81214004 REV3 RR2613 long bwi sensor thomas comp · the jounce bumper cup. ASSURE THERE IS NO GAP BETWEEN THE TOP OF THE UPPER BRACKET AND THE BOTTOM OF THE JOUNCE BUMPER CUP. 2 Press

1 812-482-2932

Congratulations - your new TowPro Helper Springs are quality products capable of improving the handling and comfort of your vehicle. As with all products, proper installation is the key to obtaining all of the benefi ts your kit is capable of delivering. Please take a few minutes to read through the instructions to identify the components and learn where and how they are used. It is a good idea to start by comparing the parts in your kit with the parts list below.

81214004 2011-2020 GM 2500/3500

��

REV3 7/10/20

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PARTSCompare the parts below to your kit. Ensure you have all pieces, and organize them for an easier installation.

MAIN KIT CONTENTS

PT #

640

1

x 2 AIR SPRING

PT #

589

7

x 4 CLAMP SPRING MOUNT

PT #

589

8

x 2 UPPER BRACKET

PT #

589

9

x 2 LOWER BRACKETPT

# 5

900

x 4 HOOK SPRING MOUNT

PT #

941

4

x 1 RED AIR LINE TUBE(18 FEET)

PT #

100

4

x 1 HEAT SHIELD

A24-760-7560 INFLATION VALVE BRACKET KIT

PT #

948

3

x 1NO-DRILL INFLATION VALVE BRACKET PT

# 9

488

x 2 LARGE NYLON TIE

A21-760-2613 HARDWARE PACK

PT #

304

6

x 2 AIR FITTING

PT #

306

4

x 2 INTERNAL TOOTH LOCK WASHER

PT #

351

3

x 4 1/4" - 20 x 2" HEX SCREW

PT #

329

5

x 2 3/4" - 16 HEX NUT

PT #

351

0

x 4 1/4" - 20 FLANGE NUT

PT #

340

2

x 4 3/8" - 16 x 2" CARRIAGE BOLT

PT #

303

3

x 4 5/16" FLAT WASHER

PT #

351

4

x 8 3/8" - 16 x 1" FLAT HEAD SCREW

PT #

903

6

x 6 RED NYLON TIE

PT #

302

2

x 12 3/8" - 16 FLANGE LOCK NUT

PT #

303

2

x 2INFLATION VALVEAND VALVE CAPASSEMBLY PT

# 0

899

x 2 THERMAL SLEEVE

PT #

314

2

x 2 3/8" - 16 x .625" FLAT HEAD BOLT

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�� PAGE �

BUILD UPPER MOUNT ASSEMBLY & REMOVE EXISTING JOUNCE BUMPER

PAGE � INSTALL UPPER SPRING MOUNT ASSEMBLY

PAGE � DRY FIT AIR SPRING AND LOWER BRACKET

PAGE � SECURE LOWER BRACKET TO AIR SPRING

PAGE � IINSTALL HOOK SPRING MOUNTS & SECURE AIR SPRING

PAGE � INSTALL THE HEAT SHIELD

PAGE �� AIR LINE TUBE &INFLATION VALVE INSTALLATION

PAGE �� INSTALL & ROUTE AIR LINE TUBE

PAGE ��CHECKING THE SYSTEM

PAGE �� FIXING ANAIR LEAK

PAGE ��FINISHING THEINSTALLATION

3/8” - 16 x .625”FLAT HEAD BOLT

AIR FITTING3/4"- 16 HEX NUT

3/6"- 16 x 2"CARRIAGE BOLT


3/4" INTERNAL TOOTH LOCK WASHER

LOWER BRACKET

AIR SPRING

HOOK SPRING MOUNTSee step 6 for details.

HOOK SPRING MOUNTSee step X for details.

ALIGNMENT PIN*See important note - Step 4.

3/8" - 16 x 1" FLAT HEAD SCREWS

1/4" - 20 x 2"HEX SCREWS

CLAMPSPRING

MOUNTS

UPPER BRACKET3/8" - 16FLANGE

NUTS

3/8" - 16 FLANGE NUTS

UPPER MOUNT ASSEMBLYSee step 1 for details.

VEHICLE STRIKER PAD

Vehicle fro

nt

3/8" - 16 FLANGE NUT

3/8" - 16 FLANGE NUT

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1/4" - 20 x 2"HEX SCREWS

CLAMPSPRING

MOUNTS

UPPER BRACKET

3/8" - 16FLANGE NUTS

DO NOT FULLY TIGHTEN.


3/8" - 16 x 1" FLATHEAD SCREWS


BUILD UPPER MOUNT ASSEMBLY

REMOVE THE EXISTING JOUNCE BUMPER

1

2

1Use a pry bar or flat head screwdriver to pry out the existing jounce bumper.

START THE INSTALLATION ON THE LEFT SIDE OF THE VEHICLE WHEN FACING FORWARD.

1 Using the flat head screws and flange nuts, loosely bolt clamp spring mounts to the upper bracket, as shown. DO NOT TIGHTEN AT THIS POINT.

2 Install the hex screws and flange nuts, as shown. DO NOT TIGHTEN AT THIS POINT.

x 2 x 2 x 4 x 6

DO NOT FULLY TIGHTEN

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Vehicle fro

nt

JOUNCEBUMPER CUP

UPPER SPRINGMOUNT ASSEMBLY

Slide clamp springmounts apart.

Slide clamp springmounts apart.

Alternate tightening the flangenuts onto the hex screws on each side.1

INSTALL UPPER SPRING MOUNT ASSEMBLY TO JOUNCE BUMPER CUP31 Using the upper mount

assembly from step 1, slide clamps so that they are farthest apart and place over the jounce bumper cup.

ASSURE THERE IS NO GAP BETWEEN THE TOP OF THE UPPER BRACKET AND THE BOTTOM OF THE JOUNCE BUMPER CUP.

2 Press the upper mount assembly tight against the bottom of the jounce bumper cup, assuring there is no gap.

3 Slowly and evenly tighten hex screws and flange nuts on each side of clamp until the upper mount assem -bly is securely attached to jounce bumper cup.

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DRY FIT AIR SPRING AND LOWER BRACKET 4

ALIGNMENT PIN

UPPER SPRING MOUNT

ROTATE ASSEMBLY TOUSE MIDDLE

ALIGNMENT HOLE

VIEW FROM BELOW

LOWER BRACKET

AIR SPRING


3/8” - 16 x .625”FLAT HEAD BOLTDO NOT FULLY TIGHTENIN THIS STEP.

ALIGNMENT PIN ON AIR SPRINGS MUST BE INSTALLED TO FULLY SEAT INTO THE MIDDLE ALIGNMENT HOLE IN THE UPPER BRACKET. FAILURE TO DO SO WILL CAUSE IT TO BE PUSHED INTO THE BEAD PLATE, CREATING AN AIR LEAK, AND RESULTING IN AN AIR SPRING FAILURE THAT IS NOT WARRANTABLE. THE ALIGNMENT PIN CANNOT HOLD 2,500 LBS! IT IS USED FOR ALIGNMENT ONLY!

1Fasten the lower bracket to the air spring using the flat head bolt, as shown. DO NOT FULLY TIGHTEN IN THIS STEP.

2Dry fit into place, assuring the alignment pin is fully seated into the middle hole on the upper spring mount assembly.

INSTALLING THE RIGHT SIDE? REMEMBER TO INSTALL THE HEAT SHIELD IN STEP 7 FIRST!

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AIR SPRINGASSEMBLY

MAKE ALIGNMENTMARKS

VEHICLESTRIKER PAD

SECURE LOWER BRACKET TO AIR SPRING5

1 Position the lower bracket so that it sits squarely on the jounce bumper striker pad.

2 Assure that the alignment pin is fully seated in the middle hole, as noted in step 4.

3 Make alignment marks, as shown.

4 Remove air spring assembly.

5 Assuring your marks are aligned, fully tighten the flat head bolt to secure the low -er bracket to the air spring.

6 Fit the air spring assembly back into position.

ALIGNMENT PIN ON AIR SPRINGS MUST BE INSTALLED TO FULLY SEAT INTO THE MIDDLE ALIGNMENT HOLE IN THE UPPER BRACKET. FAILURE TO DO SO WILL CAUSE IT TO BE PUSHED INTO THE BEAD PLATE, CREATING AN AIR LEAK, AND RESULTING IN AN AIR SPRING FAILURE THAT IS NOT WARRANTABLE. THE ALIGNMENT PIN CANNOT HOLD 2,500 LBS! IT IS USED FOR ALIGNMENT ONLY!

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HOOK SPRING MOUNTHook under lip of vehicle striker pad.

3/8" - 16 FLANGE NUTAlternate tightening both flange nuts

to evenly secure the lower bracket.

HOOK SPRING MOUNTHook under lip of

vehicle striker pad.

3/8" - 16FLANGE NUTAlternate tightening both flange nuts to evenly secure the lower bracket.

AIR FITTING3/4"- 16 HEX NUT

3/4" INTERNALTOOTH LOCK

WASHER



VEHICLESTRIKER PAD

BLIND SIDE VIEW

INSTALL HOOK SPRING MOUNTS & SECURE AIR SPRING 6

1 Assure that the alignment pin is fully seated in the middle hole, as noted in step 4.

2 Fasten the air spring to the upper spring mount as -sembly, as shown.

3 Install the hook spring mounts, as shown. Assure that the mount hooks under the edge of the striker pad.

4 Slowly and evenly tighten the nut on each carriage bolt until lower bracket is secure.

x 2 x 2 x 2

USE YOUR HAND TO CHECK FOR THE PROPER CLEARANCE AROUND THE AIR SPRING. IF YOUR HAND DOES NOT FIT BETWEEN THE AIR SPRING AND OTHER COMPONENTS, IT WILL RUB!

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HEAT SHIELD

AIR SPRING

Position heat shield toclosest point of exhaust.

DO NOT PLACEDIRECTLY ABOVE AXLE.

HEAT SHIELD


INSTALL THE HEAT SHIELD7

AWESOME! You’re done with the left side. Go back to step 1 and repeat the steps for the right side installation.

1Secure the heat shield by clamping it between the air spring and upper spring mount assembly.

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1 Secure the air Inflation valve bracket to a pro -tected, secure location. PROCEED TO STEP 3.

2 Select a protected location to install the inflation valves, such as the bumper or the body of the vehicle.

Drill two 5/16" holes for inflation valve install locations.

3 Install inflation valve assembly as shown.

INSTALL INFLATION VALVES

CUT THE AIR LINE TUBE INTO TWO EQUAL LENGTHS

8

9

x 2 x 2x 4 x 2

1Match air line tube ends.

2Find center of air line tube, make a square cut with tube cutter or sharp utility knife.

LARGENYLON TIES

Inflation valveinstall locations.

BUMPER

INFLATIONVALVES

EXAMPLEINFLATION VALVE

AIR LINE TUBE

VALVE CAP

INFLATION VALVE NUT

5/16” - 16 FLAT WASHER

Vehicle body,bumper orinflation valvebracket.

DO Make sure the cut is as square as possible.Use a tube cutter or sharp utility knife. DON’T Fold or kink the air line tube.

Cut the air line tube at an angle.Use pliers, scissors, snips,saws, or side cutters.

Square cut

90˚AIR LINE TUBE AIR LINE TUBE AIR LINE TUBE AIR LINE TUBE

PROPER AND IMPROPER CUTS IN THE AIR LINE TUBE

AIR LINE TUBE

�� THIS KIT INCLUDES THE LEVELTOW COMPRESSOR

SYSTEM, REFER TO THE COMPRESSOR SYSTEM SECTION OF THESE INSTRUCTIONS

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INSTALLING AIR LINE TUBE INTO AIR FITTINGS AND INFLATION VALVE

ROUTE AND SECURE AIR LINE TUBES

10

11

1 Insert end of air line tube into air fitting. 2 Push air line tube

into air fitting asfar as possible. 3 Gently pull on

the air line tube to check for a secure fit.

4 To remove, pushdown collar andgently pull air linetube away.

DOSelect routes protected from heat,debris, and sharp edges.Use thermal shields near heat sources.Use Nylon ties to secure the air line tube. DON’T

Bend or sharply curve air line tubes.Leave air line tube exposed to sharp edges.Use unnecessary lengths of air line tube.Route air line tube near moving parts.Let air line tube hang unsecured from vehicle.Scar air line tube while routing.

Air line tube routes will vary, depending on your truck, and requires you to choose the best path from the air springs to the inflation valves. Use the instructions below to help you choose.

AIR LINE TUBE THERMAL SHIELD

INFLATION VALVE

AIR LINE TUBE

AIRFITTING

x 7

x 2

USE SUPPLIED THERMAL SHIELDS WHEN AIR LINE TUBE RUNS WITHIN 6 INCHES OF HEAT SOURCES.

Removal Tip: Use a 1/4”, 5/16”, or 6mm open-ended wrench to push the collar down.

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1 Place an air chuck onto theinflation valve and fill thesystem to 70 PSI .

70PSI

2 Spray fittings with soap and water mixture.

WATER+

SOAP

3 Observe bubbles.

SMALL SOAP BUBBLESTHAT DO NOT EXPAND

SOAP BUBBLESTHAT EXPAND

CHECKING THE AIR SYSTEM 12

AIR SPRINGS INFLATE QUICKLY. CHECK AIR PRESSURE WHILE INFLATING.

NO LEAKS?Congratulations! Continue to step 15 to finish installation. Review the Operating Instructions.

LEAK?Bummer. Continue to step 14 to fix the leak.

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FIXING AN AIR LEAK131 Press the air valve on end

of inflation valve to release all air pressure.

0PSI

STILL HAVE A LEAK?Refer to the Troubleshooting section of the Instruction Manual. If the leak persists, or if there is an issue with a leaking part, call 1-812-482-2932.

LEAK AT AIR LINE TUBE AND AIR FITTING

LEAK AT BASE OF AIR FITTING ON AIR SPRING

LEAK OUT OF THE VALVE CORE ON INFLATION VALVE

Release air line tube (see page 12). Review proper cuts and procedures in step 10. Repeat steps 11 and 13.

Tighten air fitting one turn or until leak stops.

Tighten valve corewith valve core wrenchon inflation valve cap.

EXHAUST ALL AIR FROM THE SYSTEM PRIOR TO RELEASING AIR LINE TUBES FROM AIR FITTINGS.

AIR VALVE

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FINISHING THE INSTALLATION 14SAFELY RETURN VEHICLE TO OPERATIVE STATEIf you removed any wheels during installation, install the wheels and torque the lug nuts to the manufacturer’s specifications.

Safely remove any jack stands and wheel chocks used during installation.

Re-attach the negative battery cable.

DOUBLE-CHECK AIR SPRING CLEARANCECheck the air springs once again for the proper 1/2” minimum clearance. Perform clearance check again when vehicle is under load.

VEHICLE GVWRNEVER exceed the maximum load recommended by the vehicle manufacturer (GVWR). The GVWR can be found in your vehicle’s owner’s manual or on the data plate on the driver’s side door. Consult your local dealership for additional GVWR specifications.

READ AND UNDERSTAND THE OPERATING INSTRUCTIONSThe Ride-Rite system can improve handling and comfort. Take the time to learn how to properly use and maintain your investment by reading the Operating Instructions.

! IMPORTANTA MINIMUM OF 5 PSI MUST BE MAINTAINED IN THE AIR SPRINGS AT ALL TIMESToo much air pressure in the air springs will result in a firmer ride, while too little air pressure will allow the air springs to bottom out over rough conditions, and will not provide the improvement in handling that is possible.

1/2"1/2"

USE YOUR HAND TO CHECK FOR THE PROPER CLEARANCE AROUND THE AIR SPRING. IF YOUR HAND DOES NOT FIT BETWEEN THE AIR SPRING AND OTHER COMPONENTS, IT WILL RUB!

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Congratulations - your new LevelTow Compressor System is a quality product, that when used in conjunction with the LevelTow helper Air Springs, is capable of improving the handling and comfort of your vehicle. As with all products, proper

through the instructions to identify the components and learn where and how they are used. It is a good idea to start by comparing the parts in your kit with the parts list below.

Compressor Unit 31920022 1 Smart Sensor Height Sensor 31980006 1 Compressor Mounting Bracket 90002637 1 Smart Sensor Mounting Bracket 70014456 1 Sensor Linkage 31980011 1 Linkage Axle Bracket 70011429 1 Control Panel Bracket 70011439 1 Airline Fitting (mounted in compressor) 31957016 1 Main Activation Switch 70006302 1 Manual Control Switch 70011413 1 Main Wire Harness 31900051 1 Axle Bracket Clamp 99000005 1 1/4” TEE Fitting 31954400 1 1/4” Fitting for airsprings Straight / 90 Degree 31954000 / 31954201 2 20 amp fuse 90001922 1 Fuse Holder 90001924 1 10-12 Butt Connector for Fuse Holder 90001913 1 Ring Terminal for Main Power Hookup 90001916 1

#10 x 5/8” Phillips pan head - sensor to bracket 99104002 4 1/4”-14 x 1” Self Drilling Screw- Sensor to Frame 99254001 5 3/8-16 x 1” Thread Forming - Compressor Bracket to Frame 99373007 5 10-24 x 1 1/4” Maching Screw - Compressor to Bracket 99101007 4 10-24 Nylok Nut - Compressor to Bracket 99102002 4 #10 Flat Washer - Compressor to Bracket 99103001 8

REV6 7/10/20

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The LevelTow Compressor System is an automatic leveling system, once it is turned on(button illuminated blue) it will operate without any assistance.

to keep the vehicle level. It has a dwell range built in so that when the truck is going down the road hitting small defects the system will be idle. It isn’t until the sensor gets out of this dwell range for 18 seconds that the system will react.

The activation switch has to be illuminated blue for the system to work.

Activation Button

1. Before you install the compressor system,you will need to have the helper Airspringsinstalled. This will ensure that the LevelTowlinkage does not get in the way of theAirsprings.

vehicle at ride height, measure the lip of the fender to the ground at the center of the wheel and write it down.Measurement_________________This measurement will be used as a reference once you have the compressor system installed.

2. Unpack the wiring for the LevelTow systemand lay it out. This will give you an idea towhere you can mount the components withouthaving to modify the wiring harness.

NOTE:There is a wiring diagram on Page 7 to assist you in component location.

RedW

ire

20 AmpFuse

Activation Switch

ManualInflate/Deflate

GREEN

BLACK

BLUE

White4 pin plug

(these wirescan be attached

at the same point)

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3. Bolt the compressor to the bracket.Position the compressor on the Bracket inthe orientaion shown. Line up the holes inthe (4) Mounting Bushings with the (4) holesin the Bracket. Install a #10 Flat Washer oneach of the (4) #10-24 x 1 1/4” Pan HeadScrews. Insert a Screw/Washer in each ofthe 4 holes. Install a #10 Flat Washer onthe threads sticking through the bottom ofthe bracket followed by a #10-24 Nylok Nut.Tighten the hardware.

4. The compressor needs to be mountedon the frame rail with the dryer up. Attachthe compressor bracket to the frame with (4)3/8”-16 x 1” Thread Forming Bolts supplied inthe kit. Drill a 5/16” Hole for the bolts.

5. The Axle bracket can be mounted in anylocation on the axle tube to get the sensorlinkage to line up. The Axle mount shouldbe mounted on the axle so that the linkagewill line up from the axle mount to the sensor.Keep this in mind when establishing thesensor location.

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6. The next step will be to mount the sensor. The Smart Sensor needs to be centered in its travelat the trucks ride height to operate properly.This can be done by cutting the linkage rod to

sensor mounting screws and twisting it in themount and retightening the 4 screws. When themounting and linkage is done it should look likethe diagram seen here.

7. The sensor needs to be mounted on the framerail with the wires pointing down. The arm willneed to swing up opposite the direction of thewires as the suspension is being compressed.Attach the sensor bracket to the frame with (4)self drilling screws supplied with the kit.

8. This diagram shows how the clamp sticksthrough the axle bracket. Loosen the clampuntil it will open up and then slide it throughthe bracket. The whole assembly can thenbe put on the axle tube. Reinsert the end ofthe clamp back into the adjuster and tightenthe clamp until the bracket is tight on the axletube.

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9. With the sensor and the axle bracketmounted, it is time to connect the 2 with thesupplied linkage. The linkage is a universallength and will have to be cut to achieve thenecessary length for your application. Todo this it will be necessary to have the trucksitting at its factory ride height. With the truckat ride height center the sensor in its travel.The rod can slide into each rubber rod endup to 1”.

10. The linkage rod has barbs on the outsideof it to keep it in the end link. After you push

Push the linkage into the ends a little at a timeuntil you get the desired length of the linkageassembly. If for some reason you must pullthe rod out of the end, it is best done bytwisting the end while pulling on it.

11. Mount the control panel in a convenientlocation. Install the Power Button andManual Control Rocker into the panel. ThePower Button gets installed into the roundhole. The nut that is on the button is used toattach the button in the panel. The RockerSwitch goes into the hole with the notch in it.Align the tab on the switch with the slot andpush the switch into the hole until it snaps inplace. The rocker will only go into the holeone way. You can also custom mount thebuttons if desired. They both use a 3/4” hole.The hole for the manual switch will have tohave a slot for the tab

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RedW

ire

20 AmpFuse

Activation Switch

ManualInflate/Deflate

GREEN

BLACK

BLUE

White4 pin plug

(these wirescan be attached

at the same point)

GREEN

BLACK

BLUE

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14. Once the system is installed you canverify the operation of the system by puttinga load on the truck. With a load on the truckand the button illuminated blue, your fenderto ground measurement that you took on

higher or lower you can adjust the height byloosening the 4 screws that attach the sensorto the bracket and twist in its mount. If rideheight can not be achieved by adjusting in thebracket the linkage will need to be lengthenedor shortened to achieve the height you need.

AIR LINEAIR

SPRINGS

COMPRESSOR

AIR LINE “T” FITTING

13. . Start at the Airspringfurthest from the compressor. Trim the airline so that the cut is clean and as square as possible.

from the airspring to the compressor keeping it away the exhaust pipe and sharp edges. If it isnecessary to run the line over a sharp edge, use a supplied thermal sleeve over the airline toprotect it. The sleeve is installed by sliding it over the airline to the area where the line needsprotected.

line to the compressor. With both lines ran from the air spring to the compressor, install the “T”

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Manual Operation:The LevelTow Compressor System also has a manual control function. This function allows you to manually

Note:If the Activation Button is illuminated blue and the manual button is pushed the truck will relevel itself. The

Troubleshooting:

direction. You can verify this by turning the truck on and check that the activation button is illuminated blue. Unhook one end of the linkage and move the sensor arm by hand. If when you move the arm down (Keep in

screwdriver pop the purple retainer out of the plug by prying up on each end of it. After removing the retainer if you look into the end of the plug you will see a tang holding each wire terminal. Simply pry it down just enough to release the terminals of the blue and green wires. Swap the blue and green wire postion and reinstall the wires into the plug paying attention to the direction of the small tab on the wire terminal. This tab will point to the center of the plug. Push the wire terminals into the plug making sure they catch on the tang and reinstall

RED

RED

BLACK

BLUE

GREEN

VIEW FROM WIRE SIDE

WIRE SIDE

SIDE VIEW

WIRE LOCATIONS AT HEIGHT SENSOR

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BEFORE YOU DRIVE, CONFIRM THE FOLLOWING: Do you have a minimum of 5PSI in your air springs?

Are your air springs standing 5 1/2" - 6 1/2" tall?

Are your air springs properly aligned, left-to-right and front-to-back?

Are your nuts and bolts tight?

Put your paper work back into the sleeve and keep it in your glove compartment for future reference.

You’ve been bagged…and now your suspension is Airide equipped! Show it off with the supplied decal!

5 1/2" - 6 1/2"

Documents

81214004 REV3 RR2613 long bwi sensor thomas comp · the jounce bumper cup. ASSURE THERE IS NO GAP BETWEEN THE TOP OF THE UPPER BRACKET AND THE BOTTOM OF THE JOUNCE BUMPER CUP. 2 Press