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‘82-’03 2nd Generation S-10/ MN-581
(02401)
ET
Sonoma NPR 4372
TRE
EA
S YS Front Kit Part No. 75538B
www.airliftcompany.com
Please read these instructions completely before proceeding with installation
We recommend installing drop spindles for this application.
Left-Side Upper Right-Side Upper
Shock Mount Shock Mount
Long Tab
on Bracket
Driver-Side
WHEEL ENGINE
Assembly
Warranty Information
1. All goods come with a one year manufacturer’s warranty against defects.
2. Warranty will be void if the kit is altered for any reason and/or adapted to applications
other than those suggested.
3. Any abrasions or rub marks on the air spring portion of the kit will not be covered
under warranty. The customer is responsible for all repair charges.
4. Driving at a low PSI can cause the air spring to bottom out. Repeated bottoming out
can cause the air spring to fail. Failure resulting from repeated bottoming out is not
covered under warranty.
5. The customer is responsible for all shipping costs to Air Lift Company for all warranty
claims.
6. Please call tech support at 1-800-248-0892 before shipping a product to Air Lift
Company.
Technical Support
1-800-248-0892
1
Hardware
Item P/N Description Quantity Item P/N Description Quantity
A 07151 Front Upper Bracket (Left) 1 L 10428 Brake Line Bracket (Right) 1
B 07152 Front Upper Bracket (Right) 1 M 10429 Brake Line Bracket (Left) 1
C 03234 Front Lower Bracket 2 N 10489 Shock Mounting Pins 4
3
D 58505 2B6 1/2" Bellow 2 O 17144 /8" - 16 x 7 Bolt GD 5 2
3
E 11916 Roll Plate 4 P 18435 /8" - 16 Nylock Nut 2
1
F 10410 Upper Shock Mount (Left) 1 Q 21370 /2" MNPT 1/2" Tube Elbow 2
1
G 10411 Upper Shock Mount (Right) 1 R 18469 /8" x 1.75 Stainless Steel Cotter Pin 6
3
H 50633 Shock Absorbers 2 S 17106 /8" - 16 x 1.5 Bolt GD 8 6
3 3
I 17203 /8"-24 x 7/8" Bolt GD 2 8 T 18407 /8" Flatwasher 12
3
J 18427 3
/8" Lockwasher 8 U 18476 /8" - 16 Nylock Nut 6
3
K 18444 /8" Flatwasher 8
IMPORTANT: Always keep safety in mind when working on your vehicle.
I. Preparing the Vehicle
1. Elevate the truck and place the frame securely on the jack stands.
2. Remove the wheels.
3. Disconnect the sway bar links from each of the lower control arms.
4. Remove the shock absorbers.
5. Disconnect the battery.
6. Remove the brake caliper and secure out of the way.
7. Remove the stock jounce bumper.
8. Disconnect the steering arm from the spindle.
9. If the vehicle is equipped with ABS lines, disconnect them at this time.
II. Removing the Coil Spring
NOTE: Work on one side at a time.
1. Starting on the driver-side, place a floor jack securely under the lower control arm. Elevate the control arm so that
the spring is slightly loaded.
2. Install a spring compressor and tighten as required to lift the coil off of the control arm seat.
NOTE: Use extreme caution. Follow the spring compressor directions and safety guidelines.
3. Loosen both the lower and the upper ball joint retaining nut but do not remove it at this time.
4. Using a ball joint separator (pickle fork), separate the ball joint from the spindle. Remove both ball joint nuts.
5. Remove the stock spindle and set aside. Using the jack, lower the control arm far enough to remove the coil spring
from the pocket. Remove and discard any rubber spring pocket bushings.
NOTE: Use extreme caution. Follow directions and safety guidelines.
Technical Support
1-800-248-0892
2
III. Assembling the Spring
1. Set roll plates (E) on the top and bottom of the bellows (D).
2. Install 90° fitting (Q) to the bellows (D). Tighten finger-tight plus
11/2 turns.
3. Attach the upper bracket (A) to the air spring using two 3/8" bolts
(I), two 3/8" lockwashers (J), and two 3/8" flatwashers (K) (Figure
1). Tighten securely.
4. Attach the lower bracket (C) so that the offset slots are towards
the inside (engine-side) (Figures 2 and 3). The air fitting on the
top of the assembly installs toward the engine-side, therefore, Figure 1
when assembling, the long tab on the bottom bracket must be
on the same side as the fitting at the top.
5. Loosely attach the lower bracket (C) and the roll plate (E) to the
air spring assembly using two 3/8" bolts (I), two 3/8" lockwashers
(J), and two 3/8" flatwashers (K).
Slots Go
on Inside,
IV. Trimming the Frame Section Towards
Engine
1. Clean the bottom part of the frame around the spring pocket with
a wire wheel. Also clean the bottom portion of the frame from
the center, back to the rear lower control arm mount (Figure 4).
2. Using a scribe or a good permanent marker, mark a line around Figure 2
the frame (Figure 4). Mark the area around the spring pocket
approximately 1/2"-3/4". You will need to cut out the flange on the
inside (engine-side) of the pocket. Cut out approximately the
same amount of the frame around the rest of the spring pocket
(Figure 5).
NOTE: Cut out only the top lip. Do not cut past the welds.
Long Tab
Engine-Side
Figure 3
Figure 4
Technical Support
1-800-248-0892
3
3. Use a die grinder with a cut-off wheel and cut around the hole
where marked.
NOTE: We used a plasma cutter to save time.
4. Note the area cut in figure 6 and remove the cut out section
(Figure 7).
5. Raise the lower arm until it contacts the frame. The area where
the back part of the A-arm comes in contact with the frame will
have to be trimmed (Figure 8). Mark a line 3/4" up from the bottom
of the frame, following the contour of the lower A-arm (Figure 8).
Figure 5
Figure 6
The upper spring retainer on early
model S-10/S-15 trucks has a serrated
flange that holds the stock spring in
place. One or two points towards the
rear of the flange will need to be
removed in order to obtain clearance
for the air lines (Figure 7).
Figure 7
Figure 8
Technical Support
1-800-248-0892
4
6. Mark a line down the bottom of the frame back to the inside
pocket that was previously cut (Figure 9). Blend the line going
forward into the pocket area that was cut previously (Figure 9).
NOTE: Do not cut out any welded seams.
7. Remove the cut-out section of the frame (Figure 10). Raise the
A-arm up until it contacts the frame. The front of the A-arm
should be the only thing hitting the frame. If the rear still contacts
the frame, the frame may have to be trimmed more (Figure 11).
8. Use a small grinder to smooth the edges. Remove all sharp
edges of the cut out area.
9. Clean and paint the exposed area. Figure 9
V. Installing the Assembly
1. Push the lower control arm down far enough to set the upper
bracket into the pocket of the upper spring seat (Figure 12).
2. Using the jack, raise the lower control arm up making sure the
upper bracket nests around the spring seat flange in the top of
the spring seat.
Figure 10
Figure 11
Figure 12
Technical Support
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5
VI. Installing the Shocks
1. Measure in from the stop block on the back-side of the A-arm 11/2"
(Figure 13).
2. Center punch and drill a 1/2" hole for the lower shock pin.
NOTE: You will have to drill the hole mid-point or slightly down on
1-1/2" the arm to leave clearance for the nut and washer of the shock
pin (N).
3. Remove the brake line bracket that is bolted to the top of the
frame behind the upper control arm. Pull slide-pin out of the
brake line so as to free the line from the bracket. Grind a slot in
Figure 13 the brake line bracket to remove the bracket from the brake line
(Figure 14).
CAUTION: Be careful not to grind or cut the brake line during
this process.
4. Install the left brake line bracket (M) on the driver-side using the
existing bolt that was removed in step 3 (Figure 15).
5. Insert the brake line through the slot and re-attach using the
slide pin that was removed in step 3.
NOTE: It will be necessary to bend the hard brake line. Be
careful not to kink or break. Replacement lines may be necessary
with old, corroded lines.
Figure 14
6. Set the shock bracket (F) against the frame just behind the brake
line.
IMPORTANT: The three corresponding holes go towards the
rear of the vehicle.
NOTE: The bracket has a relief in it for the brake line.
7. Mark the fender area where the bracket comes in contact with it.
Remove, the area with a die grinder and cut-off wheel (Figure 16).
CAUTION: Clear all lines behind the inner fender before cutting.
8. Only the two bottom holes will be used. The top hole will be
above the frame (Figure 17).
Figure 15
9. The upper shock bracket must be as far forward as it can be
without interfering with the hard brake line and upper control arm.
10. Insert the shock pin (N) through both ends of the shock (H).
Insert the bottom pin through the spacer (N), and A-arm. Attach
with lockwasher and nut. Leave loose at this time.
NOTE: The spacers, lockwashers and nuts used in this section
are provided in the shock pin package.
11. Attach the top bracket (F) in the same manner using the shock
pin, shock, spacer and the upper bracket. Attach with a
lockwasher and nut. Leave loose at this time.
Figure 16
Technical Support
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6
12. Raise the A-arm up until it bottoms out. Set the shock bracket,
with the shock collapsed, against the frame. Let the shock open
1
/4" so the shock will not be the suspension limiter and mark the
lower shock bracket hole on the frame.
NOTE: It may be helpful to have someone assist you in this
operation.
13. Remove the bracket from the shock and bend the shock out of
the way.
14. Center punch and drill a 3/8" hole where it is marked on the frame.
Set the bracket up against the frame and attach using a 3/8" bolt REAR
(S), two flatwashers (T) and nylock nut (U).
Figure 17
15. Check the alignment of the assembly. Drill two additional 3/8"
holes in the frame using the upper shock bracket as a template.
Install two more 3/8" bolts (S), four flatwashers (T), and two more
nylock nuts (U) (Figure 17).
16. Remove the shock and shock pins.
VII. Installing the Drop Spindle
In order to obtain maximum laying of the frame, we recommend using a drop spindle for
optimum drop effect.
1. Follow the assembly procedures recommended from the drop spindle manufacturer.
2. Lift the drop spindle assembly onto the lower ball joint. Attach nut, torque and install the cotter pin (R), supplied.
3. Insert the upper control arm ball joint into the drop spindle. Attach the nut, torque and install the supplied cotter pin
(R).
4. Attach the steering arm, torque the nut and insert the cotter pin (R), supplied.
5. Re-attach the brake caliper.
6. If the ABS connector was diconnected, reconnect it at this time.
7. Re-attach the shock and cotter pins (R) and torque the nuts.
VIII. Re-attaching the Components
1. Repeat the entire installation procedure for the passenger-side.
2. It will be necessary to cut the center spacer on the sway bar link down to a length of 13/4". Attach the sway bar using the
3
/8" bolt (O) and nut (P). Tighten securely.
3. Tighten all bolts and nuts and, if necessary, install all required cotter pins.
4. Re-connect the battery.
Technical Support
1-800-248-0892
7
IX. Before Operating
1. Inflate the installed system to 80 p.s.i. and move suspension through full range of motion to check for interference
or rub.
2. Inflate and deflate the system to check for clearance or binding issues.
NOTE: Do not to exceed 180 p.s.i.
3. If custom wheels and tires are used, be sure to note the tire to fender-well clearance. Adjust if necessary.
4. Check tire to shock clearance in an inflated and a deflated state. If necessary, weld a small bracket to the stop block
to obtain 3/8 " clearance.
5. Air Lift’s Part #27541CD is highly recommended with this product.
6. Determine a specific ride height that the vehicle will be driven at. Note the pressure and have the front end aligned
to these specifications.
7. Read the remainder of the manual including section X, Maintenance and Operation, for more information.
X. Maintenance and Operation
Minimum Pressure Maximum Pressure
10 p.s.i. 180 p.s.i.
Failure to maintain correct minimum pressure (or pressure proportional to load), bottoming
out, overextension, or rubbing against another component will void the warranty.
By following these steps, vehicle owners should obtain the longest life and best results from their air springs.
1. Tighten, and visually inspect, all hardware after 100 miles.
2. Always maintain Ride Height. Never inflate beyond 180 p.s.i.
3. Always adjust the air pressure to maintain Ride Height. Increase or decrease pressure from the system as necessary
to attain Ride Height for optimal ride and handling.
4. IMPORTANT: For your safety and to prevent possible damage to your vehicle, do not exceed Maximum Gross
Vehicle Weight Rating (GVWR), as indicated by the vehicle manufacturer. Although your air springs are rated at a
maximum inflation pressure of 180 p.s.i. The air pressure actually needed is dependant on your load and GVWR,
which may be less than 180 p.s.i. Check your vehicle owners manual and do not exceed the maximum load listed
for your vehicle.
5. Should it become necessary to raise the vehicle by the frame or do any service work, make sure the system is at
minimum pressure (10 p.s.i.) for safety and to reduce the tension on the suspension/brake components. Do this
before operating the vehicle.
Technical Support
1-800-248-0892
8
NOTES
Thank you for purchasing Air Lift Products
Mailing Address: Street Address:
AIR LIFT COMPANY AIR LIFT COMPANY
P.O. Box 80167 2727 Snow Rd.
Lansing, MI 48908-0167 Lansing, MI 48917 ET
TRE
Local Phone: (517) 322-2144 S YS
Fax: (517) 322-0240 EA
For Technical Assistance call 1-800-248-0892
Technical Support
“The Choice of the Professional Installer”109
1-800-248-089210
Printed in the USA
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