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2004 Chevy Silverado Rear Air Suspension Installation - Makin' It Lay Part 1

How To Lay Your '99-And-Later Silverado Down On 22s
From the October, 2005 issue of Sport Truck
By Kevin Whipps
Photography by Kevin Whipps
 
2004 Chevy Silverado Lowered On 22 Inch Wheels 2004 Chevy Silverado
2004 Chevy Silverado Lowered On 22 Inch Wheels Exhaust Y Pipe
1.Exhaust Before we could... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Exhaust Y Pipe
1.Exhaust
Before we could get the truck on the ground, we had to move some of the obstructions out of the way. First on the list was the exhaust Y pipe. As you can see, it hangs down really far on our truck.
2004 Chevy Silverado Lowered On 22 Inch Wheels Catalytic Converter
2.Luke from Mighty Muffler,... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Catalytic Converter
2.Luke from Mighty Muffler, in Phoenix, started by cutting the stock catalytic converter and crossover pipe off of the truck, resulting in two separate pieces.
2004 Chevy Silverado Lowered On 22 Inch Wheels Welding
3.Then, he twisted the catalytic... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Welding
3.Then, he twisted the catalytic converter over for more clearance and welded it back in place.
2004 Chevy Silverado Lowered On 22 Inch Wheels Crossover Pipe
4.The crossover pipe was twisted,... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Crossover Pipe
4.The crossover pipe was twisted, too, which lifted it above the frame in the process.
2004 Chevy Silverado Lowered On 22 Inch Wheels Frame
5.Just like that, the exhaust... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Frame
5.Just like that, the exhaust was now tucked under the frame.
2004 Chevy Silverado Lowered On 22 Inch Wheels Exhaust
6.One last thing, we had Luke... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Exhaust
6.One last thing, we had Luke add a turn-down to our exhaust, so it would exit in front of the axle.
2004 Chevy Silverado Lowered On 22 Inch Wheels Transmission
7.Transmission X-MemberTo... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Transmission
7.Transmission
X-MemberTo start, the transmission was supported by a jack and a piece of wood so as not to dent the tranny pan.
2004 Chevy Silverado Lowered On 22 Inch Wheels Bolts
8.Using a 21mm socket and... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Bolts
8.Using a 21mm socket and wrench, we were able to remove the four bolts that secured the crossmember to the frame.
2004 Chevy Silverado Lowered On 22 Inch Wheels Bolt
9.There was also one bolt... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Bolt
9.There was also one bolt that we had to remove, hidden way up inside of the crossmember.
2004 Chevy Silverado Lowered On 22 Inch Wheels Wiring Harness
10.There were a few wiring... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Wiring Harness
10.There were a few wiring harnesses attached to the crossmember with clips, so we removed them temporarily.
2004 Chevy Silverado Lowered On 22 Inch Wheels Crossmember
11.Once all the bolts were... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Crossmember
11.Once all the bolts were out, we removed the crossmember.
2004 Chevy Silverado Lowered On 22 Inch Wheels Crossmembers
12.It's pretty easy to see... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Crossmembers
12.It's pretty easy to see the huge difference between the two crossmembers. The KP Components part also comes with additional parts for reinforcement.
2004 Chevy Silverado Lowered On 22 Inch Wheels Kp Crossmember
13.Bolting in the new KP crossmember... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Kp Crossmember
13.Bolting in the new KP crossmember was simply the reverse of the tear-down and just as easy.
2004 Chevy Silverado Lowered On 22 Inch Wheels Reinforcement Plate
14.We finished the install... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Reinforcement Plate
14.We finished the install by cutting off the remaining brackets that were level with the frame and welding in the provided reinforcement plates.
2004 Chevy Silverado Lowered On 22 Inch Wheels Marked Crossmember
15.Gas Tank X-Member The tanks... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Marked Crossmember
15.Gas Tank
X-Member The tanks on these trucks lay incredibly low, and besides that, they're plastic. Also, with the axle being so high, the driveshaft tends to hit the crossmember unless it's raised. We decided to raise the tank 1 inch, which keeps it under the floor but also above the frame. We started by marking the crossmember for reference.
2004 Chevy Silverado Lowered On 22 Inch Wheels Crossmembers Aligned
16. Using some scrap steel... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Crossmembers Aligned
16. Using some scrap steel to keep the crossmembers aligned, we cut out the two pieces to lift them.
2004 Chevy Silverado Lowered On 22 Inch Wheels Weld
Once it was lifted, we welded... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Weld
Once it was lifted, we welded it back into place.
2004 Chevy Silverado Lowered On 22 Inch Wheels Cab
17.Later on, when we were... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Cab
17.Later on, when we were putting the gas tank back in, we notched the cab for clearance.
2004 Chevy Silverado Lowered On 22 Inch Wheels Engine
18.Engine Bay The wheels won't... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Engine
18.Engine Bay
The wheels won't be able to tuck into the fender wells with all that stuff in the way, so we're going to have to make some adjustments.
2004 Chevy Silverado Lowered On 22 Inch Wheels Walls
19.After pulling everything... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Walls
19.After pulling everything off, we used an air saw to cut out the wells.
2004 Chevy Silverado Lowered On 22 Inch Wheels Computer Mounts
20.With the wheels removed,... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Computer Mounts
20.With the wheels removed, we now had to deal with the battery and the computer. The computer mounts were moved forward to accommodate the wiring.
2004 Chevy Silverado Lowered On 22 Inch Wheels Battery Tray
21.The battery tray fit just... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Battery Tray
21.The battery tray fit just right when we opened up the mounting holes, removed the windshield washer fluid, and pushed it forward a little bit.
2004 Chevy Silverado Lowered On 22 Inch Wheels Fuse Box
22.We made a mount for the... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Fuse Box
22.We made a mount for the fuse box that uses the stock bolts. It wasn't very difficult to do and keeps it out of the way of the tires.
2004 Chevy Silverado Lowered On 22 Inch Wheels Coolant Overflow Tank
23.The coolant overflow tank... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Coolant Overflow Tank
23.The coolant overflow tank was mounted using the same hardware that held it on before. We just cut them out of the fenderwell and welded them into a location farther forward on the fender.
2004 Chevy Silverado Lowered On 22 Inch Wheels Intake
24.The intake had a custom... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Intake
24.The intake had a custom bracket built to hold the filter in place near the core support.
2004 Chevy Silverado Lowered On 22 Inch Wheels Hood Hinges
25.One last thing to note:... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Hood Hinges
25.One last thing to note: We had to remove the hood hinges because they were hitting the tires.
2004 Chevy Silverado Lowered On 22 Inch Wheels Rear Leaf Springs
26.KP Components Install With... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Rear Leaf Springs
26.KP Components Install
With the bed off and the truck on jackstands, we started by taking off the rear leaf springs.
2004 Chevy Silverado Lowered On 22 Inch Wheels Grinder
27.Taking off the stock shackles... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Grinder
27.Taking off the stock shackles is a ton of fun. We used a 4-inch Grinder to melt the heads off of the factory rivets, and then used an air chisel to knock the rivets through. In the areas that are more difficult to reach, we used a die grinder to cut an X through the head. Then, we used an air chisel to knock off the rivet.
2004 Chevy Silverado Lowered On 22 Inch Wheels Kp Mounts
28.The KP mounts bolt on where... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Kp Mounts
28.The KP mounts bolt on where the factory shackles used to reside and couldn't be easier to install.
2004 Chevy Silverado Lowered On 22 Inch Wheels Axle Mounts
29.The axle mounts provided... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Axle Mounts
29.The axle mounts provided with the kit bolt on just like the leaf springs. The passenger-side assembly (pictured) also has the brackets for the Panhard bar integrated into it.
2004 Chevy Silverado Lowered On 22 Inch Wheels Rear Mounts
30.The rear mounts bolt on... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Rear Mounts
30.The rear mounts bolt on the same way the front ones do, but we had to drill four additional holes in the frame.
2004 Chevy Silverado Lowered On 22 Inch Wheels Link Bars
31.Assembling the link bars... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Link Bars
31.Assembling the link bars was pretty simple. We made sure that all of the bars were the same length. Otherwise, we would have had alignment issues later on.
2004 Chevy Silverado Lowered On 22 Inch Wheels Forward Link Bars
32.The forward link bars were... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Forward Link Bars
32.The forward link bars were then bolted onto both the frame and the axle.
2004 Chevy Silverado Lowered On 22 Inch Wheels Rear Bars
33.The rear bars were bolted... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Rear Bars
33.The rear bars were bolted up the same way. For now, we're leaving the 'bags out of the system, since we still have some welding to do. And, we also have to install the front suspension and air delivery system. We'll tackle that next month, so stay tuned.
2004 Chevy Silverado Lowered On 22 Inch Wheels Bridge Notch Kit
34.You don't have to do a... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Bridge Notch Kit
34.You don't have to do a huge notch in this style truck to make it lay frame. What we did was use the KP Components four-piece bridge-notch kit and some 1-inch tubing to space it up off the frame.
2004 Chevy Silverado Lowered On 22 Inch Wheels Notch
35.The notch was then welded... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Notch
35.The notch was then welded into place on all sides.
2004 Chevy Silverado Lowered On 22 Inch Wheels Panhard Bar
36.To mount the Panhard bar,... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Panhard Bar
36.To mount the Panhard bar, we had to bolt in this mount to the frame. You can weld this plate in, if you so desire.
2004 Chevy Silverado Lowered On 22 Inch Wheels Rear Airbags
37.Time to mount the rear... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Rear Airbags
37.Time to mount the rear 'bags. The kit came with studs to mount the 'bags to the link bars, so we installed them into the bottom of the Slam Specialties airbags.
2004 Chevy Silverado Lowered On 22 Inch Wheels Mount And Airbag
38.Next, we bolted the top... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Mount And Airbag
38.Next, we bolted the top of the 'bag onto the mounts.
2004 Chevy Silverado Lowered On 22 Inch Wheels Shocks
39.The shocks completed the... 
   
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2004 Chevy Silverado Lowered On 22 Inch Wheels Shocks
39.The shocks completed the kit, and they held on with the provided Grade 8 bolts.
Slam Specialties
Fresno
CA
KP Components
Bonspeed
Anaheim
CA

www.bonspeed.com
Viair Corp
26072 Merit Cir., Ste. 111
Laguna Hills
CA   92653

Dept. MT
Gravity-Werx
3787 Opelika Rd.
Phoenix City
AL  36870
Optima Batteries
5757 N. Green Bay Ave.
Milwaukee
WI  53201
414-524-1200

www.optimabatteries
Nitto Tires
6261 Katella Ave., Dept. MMFF
Suite 2C
Cypress
CA  90630

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