Automotive Manual PDF

The ROADMASTER is a load absorber and will assist with the load carrying ability as stated by the manufacturer with enhanced stability, provided the fitting instructions are followed correctly. The Roadmaster Active Suspension kit must never be fitted while the vehicle is standing with the rear wheels on the ground. In this position the rear leaf springs will be under load and the Roadmaster coil tension spring settings cannot be achieved, resutting in the Roadmaster not working correctly.
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This Kit must be installed with THE EDGE 4.5” HANGER KIT (part no.3-4000) or THE EDGE 6” FRONT SPRING KIT (part no.3-6000) or THE EDGE 8” FRONT SPRING KIT (part no.3-8000).
- Front Driveshaft for 8” Front Spring kit must be modified.
INSTRUCTIONS:
1. Jack up the front end of the truck and support the frame at the front frame rails with jack stands. NEVER WORK UNDER AN UNSUPPORTED VEHICLE. Remove front tires.
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1. With the truck on the ground, remove the track bar bolt at the differential Lift truck up, and make sure it is safe by using jack stands or a 2-post lift that locks in place.
1. Support the front axle with a support jack equipped with the proper fixture.
2. Undo the sway bar links.
3. Undo the four U-bolts on the passenger side leaf springs ONLY. Make sure the differential is supported as it may fall at this point.
4. If the truck has hydraulic shocks, just slide them up and out of the way. If the truck has gas shocks, it will be easier to remove them.
5. On the drivers side, LOOSEN but DO NOT REMOVE the U-bolts on the drivers side leaf springs. This will enable the passenger side to sag enough to get the Lift and Level kit into place.
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LIFT INSTRUCTIONS:
1. Disconnect the negative terminal on the battery. Jack up the front end of the truck and support the frame, at the front frame rails, with jack stands. NEVER WORK UNDER AN UNSUPPORTED VEHICLE. Remove the front tires.
2. Remove the brake calipers and tie them up out of the way. DO NOT ALLOW THE CALIPERS TO HANG FROM THE BRAKE LINES! Remove the A.B.S. lines from the plastic clips that are connecting them to the rubber brake hoses. Remove the brake line bracket from the frame and save the hardware. Remove the plastic clips that hold the hard brake lines from the top of the frame and then the brake lines from the clips. Carefully bend the hard line forward approximately seventeen to eighteen inches.
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Before installing this kit, read and understand all procedures, warnings, cautions, and notes in this instruction sheet. Also, read the appropriate sections of the factory service manual and the vehicle owner’s manual. If any of the information in these documents is unclear, DO NOT install this kit.

NOTE
Kit parts are prefaced by the word kit and appear in bold print.
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1. Place the coach on a level concrete surface. Jack the coach up so that the rear tires are just off the ground. Make sure to put jack stands on each side of the frame for safety.
2. Remove the rear shackle hanger bolt that fastens the leaf spring hanger to the shackle. Keep this bolt and nut as it will be reused. If the coach has storage compartments that are close to shackle assembly, it may be required to use a hole saw and cut a hole in the compartment to get the bolt out. If this is required, just cut a piece of tin and pop rivets to cover the hole. Use some silicone to seal the hole to prevent leaks.
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This kit is packaged as a leveling kit—raising the front 4”and the back 2”or raising the front 6”and the back 4”. If you desire a different look or if your truck has a tool box or something else that is going to bring the rear end down, please consult with your sales repetitive about option higher block and u-bolt options or the use of an add-a-leaf.
The 4”suspension system was developed for 35×12.50×17 tire on an after market wheel with 4.5”of back spacing.
The 6”suspension system was developed for 37×13.50×17 tire on an after market wheel with 4.5”of back spacing.
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Complete the following instructions one side at a time. Do not attempt to drop the entire axle at one time.
1. Raise rear of vehicle and support with jack stands under frame. Remove wheels.
2. With axle firmly supported by jack stands remove the OEM shock. Place a hydraulic jack under the rear differential.
3. Loosen the OEM u-bolts that retain the spring to the axle. Caution: To avoid axle shift, only remove/replace the u-bolts from one side at a time.
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INSTALLATION INSTRUCTIONS
1. Park and secure the vehicle on a level hard surface. Block the rear tires to avoid accidental movement.
2. Remove the track rod bolt on the driver side at the frame mount. This is a solid bar that runs from the axle on the passenger side (PS) to the frame on the driver side (DS).
3. Raise the front of the vehicle so the axle is hanging freely and the tires are just off the ground. Support the vehicle with jack stands under the frame rail about 3” behind the front spring.
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Installation Instructions Front
1. Raise vehicle and place jack stands under frame approximately 3” behind front spring shackles. Remove front wheels and shocks.
2. Remove one rivet from the outside of the frame at the engine cross member closest to the OE hose to steel line connection. Attach the 90 degree brake line extension brackets using the 3/8” x ” bolts, nuts, and lock washers.
3. Disconnect front brake line at frame and reroute through extension brackets and secure. CAUTION: Careful attention must be exercised in rerouting. Do not kink, pinch or stretch lines! When both sides have been completed, bleed the brakes. Refill the master cylinder with Dot ap- proved fluid.
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