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some tricks to install the kit in your 240 200

Dave,

yes, the 60783 kit should and will work on your '92.

First, the total rear suspension travel....max extension...is limited by the shock absorbers. In other words, if you go airborne over a hill crest, it is the shocks extending to their max length that only lets the rear axle drop down about 4 inches or so.

It's been a while since I installed a 60783 kit, so a lot of this is coming from memory:

[but if combined with the installation directions from Airlift, this should help you get the kit in.]

....to install the airlifts, you will have to remove the rear springs. And to remove the rear springs, you have to have the vehicle jacked up and supported on the jacking points. And you will want several inches more height than if you were just changing a flat tire.

....once jacked up and supported on the jack stands, remove both rear wheels.

....using the floor jack under the differential, lift the rear axle a couple of inches....to take the load off the shocks. Be careful to not lift TOO high: you do not want to start lifting the vehicle off the jack stands.

....with the shocks disconnected, you can lower the rear axle down far enough so as to take all the load off the rear springs....because the rear springs have to come out.

....at this time, you are probably going to start cussing a bit because the rear axle is being held up by the underaxle pipe of the exhaust system.

[it works better to have dropped the exhaust system down and out before you start unbolting the rear shocks.]

....with the rear axle dropped down far enough to take the tension off the rear springs, it is time to remove the rear springs. i.e., you get to unbolt the retainer under each spring that fastens each spring to the trailing arms.

....with the retainers unbolted, you can slide the bottoms of the springs off the trailing arms. The springs do not have anything attaching them to their upper perches....just the weight of the vehicle.

....you will need to unbolt each of the upper spring perches....each has one bolt holding it to the subframe.

....take a look at those spring perches: the top side is flat, with a single hole in the middle for the bolt. The upper part of the perch [that which is above the rubber ring that the spring sits in] is like a top hat that has six sides. Pick one of the hex flat panels, and drill a 1/2in hole on it. [do that to both of the perches.] Those holes are for the fill hoses that go to the airbags.

....after you drill the hole in each perch, you can reinstall each perch. Clock the holes towards the rear inside of the subframes....kind of a 45 degree angle towards the rear of the vehicle.

[by angling the holes inward and rearward, it makes the routing of the air hoses easier to route them away from other things so that the hoses do not get squished or damaged. You'll see what I mean when you do it.]

....follow Airlift's instructions on installing the bags into each of the coil springs....with the fill nipples UP towards the top of the springs.

....feed the air hose through the drilled holes in the upper perch, giving yourself a foot or more of hose sticking down through the middle of the perch.

...the large spacers that are in the kit go on the top of the airbags, so feed the air hose through its spacer.

...then, you attach the hose to the nipple on the airbag. Do not forget to use the small hose clamp. [BTDT, and it was not fun having to take things apart to reattach the hose to the airbag.]

....at this point, it is about time to slide the spring back up into its rubber mounting ring on the bottom side of the perch....WITH the plastic spacer on top of the airbag.

[that spacer is what transmits the airbags lifting capability to the perch/subframe. If you do not have the spacer in there, the airbag will be cut into by the lip of the perch's lower cone. You'll see what I mean as you do this.]

...once the spring is seated back into it's rubber ring on the perch, you can slide the bottom of the spring back onto the trailing arm. and reattach the spring to the trailing arm.

....when the springs are back in place, you can jack up the rear axle so that you can reattach the shocks.

note: the kits come with the provision to go with a single fill valve....for both airbags....OR with individual fill valves for each side. I always went with individual fill valves. That way eliminates side to side sway....going around a curve, the outboard airbag gets compressed more, so the air from it goes to the inboard airbag, causing it to expand, making the leaning of the vehicle worse. Individual fill valves prevent that from occurring.

I hope this helps you out. It's the part about how to run the air hose through the upper perch that was the fun part for me to figure out way back when.

I may not be remembering everything that you need to do; but I think I covered the essentials....[I hope]

good luck.

TF






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