Air Suspension 97-02 Navigator/ Expedition Coil Spring Conversion - Manual

SIZE
WEIGHT:
0 COIL-CONVERSION
RLS 05/19/06
DWG. NO.
A
COIL SPRING CONVERSION
PROPRIETARY AND CONFIDENTIAL NAVIGATOR / EXPEDITION
1997-2002
REV.
MATERIAL
FINISH
DO NOT SCALE DRAWING PROHIBITED.
COMMENTS:
SHEET 1 OF 1
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
DATE NAME
ARNOTT, INC. IS
WITHOUT THE WRITTEN PERMISSION OF
APPLICATION
REPRODUCTION IN PART OR AS A WHOLE
USED ON
ARNOTT, INC. ANY
NEXT ASSY
DRAWING IS THE SOLE PROPERTY OF
THE INFORMATION CONTAINED IN THIS
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL
ANGULAR: MACH BEND
TWO PLACE DECIMAL
THREE PLACE DECIMAL
SCALE:1:8
3
1
7
13
8
4
6
97-02 Navigator/ Expedition Coil Spring Conversion
Air Spring Removal
WARNING: The air suspension system is under pressure (up to 10 bar, or
150 lbf/in²). Do not allow dirt or grease to enter the system. Always wear
standard protective hand, ear, and eye protection when servicing the air
suspension system.
Removal
1. Turn the air suspension switch to the OFF position. (Switch is located on the
passenger front kick plate)
2. Raise the vehicle on a hoist or with the proper lifting equipment. Suspension
must be at full rebound with no load.
WARNING: Always support the chassis on safety stands. Refer to your
vehicle’s Owner’s Manual for correct lifting instructions.
3. Remove both rear tires.
4. Remove air spring solenoid retaining clip.
5. Remove electrical connector and air line from air spring solenoid valve.
6. Rotate solenoid counterclockwise to the first stop, and then carefully pull out to
vent the air pressure from the air spring. After air spring is deflated, turn again
and completely remove solenoid from air spring.
7. With pliers, or a suitable hooked tool, remove the clip that secures the top of the
air spring to the chassis. NOTE: To access the clip, go under the wheel arch,
between the body of the vehicle and the chassis.
8. Remove the piston-to-axle spring seat clip. (Air Spring is held in place with a
round retainer clip under the piston cap. To unsnap clip, gently pry between the
piston and the axle. Clip will unsnap when pressure is applied)
9. Carefully remove air spring from the vehicle.
10. Unplug the air spring solenoid power supply, and remove the air hose by pushing
down on the orange quick release ring while pulling outward on the hose.
11. Remove the air spring solenoid.
NOTICE: It’s important to unplug and remove the air spring solenoid.
Removing the solenoid will prevent the air suspension system from operating
after the conversion is installed.
12. Seal off hose to prevent dirt or grease from entering system.
13. Remove both lower shock bolts. Allow axle to hang free unsupported. This will
give you extra clearance for the coil spring.
Coil Spring Installation
Tie the wires and air hose back away from any hot or moving parts. Do not cut the
wires. Leave the system whole in case you ever want to reinstall air suspension on
the vehicle.
1. Install the coil springs onto the rear axle.
2. Using a floor jack, raise the rear axle.
3. Install the lower shock absorber retaining nut and bolt to the rear axle. Tighten the
lower shock absorber retaining nut and bolt to 95 N-m (70 lb-ft).
4. Remove the rear axle support.
5. Replace tire and wheel assembly. Tighten wheel hub bolt nuts to 115-142 N-m
(85-105 lb-ft).
6. Remove all safety stands and lower vehicle.
WARNING: Make sure to tighten all wheel hub bolt nuts to 115-142 Nm
(85-105 lb-ft). Failure to heed to this warning could result in serious bodily
and vehicular damage.
Disarming the Air Suspension System
To disarm the suspension light, you will need to remove the instrument cluster, and
unplug or remove the light bulb for the Check Air Suspension warning lamp.