Pacbrake HP10216 User manual

HP10216 KIT
Chevrolet Silverado / GMC Sierra 1500
(2WD / 4WD) †*
† For short (69.3") and medium (78.7") truck bed lengths (Not for 97.6" Truck Beds)
Will not t vehicles equipped with MagneRide.
* See application guide for proper fitment.
Use the most advanced air springs on the market to eliminate your
vehicle’s sag, sway and bottoming out. Pacbrake air suspension levels
your truck’s stance while providing added support for an overall smooth
and safe ride.
ECN 1-1789

Pacbrake is a registered trademark of Pacbrake Co. 1
HP10216 AMP AIR SUSPENSION KIT L6360
ECN 1-1789
L6360_Rev4_17.07.2018
KIT CONTENTS
REQUIRED TOOLS
• Hoist or Floor Jacks
• Safety Stands
• Safety Glasses
• Torque Wrench
• Standard Open-End Combo
Wrenches
• Ratchet
• Metric and Standard Sockets
• 7⁄32" Allen Wrench (socket if available)
• 5⁄16" Drill Bit (very sharp)
• Heavy Duty Drill
• Hose Cutter, Razor Blade or
Sharp Knife
• Air Compressor or Compressed
Air Source
• Spray Bottle with Dish Soap & Water
Make sure all the items shown in
the photo are provided in your kit
before starting the installation.
KIT CONTENTS
A Air Spring (2) HP10000D
B Upper Bracket Driver Side (1) HP1432
C Upper Bracket Passenger Side (1) HP1431
D Lower Bracket (2) HP1433
E J Clamp (4) HP1434
F SUB GROUP (1) HP10217
F1 Capscrew, Countersunk (8) HP1008
F2 Bolt 3⁄8x 1 ½ NC (2) C18018
F3 Flat Washer 3⁄8" (2) C18006
F4 Flat washer 3⁄8" SAE (14) C653
F6 Screw Hex Cap 3⁄8"-16 (4) HP1416
F7 Nut Nyloc 3⁄8"-16 (10) HP1000
F8 U-Bolt (2) HP1331
F9 Airline Hose Assembly (1) HP1344
F10 Bolt, Self-Tapping 3 (2) HP1078
F11 Cable Clamp 5⁄8" (2) HP1435
F12 Cable Clamp 1" (1) HP1436
F14 Bolt Leader Tool (1) Hp1440
F15 Heat Shield (1) HP0012
F16 Worm Gear Ring Clamp (2½" - 4 ½") (2) HP1001
F17 Worm Gear Ring Clamp (4½" - 6½") (2) HP1377
H AIR SPRING SUB GROUP (1) HP10180
H1 Fitting, Brass, Push (2) HP1099
H2 Tywrap (6) C11618
H3 Roll Plate (4) HP10054
A
B
C
E
D
D
F12
F11
F2
F10
F6
F17
F16
H15
F14
H1
H2
H3
F9
F8
F7F4
F3
F1

Pacbrake is a registered trademark of Pacbrake Co. 2
HP10216 AMP AIR SUSPENSION KIT L6360
ECN 1-1789
L6360_Rev4_17.07.2018
H3
F8
F3
F11
H3
E
F6
D
F7
A
F10
F4
H1
B/C
F1
F7
F4
F4
F2
F4
F7
F7
F4
E
F4
F6
F1
F1
12345678
A
B
C
D
E
UNAUTHORIZED DISCLOSURE, USE OR MANUFACTURE IN WHOLE OR IN PART IS PROHIBITED.
DRAWING DESIGN AND OTHER DISCLOSURES PROPERTY OF PACBRAKE CO. SURREY, B.C., CANADA
CUSTOMER PART #:
APP:
CHK:
DESCRIPTION:
D.M.Y.
ECN:
MATERIAL:
1:5
SIZE:
INTERPRET ALL DIMENSIONS
AND TOLERANCES
PER ASME Y14.5-2009
THIRD ANGLE PROJECTION
B
SCALE:
PART NAME:
CAD NO.:
1
AirSuspensionAssembly
OF
1
SHEET
12.1 kg
WEIGHT: APP:
ENG:
D.M.Y.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS: mm
TOLERANCES:
;
SURFACE FINISH:
CHK:
F
G
10 12119 13
72 111 4 8 105 9 1263 13
G
B
E
D
A
F
C
ENG:
DWG NO.:
File: S:\masterfile\Documentation\PAC-091B-DOC_Rev2.SLDDRT Date: 23/Apr/2014
AirSuspensionAssembly
KIT CONTENTS
Note: Passenger's side assembly shown.
FRONT OF VEHICLE
* Part F10 is only to be used
with fth wheel hitch
applications

Pacbrake is a registered trademark of Pacbrake Co. 3
HP10216 AMP AIR SUSPENSION KIT L6360
ECN 1-1789
L6360_Rev4_17.07.2018
Jack Stands
Frame
1A
1B
Thank you and congratulations on the purchase of an AMP air suspension kit. Please read the entire installation
manual prior to starting the installation to ensure you can complete the installation once started.
IMPORTANT:
This air suspension kit will not increase the GVWR (Gross Vehicle Weight Rating), as the GVWR is determined by the
axle rating. Do not exceed the maximum capacity listed by the vehicle manufacturer.
BEFORE YOU START:
NOTE: Some vehicles are equipped with a rear wheel brake proportioning valve. Check with the manufacturer before
installing the air spring kit, as it may affect braking performance.
1. Ensure the application information is correct for the make, model and year of the vehicle you are installing
the kit on.
2. Pacbrake recommends using a good quality anti-seize on all fasteners. This will reduce the chance of corrosion
on the fasteners and will help facilitate removal, if required at a later date.
1RAISE THE REAR AXLE
• Remove any unnecessary weight from the vehicle to attain normal
ride height. This is important for correct initial air spring setup
and adjustment.
• Park the vehicle on a level surface.
• Record the vehicle’s normal ride height, which is the distance
between the center of the axle and the horizontal wheel well ange.
Ensure both sides are the same before raising the vehicle.
• Raise the rear axle high enough to remove both rear wheels and
attain a comfortable working height.
• Place two jack stands under the axle, as shown in gure (1A-1B)
• Lower the oor jack until the vehicle axle is supported by the
jack stands.
• Ensure the normal ride height measurement recorded earlier is the
same. Adjust if necessary before proceeding.
• Once the rear axle is raised correctly, remove the rear wheels.

Pacbrake is a registered trademark of Pacbrake Co. 4
HP10216 AMP AIR SUSPENSION KIT L6360
ECN 1-1789
L6360_Rev4_17.07.2018
2A
2B
2C
2D
2REMOVE THE LINE HOLDER
• Remove and discard the ABS line holder located on the left side
(driver's side) of the frame rail, on the inside of the frame, just
forward of the axle
• Pull the ABS line holders out from the frame and remove from the
ABS line. They are attached to the bottom of the frame, behind the
axle, on the left (driver's) and right (passenger's) hand side.
(See picture 2C)
• Use a small screw driver to unhook the clamp from the line and
remove it. Discard the clamp since it will no longer be used.
• Install the small cable clamps facing up, onto the ABS line where
the stock line holders were attached with the hole facing forward on
the line. Do this on both sides. (see picture 2D)
• Leave the ABS line hanging loose for later installation.
CAUTION: BECAUSE THE EMERGENCY BRAKE CABLE IS IN A
LOCATION THAT MAKES IT POSSIBLE TO RUB A HOLE IN
THE SIDE OF THE AIR SPRING, IT WILL BE NECESSARY TO
RELOCATE IT AWAY FROM THE AREA WHERE THE AIR SPRING
IS INSTALLED.

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HP10216 AMP AIR SUSPENSION KIT L6360
ECN 1-1789
L6360_Rev4_17.07.2018
3A
3REMOVE THE JOUNCE BUMPERS
• Remove the jounce bumpers from under the frame rails on
both sides. (See picture 3A)
• Remove the jounce bumpers by unbolting them from the jounce
bumper mounting cups welded to the frame, using a 10 mm socket.
• Pull or pry the jounce bumpers out of the cup with a screw driver
once the bolt has been removed.
4ASSEMBLING THE AIR SPRING
• Set a roll plate (H3) over the top of the air spring (See photo 4A).
NOTE: The rounded edge of the roll plate (H3) will be towards the
bellows so that the bellows is seated inside both roll plates.
• Install the swivel tting (H1) into the top of the air spring nger tight
plus one and a half turns.
• Install the upper bracket (see photo 4B ) onto the air spring using
four at head screws (F1). Torque to no more than 20 ft-lbs.
• Install the lower bracket (see photo 4C) onto the bottom of the air
spring using the at head screws (F1). Torque to no more than
20 ft-lbs.
NOTE: The lower bracket has one corner cut off, this side of the
bracket must point to the opposite side of the air tting on the air
spring assembly.
The gure 4C - 4D below shows both left and right hand assemblies
ready for installation.
4A
4B
4D4C

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HP10216 AMP AIR SUSPENSION KIT L6360
ECN 1-1789
L6360_Rev4_17.07.2018
5A
5INSTALLING THE AIR SPRING ASSEMBLIES
• Install a large at washer (F3) over the hex head bolt (F2) and
thread the bolt onto the supplied wire to create a leader tool.
• Insert the bolt and washer through the slot on the side of the frame
and through the slot on the bottom of the frame where the ABS line
holder was removed. Repeat on the other side.
NOTE: The ttings on both air springs will be facing inboard.
• While raising the assembly, line up the bolt previously installed with
the back hole on the bracket. Set the new ABS line holder over the
bolt once the upper bracket is in place and cap with a at washer
(F4) and nylon locknut (F7). Leave loose at this time.
There are two ways to attach the front side of the upper bracket
depending on whether you have a 5th wheel bracket running
alongside of the frame or not.
FOR VEHICLES WITHOUT A 5TH WHEEL BRACKET ALONG
THE SIDE OF THE FRAME:
• Set the U-bolt (F8) over the frame and through the holes in the
upper bracket forward of the axle.
CAUTION: DO NOT PINCH THE LINES ON THE LEFT (DRIVER)
SIDE FRAME RAIL.
• Cap with at washers (F4) and nylon locknut (F7). Position the front
upper bracket onto the frame rail so the center hole is in the middle
of the frame and there is sufcient clearance between the tting
and the stock jounce bumper cup.
• Torque the U-bolts to 10 ft-lbs. Repeat on the other side.
5B
5D
5C

Pacbrake is a registered trademark of Pacbrake Co. 7
HP10216 AMP AIR SUSPENSION KIT L6360
ECN 1-1789
L6360_Rev4_17.07.2018
5E
5INSTALLING THE AIR SPRING ASSEMBLIES
CONTINUED
FOR VEHICLES WITH A 5TH WHEEL HITCH BRACKET THAT RUNS
ALONGSIDE THE FRAME:
• Center the upper bracket in the middle of the frame rail, make sure
there is sufcient clearance between the tting and the stock jounce
bumper cup, and drill a 5⁄16" hole in the frame using the center hole in
the front side of the upper bracket as a template. Install the Washer
Head Self Tapping Screw (F10) in the hole.
• Torque to 15 ft-lbs. Repeat on the other side.
• Finish the upper bracket installation by torquing the rear bolt
to 15 ft-lbs.
NOTE: use a ¼" ratchet with an extension and universal joint with a
9⁄16" socket through the hole in the side of the frame to hold the rear
mounting bolt for torquing.
NOTE: Long box models may require a short extension.
AIR SPRING ALIGNMENT
5F 5G
5H 5I

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HP10216 AMP AIR SUSPENSION KIT L6360
ECN 1-1789
L6360_Rev4_17.07.2018
6LOWER BRACKET INSTALLATION
Push the lower bracket (D) forward or back to center it over the
jounce bumper strike plate. Insert a Hex Head Bolt (F6) through a
Flat Washer (F4) and J-clamp (E). Install the J-clamp with the short
end under the Jounce Bumper Strike Plate with the bolt through the
lower bracket. Cap with a Flat Washer (F4) and Nylon Locknut (F7).
Do this on the front and rear of the lower bracket and evenly torque
both sides to 10 ft-lbs keeping the lower bracket centered over the
jounce bumper strike plate on the axle. Repeat on the other side.
NOTE: It may be necessary on some models to slightly pull down the
hard brake line on the rear right (passenger side) in order to install
the lower bracket mounting hardware.
7EMERGENCY BRAKE CABLE MODIFICATIONS
• It will be necessary to re-locate the emergency brake cable that is
held by a bracket on the top of the axle center carrier section of the
rear end.
• Remove the top bolt that is holding the emergency brake cable
bracket onto the center section of the rear end.
• Remove the bracket from the emergency brake cable and
discard it.
• Install the large cable clamp over the emergency brake cable facing
the rear with the hole down and attach to the rear end using the
stock bolt previously removed.
• Bend the large cable clamp slightly to obtain clearance of the hard
brake lines. Mounted on top of the axle.
• Insert the emergency brake cable into the large cable clamp.
6A
7A
7C
7B

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HP10216 AMP AIR SUSPENSION KIT L6360
ECN 1-1789
L6360_Rev4_17.07.2018
8AIR LINE INSTALLATION
• Choose a convenient location for mounting the ination valves.
Popular locations for the ination valve are:
A The wheel well anges
BThe license plate recess in bumper
CUnder the gas cap access door
DThrough the license plate
NOTE: Whatever the chosen location, make sure there is enough
clearance around the ination valves for an air chuck.
• Drill two 5⁄16" holes to install the ination valves
• Cut the airline assembly in two equal lengths
CAUTION: WHEN CUTTING OR TRIMMING THE AIR LINE, USE THE
SUPPLIED HOSE CUTTER, A RAZOR BLADE, OR A SHARP KNIFE.
A CLEAN, SQUARE CUT WILL ENSURE AGAINST LEAKS. DO NOT
USE WIRE CUTTERS OR SCISSORS AS THEY MAY FLATTEN OR
CRIMP THE AIR LINE CAUSING IT TO LEAK AROUND THE O-RING
SEAL.
• Place a 5⁄16" nut on the air valve. Leave enough of the ination valve
in front of the nut to extend through the hole, install a at washer,
and 5⁄16"nut and cap. There should be enough valve exposed after
installation—approximately ½"—to easily apply a pressure gauge or
an air chuck.
Air Line
Schrader Valve
Hex Nut
Flat Washer
Vehicle Body
Valve Cap
12345678
7654321 8
A
B
C
D
E
A
B
D
E
C
UNAUTHORIZED DISCLOSURE, USE OR MANUFACTURE IN WHOLE OR IN PART IS PROHIBITED.
DRAWING DESIGN AND OTHER DISCLOSURES PROPERTY OF PACBRAKE CO. SURREY, B.C., CANADA
CUSTOMER PART #:
APP:
CHK:
DESCRIPTION:
D.M.Y.
ECN:
MATERIAL:
1:2
SIZE:
INTERPRET ALL DIMENSIONS
AND TOLERANCES
PER ASME Y14.5-2009
THIRD ANGLE PROJECTION
A
SCALE:
PART NAME:
CAD NO.:
1
AirLineAssembly
OF
1
SHEET
0.0 kg
WEIGHT: APP:
ENG:
D.M.Y.
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS: mm
TOLERANCES:
;
SURFACE FINISH:
CHK:
ENG:
AirLineAssembly
DWG NO.:
File: S:\masterfile\Documentation\PAC-091A-DOC_Rev2.SLDDRT Date: 23/Apr/2014
8A

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HP10216 AMP AIR SUSPENSION KIT L6360
ECN 1-1789
L6360_Rev4_17.07.2018
9A
• Push the ination valve through the hole, install
a at washer, and another 5⁄16"nut to secure
it in place. Tighten the nuts to secure the
assembly.
• Route the air line along the frame to the air
tting on the air spring. Keep AT LEAST 6" of
clearance between the air line and any heat
sources, such as the exhaust pipes, mufer,
or catalytic converter. Avoid sharp bends and
edges. Use the plastic tie straps to secure the
air line to xed (non-moving) points along the
chassis. Be sure that the tie straps are tight,
but do not pinch the air line. Leave at least 2"
of slack to allow for any movement that might
pull on the air line.
NOTE: Tie off the hose to the front hole of
the upper bracket or U-bolt, depending on the
mounting, with a tie strap to keep the hose away
from the exhaust.
• Cut off the air line, leaving approximately 12"
of extra air line. A clean square cut will ensure
against leaks. Insert the air line into the air
tting. This is a push-to-connect tting. Simply
push the air line into the swivel tting until it
bottoms out (9⁄16"of air line should be in the
tting).
9INSTALL THE HEAT SHIELD
• Bend the tabs on the heat shield (F15) so there will be the
necessary ½" dead space between the heat shield and the exhaust
pipe when the heat shield is attached.
• Attach the heat shield (F15) to the exhaust pipe on the passenger
side using two hose clamps (F16 / F17). Each hose clamp holds a
tab against the exhaust pipe. Make sure the heat shield is facing
toward the air spring.
NOTE: The small worm gear clamps (F16) are intended to be used
with an exhaust that is between 2.5 - 4.5" in diameter. The larger
worm gear clamps (F17) are intended to be used with an exhaust that
is between 4.5 - 6.5" in diameter.
AIRLINE (OPTION 1)
AIRLINE (OPTION 2)
8B

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HP10216 AMP AIR SUSPENSION KIT L6360
ECN 1-1789
L6360_Rev4_17.07.2018
10A
10 CHECK SYSTEM FOR LEAKS
• Inate both air springs to 90 PSI, and then use a mixture of dish soap
and water on all air line connections to detect any air leaks. Repair as
necessary and retest.
• Inate the air springs to a predetermined value, and on the following
day recheck the pressure. If one or both the air springs have lost
pressure, an air leak is present. The leak must be repaired, and then
retested until no leaks exist.
11 AFTER THE INSTALLATION IS COMPLETED, PLEASE
REMEMBER:
• Install the wheels, and torque the fasteners to the manufacturer’s
specications.
• Re-torque all the fasteners after the rst 500 miles of driving.
• For safe and proper operation, never operate the vehicle under the
minimum of 10 PSI or over the maximum of 100 PSI. Staying within
the pressure limit will ensure maximum air spring life. Failure in doing
so may result in a void warranty (see Note below).
OPTIONAL ACCESSORIES
Pacbrake offers an optional dual needle air gauge to monitor the pressure in each spring from the vehicles cab.
Pacbrake offers a full line of air compressors, air tanks and solenoids to control your air spring system.
OPERATING YOUR VEHICLE WITH PACBRAKE AIR SUSPENSION
Air springs have minimum and maximum pressure requirements. Never operate your vehicle with less than 10 PSI in
the air spring and never inate the air springs over 100 PSI. Damage to the air springs will result.
Check the air pressure in the air springs daily for the rst couple of days to ensure a leak does not develop. The air
springs are designed to maintain the vehicles stock ride height with a load. Do not use the air springs as a means to lift
the vehicle with no load. A rough ride will result.
SERVICING YOUR VEHICLE WITH PACBRAKE AIR SUSPENSION
When lifting the vehicle with a oor jack or hoist on the frame, never allow the air spring to limit the travel of the axle.
Try to always jack the vehicle on the axle. Suspending the axle with the air spring limiting the axle travel will damage
the air spring and void the air spring warranty.
WARRANTY
To be eligible for warranty, owner must submit their warranty card or register online within 30 days of purchase date.
NOTE: The owners warranty will be void if air springs run with less than the minimum of 10 PSI.