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3-T’s RV Products, Inc.
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INSTALLATION INSTRUCTIONS FOR THE T-9CD1 AND T-9CD2
The T-9CD1 fits the Chevrolet P30 Class A chassis with disk brakes,
14500/16000 GVWR 1992 and older
The T-9CD2 fits the Chevrolet P30 Class A chassis with drum brakes,
14500/16000 GVWR 1993 and older.
PARTS LIST: 2 Air sleeve assemblies with 7100 air sleeves
1 Airline kit including 16’ airline
4 1/2" x 1-1/2" GR5 bolts
4 1/2" flange nuts
4 9/16" GR8 flat washers
4 5/16" x 3-1/2" GR5 bolts
4 5/16" top lock nuts
2 3/8" x 1-1/2" bolts GR5
2 3/8" flange nuts
2 Air pressure decals; Owner's leaflet
READ ALL INSTRUCTIONS THOROUGHLY BEFORE BEGINNING THIS INSTALLATION. WELDING THE TOP BRACKET TO THE FRAME VOIDS ALL WARRANTIES. MAKE SURE THE AXLE HAS NORMAL TRAVEL. IF IT HAS SPACER BLOCKS MAKE SURE THEY LOWERED THE DOWN STOP. THIS KIT WILL FAIL IF THEY DID NOT
Lift the vehicle at the differential. Place jack stands under the frame behind the axle. Lower the vehicle onto the stands, allowing the axle to go to a full hang. Remove the rear wheels and disconnect the battery(s). Divide the assemblies, brackets and bolts into two groups, one for each side. Each side comes completely assembled. Do not take apart.
CAUTION: BEFORE DRILLING, CHECK FOR FUEL, BRAKE, OR ELECTRICAL LINES THAT MAY BE INSIDE THE FRAME RAIL. BE CAREFUL NOT TO DRILL INTO THESE LINES.
Locate the two 5/16" diameter holes on the frame forward of the center of the spring. These holes must be drilled out to 1/2". Pilot drill these holes to 3/8" then to 1/2". On the left side frame rail of some year models these holes are used for tie-wraps holding the electrical wires for the fuel pump in the fuel tank. Remove these tie wraps.
Put the 1/2” flat washers on the 1/2”x1-1/2” bolts and place them thru the two oblong holes in the top bracket, from the inside of the frame, place a 1/2” nut on these bolts , finger tighten at this time. PUSH THE BRACKET FORWARD AGAINST THE RIVET. Mark the location of the top brackets 3/8” hole on the frame. Remove the assembly and drill out the marked location to 3/8”.
Note: On some P30 chassis produced prior to 1986, the front hole may not be in the frame rail. Drill out the center hole. Before drilling your final two holes, place the top bracket against the frame rail with your 1/2" bolt in place and make finger tight, tap the top bracket as far forwards as it will go. (Note: there is a notch in the top bracket that will lineup with a rivet in the frame rail.) (See Figure 1). Next take a measurement between your top and bottom brackets at your rear bag and make sure you have that same measurement at the forward bag. Mark and drill your two final holes.
Re-mount the assembly with the 1/2”x1-1/2” bolts, washers, and nuts. Using one 3/8”x1-1/2” bolt place it through the hole in the bottom of the top bracket and through the frame with a 3/8” nut on the inside of the frame, finger tighten at this time. PUSH THE BRACKET FORWARD AGAINST THE RIVET. Torque the 3/8”x1-1/2” bolt and nut to 30 ft. lbs. And then torque the 1/2”x1-1/2” bolts and nuts to 75 ft. lbs.
Loosen the two wing adjustment nuts on the bottom bracket and the two bolts that hold the air sleeves to the top bracket leaving them finger tight. (See Figure 1.) Place the air sleeve assembly on top of the spring, in front of the axle, with the hook around the front U-bolt.
Route the airline out to the wheel well opening area, securing away from all sharp edges, exhaust pipes, etc. Drill a 5/16" hole so that the air valve can be mounted through the body structure. Remove the cap and nut from the fitting. Slide the fitting through the hole in the sidewall. Replace nut and cap and tighten nut. See Figure 2 for exact placement of these parts. Install the air pressure decal next to the air valve. Repeat these steps on opposite side at this time. If the airline is removed from the air fill valve it is necessary to squarely cut 3/8” from the end of the airline before reinserting.
Lift the differential back up, putting the load of the vehicle on the springs. Place jack stands under the axle. Put air into the air sleeves until the vehicle starts to lift, about 30 pounds. This allows the bottom bracket to seat. To properly align the air sleeves, tap the bottom bracket back and forth until it is centered with the top and the air sleeves are perpendicular to both the top and bottom brackets. When you think it is straight, check it again. With 30 pounds of air in the system and a load on the axle, you should NOT feel the bottom piston pressing against the rubber of the sleeve. In other words, the piston will be centered in the rubber. The air sleeves must stand vertically on the spring within a tolerance of +/-1/8". Torque wing adjustment nuts to 20 ft. pounds. If not torqued correctly, misalignment of the air sleeves will occur. Check side-to-side alignment then torque 3/8" bolts on top bracket to 40 INCH POUNDS. ALLOWABLE TOLERANCE IS +/- 1/8". PROPER ALIGNMENT MEANS THAT THE RUBBER ON THE AIR SLEEVE IS STRAIGHT UP AND DOWN. PERPENDICULAR TO THE TOP AND BOTTOM BRACKETS WITH LOAD OF UNIT ON SPRING.
Next tighten the bottom U-bracket (attached to the air sleeve assembly) around the spring using the 5/16" x 3-1/2" bolts. Bolts must go through the hole closest to the bottom of the spring and be placed to the inside of the frame rail so that the nut is TOWARDS the tire. Torque nut to 25 foot-pounds.
Repeat the above steps on the opposite side.
Inflate the air sleeves to 100 psi. Check to insure that it is straight. Check all fittings for air leaks with a soapy water solution. Release the air pressure until the vehicle sits level. Units can carry from 20 to 100 psi; Individual owners may require different pressures to suit their own concept of best ride. Units must contain a minimum of 20 psi at all times. In some cases it will be necessary to carry more air on one side of the vehicle than the other. This is caused by the distribution of weight on the chassis. Do not drive the vehicle without air in the System Air. Reinstall wheels; reconnect battery(s), and road test vehicle.
Recommended installation time for the T-9 System Air: 2.5 hours
Registered U.S. Patent 4,494,772 et al.
1055 EmpireDriveLake Havasu City, AZ 86404
800-223-1779 928-453-3040 928-453-3140(fax)
Doc.#: II1100
Creation Date: 6-28-05Rev.#: 03Rev Date:8/15/06