassembly whenitisunrestricted.  
The assembly must be restricted by the suspension  
or other adequate structure. Do not inflate beyond  
100 P.S.I. Improper use or over inflation may cause  
property damage or severe personal injury.  
INSTALLATION INSTRUCTIONS  
Your kit includes separate inflation valves and air lines for  
eachairhelperspring. Thiswillallowyoutolevelyourvehicle  
fromsidetosideaswellasfromfronttoback. Ifyouwouldrather  
haveasinglevalveinflationsystem, yourdealercansupplythe  
required "T" fitting.  
Congratulations - your new Air Helper Springs are quality  
productscapableofimprovingthehandlingandcomfortofyour  
vehicle. As with all products, proper installation is the key to  
obtaining all of the benefits your kit is capable of delivering.  
Please take a few minutes to read through the instructions to  
identifythecomponentsandlearnwhereandhowtheyareused.  
It is a good idea to start by comparing the parts in your kit with  
the parts list below.  
IMPORTANT!  
For your safety and to prevent possible damage to your  
vehicle, do not exceed the maximum load recommended by the  
vehicle manufacturer (GVWR). Although your Air Helper  
Springsareratedata maximuminflationpressureof100P.S.I.,  
this pressure may allow you to carry too great a load on some  
vehicles. Check your vehicle owner’s manual for maximum  
loads listed for your vehicle.  
The heart of the air helper spring kit is, of course, the air  
helper springs. Rememberthattheairhelperspringsmustflex  
and expand during operation, so be sure that there is enough  
clearance to do so without rubbing against any other part of the  
vehicle.  
Be sure to take all applicable safety precautions during the  
installation of the kit. The instructions listed in this brochure  
and the illustrations all show the left, or driver’s side of the  
vehicle.Toinstalltherightsideassemblysimplyfollowthesame  
procedures.  
When inflating your Air Helper Springs, add air pressure  
in small quantities, checking pressure frequently during  
inflation. The air spring requires much less air volume than  
a tire and, therefore, inflates much quicker.  
PARTS LIST  
267C AIR SPRING  
6781  
5157  
5158  
5159  
1163  
1004  
2
1
1
2
2
1
4
4
12  
2
2
4
3/8" LARGE FLAT WASHER  
1/4" LOCK WASHER  
1/4" HEX NUT  
PUSH-TO-CONNECT  
MALE AIR FITTING  
PUSH-TO-CONNECT  
INFLATION VALVE  
5/16" FLAT WASHER  
AIR LINE TUBING  
NYLON TIE  
4
2
2
UPPER BRACKET (RIGHT)  
UPPER BRACKET (LEFT)  
LOWER BRACKET  
AXLE STRAP  
HEAT SHIELD  
3/8" -16 x 1" HEX BOLT  
3/8" -16" x 3" CARRIAGE BOLT  
3/8" -16 FLANGED LOCK NUT  
3/8" -16 x 3/4" HEX BOLT  
1/4" -20 x 1" HEX BOLT  
1/4" FLAT WASHER  
3046  
3032  
2
2
4
1
6
2
THERMAL SLEEVE  
21-8156  
12-03  
NCD-5988-2  
 
STEP 1-PREPARE THE VEHICLE  
Remove the positive battery cable. With the vehicle on a solid, level surface  
chockthefrontwheels. Raisethevehiclebytheaxleandremovetherearwheels.  
After the removal of the wheels lower the vehicle so the axle rests on jack stands  
rated for your vehicles weight.  
This installation assumes that there is no load in the truck.  
TWO-WHEEL  
DRIVE VEHICLES  
NOTE:  
This kit is designed to fit both two-wheel and four-wheel drive vehicles. The  
jounce bumper and brackets must be removed for installation of this kit. The  
jounce bumper and bracket on the two-wheel drive can be unbolted and removed  
see Figure "B". The jounce bumper and bracket on the four-wheel drive may be  
bolted or riveted in place, depending on model year. Simply unbolt the jounce  
bumper bracket and remove from the frame see Figure "C". On older models,  
remove the jounce bumper by drilling out two rivets that fasten the bracket to the  
frame. Complete the removal by cutting off the heads with a cold chisel. The  
completion of the kit installation is the same for the two-wheel and four-wheel  
drive.  
FIGURE "B"  
STEP 2 - PRE-ASSEMBLE THE KIT  
SOME FOUR-WHEEL  
DRIVE VEHICLES MAY  
HAVE BOLTS, OTHERS  
WILL HAVE RIVETS  
Thiskitissuppliedwitharightandleftupperbracket. Beginbyinstallingthe  
left (driver's side) upper bracket. This bracket will have the "over-bent tab" see  
Figure "D". The lower bracket is the same for both sides. Align the studs on the  
top of one of the air springs with the mounting holes in the upper bracket while  
ensuring that the air hole is visible through the slot in the upper bracket. Insert  
the studs into the holes and secure the air spring to the upper bracket with 3/8"  
-16 flanged lock nuts see Figure "A". Next, install the male push-to-connect air  
fittingintheairinflationhole. Tightentheairfittingsecurelytoengagetheorange  
thread sealant.  
FIGURE "C"  
To attach the lower bracket to the air spring, first position the bracket on the  
axle housing over the jounce pad see Figures "A" & "E". Position the bracket so  
that the narrow end is toward the center of the vehicle. The air spring must be  
securedtothelowerbracketthroughtheforwardhole. Oncethecorrectmounting  
holeforthelowerbrackethasbeenidentified,removethebracketfromtheaxleand  
fasten to the air spring using a 3/8" -16 x 3/4" hex bolt (finger tight). Note that  
this bolt will be tightened in Step 3.  
FRONT  
STEP 3-INSTALL THE ASSEMBLY TO THE VEHICLE  
Set the assembly in place on the axle housing over the jounce pad. The lower  
bracketshouldbuttagainsttheU-boltsontheleafspringseeFigure"E". Position  
the assembly so that the upper bracket is aligned vertically against the outside  
surface of the frame rail.  
OVER-BENT  
TAB  
Onsomevehiclestheremaybearivetheadonthebottomofthebottomsurface  
of the frame rail that will prevent the upper bracket from being mounted flush  
against the frame. To assure that the upper bracket clears the rivet head, install  
four large flat washers between the upper bracket and the bottom surface of the  
framerailseeFigure"A". Installationoftheflatwashersisonlynecessaryifyour  
vehicle has a rivet head on the bottom of the frame rail. Insert a 1/4" -20 x 1" bolt  
throughtheverticaltaboftheupperbracketandanexistingholeintheframerail.  
Secure with washers and a nut see Figure "A". On some models, a hole must be  
drilled in the frame rail for the bolt to pass through. Using the upper bracket as  
a template, drill a 5/16" hole though the frame rail. Make sure that all electrical,  
brake, and fuel lines are cleared from the path of the drill.  
VIEW OF DRIVER’S SIDE ASSEMBLY  
FROM INSIDE OF VEHICLE  
FIGURE "D"  
FRAME RAIL  
UPPER BRACKET  
LEAF  
STACK  
AIR SPRING  
LOWER BRACKET  
AXLE  
The tabs on the bracket will be secured to the lower frame flange using 3/8"  
flangedlocknutsand3/8"-16x1"hexboltsseeFigure"A". Note: onthedriver's  
side of the vehicle the 1/4" bolt will also hold a clip (on some models) used to  
hold brake and fuel lines. Secure the clip to the 1/4" bolt to secure the lines.  
Align the lower bracket against the U-bolts over the leaf spring stack see  
Figure "E". After the bracket has been squared with the U-bolts, tighten the  
3/8" hex bolt to secure the lower bracket to the air spring. Next, insert two  
3/8" -16 x 3" carriage bolts into the square holes on the lower bracket. Install one  
axle strap on the bottom of the axle housing see Figure "A". Slide the axle strap  
BRAKE LINE  
DRIVER'S SIDE  
FRONT  
SHOCK  
BRACKET  
BRACKET STRAP  
FIGURE "E"  
 
ontothecarriageboltsandsecurewith3/8"-16flangedlocknuts. Thisinstallation  
willholdthelowerbracketinplace. Note: Wheninstallingtheleft-sideassembly,  
it will be necessary to tie the parking brake line to the sway bar to prevent it from  
contacting the air spring in normal operation. There must be at leat 1/2" of  
clearance between the inflated air spring and any other part of the vehicle.  
STEP 4-INSTALL THE PASSENGER'S SIDE ASSEMBLY  
HEAT SHIELD  
Follow steps 1 - 4 for assembly and installation of the passenger's side  
assembly. On the passenger's side it will be necessary to install a heat shield  
between the upper bracket and the air spring to protect the air spring from the  
exhaust pipe heat see Figure "F". Position the heat shield so that it will reflect  
radiant heat from the point on the exhaust pipe closest to the air spring. The heat  
shield should be positioned so that it does not contact the axle housing as the  
suspension compresses.  
FIGURE "F"  
STEP 5 - INSTALL THE AIR LINE AND THE INFLATION VALVE  
Uncoil the air line tubing and cut it into two equal lengths. DO NOT FOLD  
OR KINK THE TUBING. Try to make the cut as square as possible. Insert one  
endofthetubingintotheairfittinginstalledinthetopoftheairhelperspring. Push  
the tubing into the fitting as far as possible.  
AIR  
SPRINGS  
AIR HOSE  
Select a location on the vehicle for the air inflation valves. The location can  
be on the bumper or the body of the vehicle, as long as it is in a protected location  
so the valve will not be damaged, but maintain accessibility for the air chuck see  
Figure "G". Drill a 5/16" hole and install the air inflation valve using two 5/16"  
flat washers per valve as supports see Figure "H". Run the tubing from the air  
helperspringtotheinflationvalve,routingittoavoiddirectheatfromthe exhaust  
pipe and away from sharp edges. Thermal sleeves have been provided for these  
conditions. Ifathermalsleeveisrequiredsimplyslidethesleeveovertheairline  
tubing to the location requiring protection. The air line tubing should not be bent  
or curved sharply as it may buckle. Secure the tubing in place with the nylon ties  
provided. Push the end of the air line tubing into the inflation valve as illustrated  
see Figure "H".  
INFLATION  
VALVES  
BUMPER  
FIGURE "G"  
AIR LINE  
FLAT WASHER  
STEP 6 - CHECK THE AIR SYSTEM  
Oncetheinflationvalvesareinstalledinflatetheairhelperspringsto70P.S.I.  
and check the fittings for air leaks with an applied solution of soap and water. If  
a leak is detected at a tubing connection, check to make sure that the tube is cut  
as square as possible and that it is pushed completely into the fitting. The tubing  
can easily be removed from the fitting by first releasing the pressure from the air  
spring, then by pushing the collar towards the body of the fitting and then pulling  
outthetube. Ifaleakisdetectedwheretheairfittingscrewsintothespring,release  
the air pressure, then remove the tubing as described above, then screw the brass  
fitting into the air spring one additional turn or until the leak stops. Reinstall the  
PUSH-TO-CONNECT  
INFLATION VALVE  
BODY OF  
VEHICLE  
HEX NUT  
VALVE CAP  
FIGURE "H"  
tubing and reinflate the air springs and check for leaks as noted above.  
This now completes the installation. Install the wheels and torque the lug nuts to the manufactures specifications. Raise the  
vehicle by the rear axle and remove the jack stands and lower the vehicle back onto the ground. Re-attach the positive battery  
cable and remove the wheel chocks from the wheels. Before proceeding, check once again to be sure you have proper clearance  
aroundtheairsprings. Withaloadonyourvehicleandtheairhelperspringsinflated,youmusthaveatleast1/2"clearancearound  
theairsprings. Asageneralrule,theairhelperspringswillsupportapproximately50lbs.ofloadforeachP.S.I.ofinflationpressure  
(perpair). Forexample,50P.S.I.ofinflationpressurewillsupportaloadof2500lbs.perpairofairhelpersprings. FORBESTRIDE  
use only enough air pressure in the air helper springs to level the vehicle when viewed from the side (front to rear). This amount  
will vary depending on the load, location of load, condition of existing suspension and personal preference.  
NOTE:  
Too much air pressure in the air helper springs will result in a firmer ride, while too little air pressure will allow the airhelper  
spring to bottom out over rough conditions. Too little air pressure will also not provide the possible improvement in handling.  
TO PREVENT POSSIBLE DAMAGE MAINTAIN A MINIMUM OF 5 P.S.I. IN THE AIR HELPER SPRINGS AT ALL TIMES.  
NOTE:  
Once the air helper springs are installed, it is recommended that the vehicle not be lifted by the frame, as over-extension may  
occur,resultingindamagetotheairhelpersprings. However,shoulditbecomenecessarytoraisethevehiclebytheframe,deflate  
both air helper springs completely.  
 

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