2001 Chevy Silverado 3500 Air Suspension Install - Hammer Time

Pictured here are the rear Firestone airbags accompanied by much of the plumbing needed to run the system. This particular kit includes two 2-gallon tanks, two Thomas 317 compressors, wiring harnesses, Ride-Pro valves, a 1/4-inch air line, and rear shock absorbers.

To modify the rear suspension structure, Air Ride Technologies supplied us with upper and lower 'bag bracket bars, a Panhard bar and rearend cover bracket, four-link bars and brackets, and U-bolt plates. Also pictured here is a new transmission crossmember and two plates used to relocate the front sway bar.

For the rear axle to have ample room to travel when the 'bags are deflated, Air Ride supplied us with these massive C-section pieces to use as templates to cut the frame and then bolt in for strength and rigidity.

After rolling Project Hog Hauler into the shop area at SporTrucks By Dean, the crew put the truck up on the lift and unbolted and removed the bed. All electrical connections under the box were unplugged, the gas filler neck was unbolted from the opening in the bedside, and the back bumper was removed. The shop crew carried the bed outside and set it on some sawhorses. After the rear frame clip was exposed, the mounting points for the fuel tank were loosened and it was supported with a floor jack. The gas tank was removed and set on a shop cart. The filler neck was also removed and set aside with the tank. After the bed and fuel tank were removed, the factory hitch was removed and set aside as well. With the bed off, it would be a lot easier to execute the frame alterations required to slam the dualie to this new level. Before the install was complete and the bed was reinstalled, the bed braces underneath the box needed to be notched for clearance of the top of the C-section. A small cut also needed to be made on the inner fenderwell for clearance of the top portion of the Air Ride Technologies rear shocks. You will see what we mean in about 55 steps from now.

With the supplied C-section mounted up to its prescribed location on the frame above the axle and held in place firmly with two sets of hands, a scribe tool was used to trace the cut in the frame. The C-section plate was pulled away from the frame, and the plasma cutter was fired up to do the cutting.

Following the guide line, SportTrucks by Dean owner Dean Sears used a plasma cutter to make the C-notch incision in the frame. Once the cut was complete, the raw area was smoothed out with a grinder and hit with a few squirts of black Krylon paint to prevent rust. The same process was repeated on the opposite side of the frame.

With the C-section plate mounted on the outside of the framerail and held in place with C-clamps, it was time to start drilling holes to insert the supplied hardware. The holes were first marked using a tap and a light rap of the hammer then drilled with a small drill bit to create a pilot hole. After a pilot hole was created, the big-dog Uni Bit was busted out and used to sink the required hardware hole size into the framerail.

On the inside of the framerail, where the most forward part of the C-section bolts to the frame, the truck's 'rails have a double wall, preventing access to the backside or inside of the frame to allow us to tighten the C-section hardware on the backside. To eliminate this problem, we determined how much material would have to be removed and got out the plasma cutter and removed enough metal to gain access to the backside of the bolts.

While a second pair of hands held the hardware on the back side of the C-section with an open-end wrench, the hardware was tightened on the outside with an impact gun and the appropriate socket.

The rear tailpipe section of the exhaust, just behind the muffler, had to be whacked off for clearance of the new 'bag setup and bracketry. A Sawzall was used for this step. We also removed the rear shocks at this time. While the plasma cutter was out, we whacked off the original rear lower shock mounts and ground down the jagged edges and hit them with paint.

Now that the C-section was cut in the frame and the plate was mounted, it was time to start mounting up the airbag brackets and four-link bars. To proceed with adapting these components, the factory leaf spring pack was loosened at the front and rear hangers, and the factory leaf spring baseplate and U-bolts were removed from around the axle. With the rear end supported by jackstands, Brandon McCaw and Kris Ahlman removed the factory leaf spring pack and set it aside.

The top 'bag bracket bar was hoisted up in between the framerails and fitted up to the inside lip of the C-notch plates before being secured with the supplied hardware. The hardware was slipped through the holes and secured loosely to hold the 'bag bracket bar in place, while Brandon and Kris grabbed the right tools.

Before cranking down the hardware for the upper 'bag bracket bar, the new rear axle bumpstops were installed inside the C-notch and secured with the supplied hardware.

Using an impact and socket, the hardware securing the top 'bag bracket bar to the inside upper lip of the C-notch was secured, while another pair of hands held the nut on the back side with an open-end wrench.

Taking a break from mounting airbag brackets, the top four-link bar front mounting bracket was fitted to the frame and bolted into place. A few of the holes needed to be drilled out and filled with hardware.

Before we could even think about mounting the rear airbags, the rear frame crossmember behind the top 'bag bracket bar had to be cut for clearance of the 'bags once they were installed. After test-fitting the 'bag to the bottom of the top spring cups, the amount of trimming that needed to be performed was determined and a half-circle incision was made with a plasma cutter. After the material was removed, the rough finish was ground smooth and painted.

To keep the rearend from shifting, Air Ride Technologies includes a Panhard bar and bracket with the kit. The Panhard bar mounting bracket is designed to fit over the top of the differential cover. SporTrucks By Dean shop manager Sean Baisden secured the Panhard bar bracket to the rear differential cover.

Next, the bottom airbag bracket bar assembly was hoisted up under the axle where the new rear four-link top bar mount plate bolts were dangling after being slipped through the new upper axle plate. Sean hoisted the Air Ride Technologies bottom 'bag bracket bar into position and loosely secured the hardware to temporarily hold it into position.