Part # C-3500 AirBar

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1 Components: 350 S. St. Charles St. Jasper, In Ph Fax Part # C-3500 AirBar Rolling sleeve air spring Driver side bar frame bracket Passenger side bar frame bracket Lower axle bridge assembly U bolt plate Panhard bar axle bracket Panhard bar frame bracket Driver side upper air spring bracket Passenger side upper air spring bracket Carrier bearing spacer Upper bar TW (C-C 24.5 ) Lower bar WW Panhard bar TW C-C Poly bushing half /8 inner sleeve installed into bars Metric inner sleeve installed into rod end Large rod end installed into upper bar SAE Jam nut installed onto rod end Rubber bushing pressed into panhard bar Kevlar line Heim end installed into panhard bar ¾ SAE Jam nut installed onto Heim end Short bump stop Hardware kit

2 350 S. St. Charles St. Jasper, In Ph Fax Hardware Kit: Part # /8 x2 ½ USS bolts Carrier Bearing Plate 2 3/8 USS nyloc nuts Carrier Bearing Plate 8 3/8 USS flat washers Carrier Bearing Plate / Upper Air Spring Mounts 8 7/16 x 1 ½ USS bolts Font Upper Bar Mount / Right Upper Air Spring Mount 16 7/16 flat washers Upper Air Spring Bracket 8 7/16 USS nyloc nuts Upper Air Spring Bracket 8 ½ x 1 ½ USS bolts Font Upper Bar Mount 4 ½ x 2 USS bolts Passenger side air spring mount & Panhard bar mount 4 ½ x 1 USS bolts Lower Air Spring Mount 2 ½ x 3 USS bolts Lower Shock Mounts 32 ½ SAE flat washer Shock Spacers/Air Spring Mounting/Upper Front Bar Mount 14 ½ USS nyloc nuts Shocks 4 ¼ x 1 USS bolt Upper shock mounts 7 3/8 x 1 ½ bolts Panhard Bar Differential Bracket 7 3/8 SAE flat washers Panhard Bar Differential Bracket 7 3/8 lock washers Panhard Bar Differential Bracket 7 M8 x 40mm bolts Panhard Bar Differential Bracket 7 M8 SAE flat washers Panhard Bar Differential Bracket 7 M8 lock washers Panhard Bar Differential Bracket 1 5/8 x 1 ¾ SAE bolts Gr.8 Panhard Bar / Axle Side 1 5/8 thin nyloc nut Panhard Bar / Frame Side 1 5/8 x 2 ¾ SAE bolt Gr.8 Panhard Bar / Frame Side 1 5/8 lock washer Panhard Bar / Axle Side 6 5/8 x 4 ½ SAE Gr. 8 Air Bar to Bracket Mounting 8 5/8 x 7 SAE Gr. 8 Axle Bracket 16 5/8 flat washers Gr.8 Axle Bracket 14 5/8 SAE nyloc nut Gr.8 Axle Bracket / Air Bar Ends Note: oem bolt is used in front lower bar, originally held the leaf front eye.

3 350 S. St. Charles St. Jasper, In Ph Fax GM 1 Ton C3500 AirBar Installation 1. Raise and support truck at a comfortable working height. Place jackstands under the frame ahead of the front leafspring hangar. Support the axle housing with another set of jackstands. Since you will be removing both leafsprings you will need to support the pinion yoke of the axle housing to prevent it from dropping when the leafsprings are removed. 2. Remove leafspring assemblies. 3. If your truck does not have a Belltech C notch [or equivilent] already installed, you will need to do that now. Refer to Belltech s instructions for proper installation procedure. 3. Install the axle bracket crossmember assembly. Make sure the legs of the bracket are indexed properly into the underside of the oem leaf pad. 4. Place the upper 4 link bar axle bracket onto the oem leafspring axle pad with the open side of the rode end bracket facing forward. Insert the [8] 5/8 x 7 grade 8 bolts and tighten evenly using the supplied grade 8 nyloc nuts.

4 5. Remove the oem leafspring overload bracket and Install the upper 4 link bar frame bracket into its place. You will be able to locate the bracket using some of the oem hole and use the bracket as a template to drill the remainder of the attachment holes. 6. Install the 4 link bars into their respective locations. Note that the oem leafspring bolt is used to secure the lower 4 link bar to the oem leafspring hangar. 7. Install upper airspring brackets onto the framerail using the existing Belltech C notch attachment bolt locations. [NOTE: If you are using a C notch other than a Belltech unit, you may need to modify the upper airspring bracket for proper placement. What we are trying to accomplish is to have the upper airspring bracket directly above the lower mount at a vertical distance of approx at highway ride height. This places the top of the airspring level with the bottom of the framerail] Note that the panhard bar frame bracket is attached to the passenger side framerail using the airspring bracket fasteners. Drivers side upper airspring mount. This mount is used in conjunction with the Belltech C notch. Passenger side inner framerail showing panhard bar frame bracket installation. Also note the notch in the airspring bracket to fit around the Belltech C notch.

5 8. Install panhard bar bracket on rearend housing. BE SURE TO USE THE FASTENERS SUPPLIED WITH OUR SYSTEM!! The oem fasteners will be too short! Panhard bar axle bracket. Be sure to use the fasteners supplied with our system. 9. Install panhard bar and raise rearend up to ride height. With the axle at ride height, check to make sure the axle is centered with the frame. The measurement from drum to frame [or some other fixed points] on each side should be EQUAL! Adjust panhard bar as needed. NOTE: THIS PROCESS MUST BE DONE AT HIGHWAY RIDE HEIGHT!! 10. Install airsprings into mounts. Be sure to check for airspring clearance at all suspension heights. REMEMBER: THE AIRSPRING MUST NOT RUB ON ANYTHING AT ANYTIME!!! 11. Install shocks into oem mounts.

6 12. Install the spacer block under the carrier bearing to correct the driveshaft angles. 13. The installation is now basically complete. Check for axle clearance to the bed and to the bumpstops. Pay particular attention to the brakeline junction block on top of the axle housing. You can now run the airlines and continue with the compressor kit installation. Inflate to approx. 25psi to begin tuning the air ride system. You will probably find 20 to 25psi appropriate for an unloaded truck. Try to maintain at least 3 of clearance between the axle and bumpstop to maintain a civilized ride quality. When you load the vehicle, increase the air pressure as needed to support the extra weight and to maintain this clearance.

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