Ashwin Lewis
Changing the air bags on a W 900 sleeper can be a challenging task. While some people opt to perform this maintenance themselves, others seek professional assistance. Various factors, such as the make, model, and year of the truck, as well as the specific airbag configuration, can influence the complexity of the process. Some W900 models, like the Aerocab, have airbags located at the rear of the sleeper, while others may have different setups. In addition, certain trucks might require extensive modifications, such as building a subframe or acquiring factory brackets, to accommodate the new airbags. Understanding these variations is crucial before embarking on the replacement process.
| Characteristics | Values |
|---|---|
| Vehicle Type | Kenworth W900 Sleeper |
| Year | 1999 |
| Problem | Leaky airbag |
| Solution | Replace airbag |
| Difficulty | Simple repair |
| Time | A few hours |
| Process | Remove plastic tops holding the airbag in place, replace the leaky airbag, and twist the new airbag into place |
| Conversion Option 1 | Build a steel sub-frame, mount the cab and sleeper to it, hinge the front, and add airbags to the rear |
| Conversion Option 2 | Remove interior, buy factory brackets and bracing, and bolt the cab and sleeper together |
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What You'll Learn
Identify the type of sleeper cab
The Kenworth W900 is a long-nosed conventional truck with a bumper-to-back-of-cab length of 130 inches. It has a variety of sleeper cab options, including the Kenworth Aerocab, which comes in 62-inch and 72-inch sizes, and the Studio Sleeper.
The Aerocab is a popular choice for W900 owners, offering a spacious and comfortable interior. It is available in different sizes, including the 72-inch and 86-inch versions, with the latter being the newer model. The Aerocab features a combination cab/kick panel and scuff panel cab skirt with courtesy lights. The 86-inch version also has fuel door clearance and 10 2-inch round light holes.
The Studio Sleeper is another option for the W900, offering a more luxurious experience with its hand-stitched upholstery and customized brightwork. This sleeper cab provides ample headroom, space, and light, along with a range of comfort features. These features include a full-length door-enclosed hanging closet, a cabinet with two shelves, a fold-down desk, and over-bunk side storage compartments.
To identify the type of sleeper cab you have, you can start by measuring the length of the sleeper. This will give you an initial indication of whether it is a 62-inch, 72-inch, or 86-inch sleeper. Additionally, examining the features and amenities present in your sleeper cab can help identify the specific model. For example, the presence of a full-length door-enclosed hanging closet and over-bunk side storage compartments would indicate the Studio Sleeper model.
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Assess the complexity of the task
The complexity of the task of changing the air bags on a W 900 sleeper depends on a few factors, including the make and model of the truck, the location of the air bags, and the reason for the replacement.
For example, if the air bags are located under the cab, as in the case of a non-aerocab W900, the task may involve converting the truck to an aerocab type sleeper, which can be complex and costly. This conversion can be done by building a sub-frame out of steel and mounting the cab and sleeper to it, or by removing the interior and installing factory brackets and bracing to bolt the cab and sleeper together.
On the other hand, if the air bags are located at the rear of the sleeper, as in the case of an aerocab W900, replacing them may be a more straightforward task. One source describes it as a "MINORandsimple repair", although it is noted that it can still involve several hours of work and some level of difficulty in accessing the bolts that hold the air bags in place.
Additionally, the reason for the replacement can also affect the complexity of the task. For example, if the air bags are leaky, it may be a simple matter of replacing the faulty air bag, but if there is an issue with the air pressure or the air bags are not airing up, the cause may be more difficult to diagnose and the solution may be more complex.
Overall, while some aspects of changing the air bags on a W 900 sleeper may be relatively simple, the task can also involve complex procedures and significant time and effort, depending on the specific circumstances. It is always recommended to consult a professional mechanic or a trusted source of information for guidance on such tasks.
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Prepare the necessary tools and parts
To prepare for changing the air bags on a W 900 sleeper, you will need to gather the necessary tools and parts. This process can be done at home with some basic tools and the right replacement parts.
First, you will need to purchase the replacement air bags. Ensure that you buy air bags that are compatible with your specific W 900 sleeper model. Check the owner's manual or consult a mechanic if you are unsure about the compatibility.
Next, gather the tools you will need for the job. This may include standard tools such as a set of wrenches, screwdrivers, and a socket set. You may also need more specialized tools depending on the specific design of your W 900 sleeper. For example, some models may require a torque wrench to ensure the proper tightening of bolts. It is important to have the correct tools to hand to ensure the job is done efficiently and safely.
In addition, it is recommended to have some form of support to stabilize the vehicle and ensure your safety while working. This could include jack stands or a vehicle lift, depending on what you have access to and your level of mechanical expertise. Always prioritize your safety when working with heavy vehicles.
Finally, it is a good idea to have some form of lubrication, such as grease, to help with the installation process. This will aid in the assembly and disassembly of certain parts and ensure a smoother process overall.
By gathering these necessary tools and parts, you will be well-prepared to change the air bags on your W 900 sleeper. Remember to consult repair manuals or seek advice from experienced mechanics if you encounter any issues during the process.
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Remove the old air bags
To remove the old air bags from your W900 sleeper, you'll need to begin by identifying the type of sleeper cab you have. For example, you may have a 62 or 72 Aerocab sleeper. This is important as it will determine the exact process for removing and replacing the air bags.
Next, assess the condition of the air bags. If they are weather-cracked or leaky, as is common with age, you'll want to replace them. Start by dealing with the leaky bag first, as this will ensure you always have one functional bag during the process.
The air bags are held in place by plastic tops that twist in on the top. To remove the old air bags, you'll need to carefully twist and remove these plastic tops. This will allow you to access the air bags themselves. Once the plastic tops are removed, you can then safely take out the old air bags. Be cautious and gentle during this process, as the air bags may be delicate or damaged.
For a more permanent solution, you may consider converting your W900 non-aerocab sleeper to air bags. This can be done in a couple of ways. One method involves building a steel sub-frame and mounting the cab and sleeper to it, then hinging it at the front with air bags on the rear. Alternatively, you can remove the interior and purchase factory brackets and bracing to bolt the cab and sleeper together. These options may be more extensive projects, but they offer a more integrated airbag system.
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Install the new air bags
To install the new air bags, begin by examining the plastic tops that hold the air bags in place. These plastic tops twist into the top of the air bags. Once you have familiarised yourself with this mechanism, start with the leaky bag and then move on to replacing the other one. This way, you will always have one functional bag in case of emergencies.
The next step is to build a sub-frame out of steel and mount the cab and sleeper onto it. You can then hinge the structure at the front and add the new air bags to the rear. Ensure that you follow the factory bracing instructions carefully, as this can be extensive.
Alternatively, you can take out the interior of the cab and sleeper and purchase factory brackets and bracing to bolt the structures together. This option may be more feasible if you are not experienced in mechanical work, as it does not involve the same level of customisation as the previous method.
When installing the new air bags, pay close attention to the placement of the hing and the pivot point, as this will impact the cab travel. Test the new air bags on a smooth surface to ensure they are functioning correctly and providing adequate suspension.
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