helper airbags

Helper airbags can get the load capacity back to stock or better.  I used Air Lift Slam Air bags (about $200).

Installation:  The generic instructions are pretty good.  Just make the test fixtures as shown in the instructions (the white test fit rod is shown in the photo to the left) and use them to install the mounts as shown below.

Basically, you jack up the back and put the axle on jackstands.  You bolt the lower mount of the test fixture to the top of the leaf with u-bolts.

You the mark and drill the holes for the upper mounts.  You then remove the test rod and bolt on the upper mounts.

Install the nipples in the tops of the airbags, slip them in, install the airlines, and inflate the bags to 10 PSIG.  Tighten everything down and you're done. 

There may be interference with the passenger side shock mount.  I had to grind off one side of the head of a bolt (yellow in the below photo) and put it in with the head facing in.  I also had to leave out one of the washers on the bolt below it.  I later solved the problem by removing the passenger shock mount entirely (to reverse the shock).

An air ratchet is a major timesaver.

BE CAREFUL:  On the driver's side, you will be drilling right near the fuel lines, a power harness, and the fuel tank.

So that I could move these lines out of the way, I clipped off the ends of the plastic clips and shoved the cut ends of the clips through.

I am going to redo the driver's mount with the bolt heads on the inside.  I am concerned about the bolts chafing through the fuel or power line, and it will be easier to thread the nuts.  Trust me, getting these *&$^@'s threaded was one of the hardest tasks of my life.

Also, my driver's side mounting position interfered with an existing nut.  I clearanced the upper mount with a die grinder (area in blue below) and shot some paint on the wound to protect against rust.  Also, the emergency brake cable stay (area in yellow below) had to be moved.

I installed the filler valves in the fender wells and tie-wrapped the air lines up the fender supports.

Using jackstands, this job was a lot tougher than it looks.  If I had to do it over again, I would take it to a shop with a lift and have them install the bags.

In Version 3.0 of my suspension, the airbags are now more than just "helpers."  They are an integral part of the spring rate.  So I upgraded to an in-cab controller.  The Air Lift SureSet offers digital control with no airlines running into the cab, and the ability to store a pre-set pressure.  Any time the ignition is on, the controller will make sure that the bags are properly inflated.  Not bad for a little over $200.