How to Install a Boss Air Suspension Load Assist Kit (Step-by-Step)
G'day, mates! Whether you're hitting the bush with your trusty ute loaded with gear or towing a caravan down the highway, there's one thing you don't want—your vehicle sagging under the weight. That's where Boss Air Suspension Load Assist Kits come into play. They’re a game-changer in balancing your vehicle and enhancing its handling no matter what you're towing or hauling. In this post, we'll break down how to install one of these kits like a true-blue Aussie mechanic would do.
Before we get stuck into it, have a look at our range of Load Assist Kits here.
Preparation: What You Need
First things first, gather your tools and gear. You don't want to stop halfway through because you've forgotten something.
Tools Required
- Socket set
- Screwdriver - Phillips
- Torque wrench (ideally)
- Safety glasses
- Tube Cutter (Provided in the kit)
Parts Included in the Kit
For this guide, we'll focus on the Load Assist Kit for Ford Ranger 22+/ VW Amarok 23+ (Next Gens). Be sure to check you have all parts including airbags, mounting brackets, airlines, and other necessary bits.
Planning Your Workspace
Ensure you've got a flat, stable surface to work on. Jack up the vehicle safely using jack stands, and remove the wheels for better access.
Installation Steps
Step 1: Read the Instructions
I know, I know, skipping the manual is tempting. But take a minute to read the instructions provided with your Boss kit to familiarize yourself with the components and sequence. It's always good to have the manufacturer's specifics on hand.
Step 2: Prepare the Airbags
Start by unpacking the airbags and visually inspecting them for any defects. With the Load Assist Kit for Ford Ranger, you'll find these bags are tough and designed to last.
Step 3: Mount the Upper & Lower Brackets
Begin with mounting the upper brackets to the airbags. Leave the bottom bolts a bit loose so you can rotate the bracket to line it up.
Leave about a 2mm gap between the alloy ring and the bracket. No need to use any sealant as the bag will seal against the plate perfectly.
Step 4: Install the assembly to your vehicle
Remove the bump stop.
Attach the top bracket to the chassis rail. In some kits, the bracket screws in to where the bump stop was, others wrap around or clamp to the chassis rail.
Next, attach the lower brackets to the axle. Make sure everything lines up nicely, and you're getting a snug fit. This ensures that the airbag sits properly and performs optimally.
You may need to jack up the axle to close the gap to fit the airbags. Don't worry if the bag gets stretched. They stretch to twice their length and they will never pull apart. Trust us, we've tested them.
Tighten the bolts that hold the bracket to the airbag once the bottom bracket is aligned and secure.
Step 5: Run the Air Lines
It is very important to cut the air line cleanly with no barbs so as not to damage the o-rings in the fitting. It is so important to get this right, that we give you a free tube cutter.
Identify a suitable path for the air line, keeping it away from any heat sources like the exhaust. Use zip ties to secure the line along the frame. It's important to route the air line carefully to avoid kinks and potential leaks.
Mount the Schrader valves using the bracket supplied and the self tapping screws.
Step 6: Secure Everything
Double-check the torque settings of the bolts and ensure all parts are securely fastened.
Step 7: Test the System
With the Airbag Suspension for Toyota Hilux, you'll want to test the air assist system's integrity. Inflate the airbags to 60-80lbs and check for leaks by spraying soapy water along the air line and fittings. If you see bubbles, you’ve got a leak that needs immediate attention.
Once the system is checked, deflate the airbags. Keep around 5psi on the bags if you are empty. Otherwise inflate to what ever pressure you need to get the vehicle level. The pressure won't be that high. It is totally vehicle/load dependent so hard to give any guidelines but if you get up to 80psi or beyond, you should weigh your vehicle as you might be over you GVM.
Benefits of Upgrading Your Suspension
Having a Boss Air Suspension Load Assist Kit installed isn't just about handling more load. It's about improving your vehicle's overall stability, safety, and ride comfort. You can read more about the advantages by checking out our Airbag Suspension Kit for Ford Ranger – Towing Upgrade Guide.
Conclusion
And there you have it, your own Boss Air Suspension Load Assist Kit installed and ready to tackle whatever the Aussie roads throw at you. For any additional support, you can always head over to our main site for expert advice and quality products suited to your vehicle type.
So get out there, give your rig the backup it deserves, and enjoy the ride!
Stay safe and happy driving, mates.
