DIY Network

'85 El Camino: Air Shocks, Adjustable Suspension and Sway Bar An Air-Controlled Suspension System for the "Original Hybrid" Vehicle From "Weekend Mechanic" episode WKM-402

New air springs and control arms, installed

In this project, Weekend Mechanic host Bruce Bonebrake installs an air-controlled suspension system on a classic 1985 Chevy El Camino. The system provides a more comfortable ride as well as better handling, and is popular with street rodders and collector car enthusiasts due to the lowered stance the air-controlled system provides.

For this project, BJ Ellmore and Darren Schilling, technicians from Air Ride Technologies, join Bruce for the installation, which includes installing dual air compressors and dual air tanks to provide the adjustable suspension.

The front suspension is further modified with new tubular upper and lower control arms, and a rear stabilizer bar is added to the rear of the vehicle to help with cornering.

The basic steps in these modifications are listed below.

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The components for the new gas-filled shock system

Materials:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), some of the specialty tools and materials that will be needed for this project include:

gas-filled shock absorbers
dual air compressors
dual air tanks
stabilizer-bar kit
impact wrench
die-grinder
coil-spring compressor
drill
safety gear
fire extinguisher

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools. Also wear eye protection any time that you are working beneath a vehicle.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

Bruce reinstalls the brake calipers and control arms.

Replacing the Shock-Absorber System

In preparation for installing the air-suspension upgrade, Bruce and technician B.J. Elmore and remove the stock spring and shock system on the1985 El Camino. Bruce and B.J. then modify the stock spring housing, install the air shock system, install tubular upper and lower control arms and complete the front air suspension system. Here are the basic steps:

• Begin by loosening and removing the lower shock-absorber bolts. With the cotter pin removed, the castle nut comes off.

• Insert the tie-rod separator into the joint of the tie rod end and spindle arm. A few taps on the tool should free the tie rod.

• Remove the upper shock absorber nut and bushing, and the old shock comes out.

• Next, loosen and remove the brake caliper bolts. For better access to the control arms, also remove the brake caliper from the brake assembly. Once the brake caliper is free, it's a good idea to remove the brake pads so they don't fall off.

• To remove the coil spring, insert a coil spring compressor into the spring and seat the upper arms onto the upper coils.

• Insert a wedge over the lower control arm and into the lower coils to hold the spring secure. Use an impact wrench to turn the bottom nut--which rotates the center screw--"walking" it up through the spring and compressing the coils.

• With the compressor holding the spring, place a floor jack under the lower control arm so to break the lower ball joint loose.

• After the cotter pin and castle nut of the lower ball joint are removed, the tie-rod separator helps loosen the joint.
  
  
• Separate the lower control arm and steering knuckle are separated. Do the same on the upper ball joint, and the spindle and brake assembly are free.

• Remove the lower control arm mounting bolts and the lower control arm comes off.

• Loosen the upper control arm camber bolts and remove the alignment shims. Save these for the new upper control arm installation.

• Continue loosening and removing the upper control arm mounting bolts. With a little persuasion, the upper control arm should come out.
  

  	Figure A
  	Figure B

• Holding the top of the bolt secure, an impact wrench will make quick work of loosening the stabilizer bar--or "sway bar"--link.

• Use a die-grinder to cut out sections of the front coil spring pocket so the air spring bellows fit without any interference (figure A).

  Safety Alert: Be sure to wear safety glasses and ear protection when die-grinding.

• If necessary, mark and trim any additional metal that impedes clearance of the air-spring bellows (figure B).

• Install the fasteners on the new "strong arm" lower control arm.

• The freshly cut air hose goes into the air spring fitting. Press it all the way in, then pull it back to lock it in place.
  

  	Air springs and control arms, installed

• The air-spring assembly is installed into the trimmed pocket, with the mounting stud going up through the factory shock hole.

• The bushing, washer, and nut go onto the air-spring mounting stud and the nut is tightened down--for now, just hand-tight.

• Pull the new lower control arm up, seat it under the air-spring and install the mounting bolts, washers and nuts.

• Next, the new upper control arm is installed and secured with the mounting bolts and nuts.

• The spindle goes back on, seating the steering knuckle onto the lower ball joint stud and the castle nut is installed.

• The spindle goes back onto the lower ball joint.

• Connect the upper control arm ball joint.

• Re-attach the tie-rod end and install the sway bar link.

• Next, the upper control arm ball joint is installed into the spindle and the washer and castle nut are installed.

• Reinstall the tie rod end onto the spindle and secure with it's castle nut.

• The sway bar end link is fitted with washers, bushings and a spacer as it's installed through the lower control arm up through the sway bar end.

• Reassemble the brake caliper with the shoes and re-install onto the brake.

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