Air Lift 57397 LoadLifter 5000 Installation guide
Air Lift 57397: Enhance Your Vehicle's Load-Carrying Capacity and Improve Ride Quality
Air Lift 57397 is an innovative air spring kit designed to provide exceptional load-leveling support and enhanced ride quality for your Ford F-250/F-350 pickup truck. With its sturdy reinforced commercial-grade construction and convolute bellows, this kit can handle up to 5,000 lbs. of load, making it ideal for heavy-duty hauling or towing applications. Whether you're carrying a heavy payload, towing a trailer, or simply want a more comfortable ride, Air Lift 57397 has you covered.
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Kit 57397
Ford F-250/F-350
(Single and Dual Rear Wheel)
2-Wheel Drive
INSTALLATION GUIDE
For maximum effectiveness and safety, please read these instructions completely before proceeding with installation.
Failure to read these instructions can result in an incorrect installation.
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Notation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hardware and Tools Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installing the LoadLifter 5000 System . . . . . . . . . . . . . . . . . . 5
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Side Brace Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bellows and Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Attaching the Assemblies to the Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lower Bracket Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Final Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Installing the Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Installing the Heat Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Fixing Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Post-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Product Use, Maintenance and Servicing . . . . . . . . . . . . . . .14
Minimum and Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Tuning the Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Guidelines for Adding Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Warranty and Returns Policy . . . . . . . . . . . . . . . . . . . . . . . . .16
Replacement Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1
2
LoadLifter 5000
Introduction
The purpose of this publication is to assist with the installation, maintenance and troubleshooting of the LoadLifter 5000 air spring kit. LoadLifter 5000 utilizes sturdy, reinforced, commercial grade single or double, depending on the kit, convolute bellows. The bellows are manufactured like a tire with layers of rubber and cords that control growth. LoadLifter
5000 kits are recommended for most 3/4 and 1 ton pickups and SUVs with leaf springs and provide up to 5,000 lbs. of oad leveling support with air adjustability from 5-100 PSI. The kits are also used in motor home rear kits and some motor home fronts where leaf spring are used.
It is important to read and understand the entire installation guide before beginning installation or performing any maintenance, service or repair. The information here includes a hardware list, tool list, step-by-step installation information, maintenance guidelines and operating tips.
Air Lift Company reserves the right to make changes and improvements to its products and publications at any time. For the latest version of this manual, contact Air Lift Company at
(800) 248-0892 or visit our website at www.airliftcompany.com.
IMPORTANT SAFETY NOTICE
The installation of this kit does not alter the Gross Vehicle Weight Rating (GVWR) or payload of the vehicle. Check your vehicle’s owner’s manual and do not exceed the maximum load listed for your vehicle.
Gross Vehicle Weight Rating: The maximum allowable weight of the fully loaded vehicle
(including passengers and cargo). This number — along with other weight limits, as well as tire, rim size and inflation pressure data — is shown on the vehicle’s Safety Compliance
Certification Label.
Payload: The combined, maximum allowable weight of cargo and passengers that the truck is designed to carry. Payload is GVWR minus the Base Curb Weight.
NOTATION EXPLANATION
Hazard notations appear in various locations in this publication. Information which is highlighted by one of these notations must be observed to help minimize risk of personal injury or possible improper installation which may render the vehicle unsafe. Notes are used to help emphasize areas of procedural importance and provide helpful suggestions. The following definitions explain the use of these notations as they appear throughout this guide.
DANGER
WARNING
CAUTION
INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL
INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE
TO THE MACHINE OR MINOR PERSONAL INJURY.
NOTE
Indicates a procedure, practice or hint which is important to highlight.
MN-773
LoadLifter 5000
Installation Diagram
3/4” Flat Washer* or (R)
5th Wheel
Bracket (Plate)
Y or R
I
V
W
J
S
L
3/4” Bolt* or (O) or (HH)
F
P
M
NOTE: Single rear wheel mounting location shown.
Q**
P
V W
E
NOTE: Use hole that is closest to the leaf spring!
K
MN-773
W
V
W
V
Driver side shown
Z
B
V
W
N
U
W
T
S
3/4” Flat Washer* or (R)
3/4” Nyloc Nut* or (X)
C
P
H
G
fig. 1
P
Q**
NOTE: Single rear wheel mounting location shown.
A
W
V
W
D
U
N
* 3/4” hardware is supplied by the
5th wheel hitch manufacturer. Use the 1/2” hardware supplied with this kit if no hardware is supplied by the manufacturer.
** On some models with sway bars under the axle, it may be necessary to invert the long carriage bolt.
3
LoadLifter 5000
Hardware and Tools Lists
HARDWARE LIST
Item Part # Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qty
A 03991
B 07996
C 07997
Lower Bracket .....................................2
Upper Brace ........................................2
Upper Bracket .....................................2
D 01531
E 10861
G 11951
Clamp Bar ...........................................2
Spring Clamp Bar ................................2
F 13966 Spacer .................................................2
Roll Plate .............................................4
H 58437 Bellows ................................................2
I 10880
J 10886
K 17110
L 17135
M 17141
N 17203
O 17271
P 17361
Q 17387
Four Hole Locating Bracket ................4
“L” Bracket ..........................................1
3/8-16 x 5.5 Hex Head Cap Screw .....4
1/4”-20 x 1” Hex Cap Screw................1
3/8-16 x 2.5” Carriage Bolt ..................2
3/8-24 x 7/8” Hex Head Cap Screw ....8
1/2”-13 x 3” Hex Cap Screw................2
3/8-16 x 1.25” Carriage Bolt ................8
3/8-16 x 10” Carriage Bolt ...................4
Item Part # Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qty
R 18207 1/2” Thick Flat Washer ........................6
S 18419 Flat Washer #12 ..................................2
T 18425
U 18427
V 18435
W 18444
X 18460
Y 18556
Z 21837
AA 10466
BB 18411
CC 21230
DD 21233
EE 21234
FF 20086
GG 34924
HH 17208
1/4”-20 Nyloc Nut ................................1
3/8” Lock Washer ................................8
3/8”-16 Nyloc Nut ...............................18
3/8” Flat Washer ................................34
1/2-13” Nyloc Nut ................................2
3/4” Flat Washer .................................2
90 ˚ Swivel Air Fitting ..........................2
Zip Ties ...............................................6
5/16” Lock Washer ..............................2
Valve Caps ..........................................2
5/16” Hex Nut ......................................2
Rubber Washer ...................................2
Air Line Assembly ...............................1
Heat Shield Kit ....................................1
1/2-13 x 2” Hex Head Cap Screw .......2
TOOLS LIST
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Qty
7/16” and 9/16” Open-end or box wrenches .......................2
Crescent wrench.................................................................1
Ratchet with 3/8”, 9/16”, & 1/2” deep well sockets .....................1
5/16” drill bits (very sharp) ..................................................1
DIR grinder .........................................................................1
Hacksaw .............................................................................1
Heavy duty drill ...................................................................1
Torque wrench....................................................................1
Standard, metric and SAE sockets and wrenches .............1
Hose cutter, razor blade, or sharp knife .............................1
Hoist or floor jacks ..............................................................1
Safety stands ......................................................................1
Safety glasses ....................................................................1
Air compressor or compressed air source ..........................1
Spray bottle with dish soap/water solution .........................1
4
STOP!
Missing or damaged parts? Call Air Lift customer service at (800) 248-0892 for a replacement part.
MN-773
LoadLifter 5000
Installing the LoadLifter 5000 System
GETTING STARTED
1. Raise the vehicle and support the axle with jack stands, setting the jack stands as wide as possible on the axle (fig. 2).
NOTE
NOTE
MN-773
Jack Stands
fig. 2
2. Remove the jounce bumpers from under the frame, over the axle.
3. If necessary, disconnect the wiring harness from the driver side frame rail to gain clearance for the upper bracket.
4. For all dual rear wheel vehicles (DRW) it will be necessary to remove the sway bar strap and bolts holding the sway bar to the axle. Retain for later reinstallation.
5. If you have a fifth wheel hitch already installed, it will be necessary to remove the ¾” hardware that bolts the side bracket to the outside of the frame above the axle (fig. 1).
Some hitch models have a spacer between the bracket and the frame rail. Be sure to reinstall the spacer when attaching the upper bracket.
If your model truck has emission lines running along the inside of the frame rail (fig. 3), it will be necessary to relocate those lines as follows. Follow the directions in the section,
“Attaching the Assemblies to the Frame” for reattaching these lines.
l
Carefully push the line holder out of the frame above the axle. Try to minimize damage because it will be reused later. It may also be helpful to remove any holders forward or rearward of the axle to aid in positioning the lines once the upper bracket has been installed (fig. 3) .
l
Attach the L-bracket (J) to the back frame brace using the 1/4” bolt (L), flat washers
(S) and nyloc nut (T) supplied (fig. 1). This L-bracket will eventually be used to attach the previously removed emissions line. Do not attach the line holder to it at this time.
Emissions lines
Line holder
Electrical wiring loom
fig. 3
5
NOTE
LoadLifter 5000
SIDE BRACE INSTALLATION
3/4” Flat Washer* or (R)
5th Wheel
Bracket (Plate)
Y or R
V
W
J
S
L
3/4” Bolt* or (O) or (HH)
F
Driver side shown
Z
B
V
W
N
U
W
T
S
3/4” Flat Washer* or (R)
3/4” Nyloc Nut* or (X)
C
fig. 4
P
P
M
1. Set the upper brace (B) into the driver and passenger side frame (fig. 4).
If you have no fifth wheel hitch or a hitch that does not have a plate running alongside the full length of the frame (these will have an “L” bracket forward and behind the axle leaving the middle frame open) use the 1/2-13 x 2.00” Hex Cap Screw (HH) with a flat washer (R) through the slot in the side of the frame, then through another flat washer
(R) and finally through the upper brace. Cap with a flat washer (R) and a 1/2-13 nyloc nut (X) (fig. 5). Leave loose at this time.
OR
If you have an aftermarket fifth wheel hitch that has a bracket (plate) running along side of the frame and it used this slot to secure the bracket to the frame with existing hardware, install the existing hardware previously removed in the “getting started section” from the fifth wheel installation for securing the brace (fig. 4). Make sure to install the large 3/4” flat washer (Y) between the brace and frame (figs. 1 and 4). Do not tighten at this time.
OR
If you have an aftermarket fifth wheel hitch that has a bracket (plate) running along side of the frame and it does not have any attaching hardware on the side where the slot in the frame is, it will be necessary to drill a ½” hole through the plate using the slot in the frame as a template. Drill the hole as far back in the slot as you can.
It may be necessary to mark and remove the bracket (plate) from the side of the frame in order to drill the hole correctly. Re-attach once the hole is drilled.
Insert a ½”-13 x 3.00” hex cap screw (O) with a flat washer (R) through the fifth wheel plate previously drilled, the frame, then through another flat washer (R)and finally the upper frame brace. Cap with a flat washer (R) and a ½”-13 Nyloc nut (X) (fig. 4). Leave loose at this time.
6
MN-773
LoadLifter 5000
NOTE
NOTE
NOTE
BELLOWS AND BRACKET ASSEMBLY
1. Set a roll plate (G) over the top and bottom of the bellows (H) (fig. 1).
The radiused (rounded) edge of the roll plate (G) will be towards the bellows so that the bellows is seated inside both roll plates.
2. Install the swivel elbow fitting (Z) into the top of the bellows finger tight. Tighten the swivel fitting one and a half turns.
3. The lower bracket (A) has two sets of bellows mounting holes. Using the corresponding holes in the lower bracket designated (fig. 5), attach the bellows to the brackets using the 3/8” flat washers (W), lock washers (U), and 3/8”-24 x 7/8” hex head cap screws (N).
Torque both mounting screws to 20 ft/lbs.
The fitting on top of the bellows points inward (fig. 7).
Outside (wheel)
Left (driver) side holes
fig. 5
(A) Lower bracket
Right (passenger) side holes
5. Insert two 3/8”-16 x 1.25” carriage bolts (P) up through the bottom of the upper bracket s( fig. 7), through the two square holes that are on the corresponding side. Also, insert one 3/8”-16 x 2.5” carriage bolt (M) through the remaining hole. The head of this carriage bolt will be hidden once mounted to the bellows.
6. Set the driver side (left) upper bracket onto the driver side bellows assembly previously assembled, using the holes in the upper bracket designated (fig. 6), and attach to the bellows with two 3/8” flat washers (W), lock washers (U), and 3/8”-24 x 7/8” hex head cap screws (N). Torque both mounting screws to 20 ft/lbs.
7. Repeat the above process for the opposite side assembly (fig. 7).
8. Set the spacer (F) over both long carriage bolts (fig. 7).
The hole in the flat spacer (F) is offset. Install the spacer so that the wide portion faces the outside of the vehicle (fig. 7).
(C) Upper bracket
(F) - wide portion of spacer points outboard
(V), (U), (N)
(M)
Passenger Side
(H) Bellows
(C)
Upper bracket
(A) Lower bracket
Driver Side
fig. 6
(P)
fig. 7
MN-773
Left (Driver Side) shown
7
CAUTION
LoadLifter 5000
ATTACHING THE ASSEMBLIES TO THE FRAME
1. If not done so yet, drop the axle or raise the frame up to make room for the assemblies to be put into position.
2. Set the left (driver side) assembly onto the axle (fig. 1). Raise the axle just enough to insert the long carriage bolt (M) (that is installed in the upper bracket) through the existing jounce bumper hole in the bottom of the frame. At the same time, line up the upper brace previously installed onto the remaining two carriage bolts (P) in the upper bracket. Do this just enough for the carriage bolt to hold the assembly into position on the axle (fig.
1).
3. Set the right (passenger side) assembly into position on the axle the same way the left side was positioned (fig. 1).
4. Raise the axle or lower the frame down so that the thick spacer (F) on the upper bracket is parallel to, and contacts the frame (on both sides).
5. Install the 3/8” Flat Washer (W) and a 3/8’-16 Nyloc nut (V) on the carriage bolt (M) that went through the existing jounce bumper hole and tighten securely on both sides (fig. 1).
BE SURE NOT TO PINCH THE PREVIOUSLY MOVED WIRING OR LINES INSIDE THE
LEFT FRAME RAIL.
6. Cap the brace/upper bracket carriage bolts (P) with a 3/8” flat washer (W) and 3/8” nyloc nut (V) and tighten both securely on both sides.
7. With the spacers (F) on the upper brackets tight to the bottom of the frame and the braces tight to the upper bracket, tighten the ½ or ¾” hardware previously installed, that hold the braces to the frame. Tighten both sides securely.
8. If so equipped with the emissions line previously loosened from the frame, insert the line holder post into the L-bracket (J) attached to the back leg of the upper left brace (B)
(fig. 8). It may be necessary to move the line holder post forward or back on the lines to line up correctly with the L-bracket hole. Reattach any line holders removed forward or behind the axle, if possible, that were removed to aid in positioning the upper bracket.
Emissions line holder (stock)
NOTE
8
CAUTION
fig. 8
(J) L-bracket
LOWER BRACKET ATTACHMENT
ATTACHING THE LOWER BRACKET WILL DEPEND ON THE MODEL TRUCK YOU
HAVE. SEE FIGURE 10 TO DETERMINE WHICH HOLES TO USE FOR INSERTING THE
CARRIAGE BOLTS.
1. Insert a 3/8-16 x 5.5 hex head bolt bolt (K) and flat washer (W) into one of the two bottom holes of the locating bracket (I) (fig. 9).
Use the hole that is closest to the leaf spring.
MN-773
LoadLifter 5000
2a.If you are installing this kit on a single rear wheel (SRW) vehicle, use position 2 to insert the long 3/8-16 x 10” carriage bolt (Q) through the top of the locating bracket and lower bracket (fig. 9).
2b.If you are installing this kit on a dual rear wheel (DRW) vehicle, use position 1 to insert the long 3/8-16 x 10” carriage bolt (Q) through the top of the locating bracket and lower bracket (fig. 9).
3. Attach the locating bracket (I) to the lower bracket with a 3/8-16 x 1.25” carriage bolt
(P), flat washer (W) and nyloc nut (V) using the remaining slot in the top of the locating bracket. Leave loose at this time.
4. Push the front and back locating brackets against the u-bolts and tighten the short carriage bolts at this time.
5. Using the 3/8-16 x 5.5 hex head bolts (K) and flat washers (W) previously installed on the locating brackets, insert them into the spring clamp bar (E) on the opposite side of the leaf spring assembly (fig. 9). Cap with 3/8” flat washers (W) and nyloc nuts (V). Leave loose at this time.
Position 1
Position 1
Position 2
Position 2
(A) Lower bracket
NOTE
MN-773
I
(I) Locating bracket
fig. 9
6. Set the axle clamp bar (D) onto the long 3/8-16 x 10” carriage bolts (Q) (fig. 1) and cap with 3/8” flat washers (W) and nyloc nuts (V).
If you have a sway bar under the axle and the carriage bolt (Q) interferes, invert the carriage bolt.
7. Carefully draw the side hardware and axle hardware evenly. Torque the spring clamp bar bolts to 10 ft/lbs and the axle clamp bar bolts to 16 ft/lbs. Repeat for opposite side.
Trim carriage bolts below nyloc nuts if necessary.
H
NOTE: Single rear wheel mounting location shown.
Q**
P
P
Q**
NOTE: Single rear wheel mounting location shown.
A
W
V W
E
W
NOTE: Use hole that is closest to the leaf spring!
K
W
V
W
V
V
D
U
fig. 10
N
* 3/4” hardware is supplied by the
5th wheel hitch manufacturer. Use the 1/2” hardware supplied with this kit if no hardware is supplied by the manufacturer.
** On some models with sway bars under the axle, it may be necessary to invert the long carriage bolt.
9
NOTE
CAUTION
LoadLifter 5000
For 2WD and 4WD DRW vehicles, in order to install the sway bar and sway bar retaining straps back onto the axle, it will be necessary to slot the retaining straps (fig. 11). Reattach the sway bar once this is done.
Grind slot larger Grind slot larger fig. 11
FINAL STEPS
1. The emergency brake cable will have to be re-located away from the bellows.
FAILURE TO DO SO MAY CAUSE FAILURE TO THE BELLOWS AND VOID THE
WARRANTY.
2. Secure the emergency brake cable to the bottom bracket with supplied wire tie using the hole in the corner of the lower bracket (fig. 12).
Secure emergency brake cable using this hole fig. 12
(A) Lower bracket
10
MN-773
LoadLifter 5000
NOTE
INSTALLING THE AIR LINES
1. Choose a convenient location for mounting the inflation valves. Popular locations for the inflation valve are: a. The wheel well flanges b. The license plate recess in bumper c. Under the gas cap access door d. Through the license plate
Whatever the chosen location, make sure there is enough clearance around the inflation valves for an air chuck.
2. Drill two 5/16” holes to install the inflation valves.
3. Cut the air line assembly in two equal lengths.
MN-773
CAUTION
fig. 13
Good Cut Poor Cut
WHEN CUTTING OR TRIMMING THE AIR LINE, USE A HOSE CUTTER, A RAZOR BLADE,
OR A SHARP KNIFE. A CLEAN, SQUARE CUT WILL ENSURE AGAINST LEAKS. DO
NOT USE WIRE CUTTERS OR SCISSORS TO CUT THE AIR LINE. THESE TOOLS MAY
FLATTEN OR CRIMP THE AIR LINE CAUSING IT TO LEAK AROUND THE O-RING SEAL
INSIDE THE ELBOW FITTING (FIG. 13).
Air line
Vehicle body or bumper
5/16” Flat washer
5/16” Hex nut
Star washer
Valve cap
5/16” Hex nut
Rubber washer
fig. 14
4. Place a 5/16” nut and star washer on the air valve. Leave enough of the inflation valve in front of the nut to extend through the hole and have room for the rubber washer, flat washer, and 5/16” nut and cap. There should be enough valve exposed after installation— approximately ½”— to easily apply a pressure gauge or an air chuck (fig. 14).
5. Push the inflation valve through the hole and use the rubber washer, flat washer, and another 5/16” nut to secure it in place. Tighten the nuts to secure the assembly.
6. Route the air line along the frame to the air fitting on the air spring (fig. 15). Keep AT
LEAST 6” of clearance between the air line and heat sources, such as the exhaust pipes, muffler, or catalytic converter. Avoid sharp bends and edges. Use the plastic tie straps to secure the air line to fixed, non-moving points along the chassis. Be sure that the tie straps are tight, but do not pinch the air line. Leave at least 2” of slack to allow for any movement that might pull on the air line.
11
LoadLifter 5000
NOTE
12
Option 1
Option 2
fig. 15
7. Cut off the air line, leaving approximately 12” of extra air line. A clean square cut will ensure against leaks. Insert the air line into the air fitting. This is a push-to-connect fitting. Simply push the air line into the 90° swivel fitting until it bottoms out (9/16” of air line should be in the fitting).
INSTALLING THE HEAT SHIELD
1. Bend tabs to provide a ½” dead air space between exhaust pipe and heat shield (fig. 16).
2. Attach the heat shield to the exhaust pipe using the clamps. Bend the heat shield for maximum clearance to the air spring (fig. 16).
Some vehicles have large resonators in this area, it will be necessary to double up on the clamps to fit these models (fig. 17).
½” Dead air space
Bend tabs
fig. 16
Exhaust resonator
Double up supplied hose clamps provided fig. 17
CHECKING FOR LEAKS
1. Inflate the air spring to 30 PSI.
2. Spray all connections and the inflation valves with a solution of 1/5 liquid dish soap and
4/5 water. Spot leaks easily by looking for bubbles in the soapy water.
3. After the test, deflate the springs to the minimum pressure required to restore the system to normal ride height. Do not deflate to lower than 5 PSI.
4. Check the air pressure again after 24 hours. A 2 - 4 PSI loss after initial installation is normal. Retest for leaks if the loss is more than 5 lbs.
FIXING LEAKS
1. If there is a problem with the swivel fitting: a. Check the air line connection by deflating the spring and removing the line by pulling the collar against the fitting and pulling firmly on the air line. Trim 1” off the end of the air line. Be sure the cut is clean and square (see fig. 13). Reinsert the air line into the push-to-connect fitting.
b. Check the threaded connection by tightening the swivel fitting another ½ turn. If it still leaks, deflate the air spring, remove the fitting, and re-coat the threads with thread sealant. Reinstall by hand tightening as much as possible and then use a wrench for an additional two turns.
MN-773
LoadLifter 5000
CAUTION
2. If there is a problem with the inflation valve: a. Check the valve core by tightening it with a valve core tool.
b. Check the air line by removing the air line from the barbed type fitting. Cut the air line off a few inches in front of the fitting and use a pair of pliers or vice grips to pull/ twist the air line off of the fitting.
DO NOT CUT OFF THE AIR LINE COMPLETELY AS THIS WILL USUALLY NICK THE
BARB AND RENDER THE FITTING USELESS.
3. If the preceding steps have not resolved the problem, call Air Lift customer service at
(800) 248-0892.
Before Operating
INSTALLATION CHECKLIST
(To be completed by installer)
Clearance test — Inflate the air springs to 60 PSI and ensure there is at least ½” clearance around each bellow, away from anything that might rub against them. Be sure to check the tire, brake drum, frame, shock absorbers and brake cables.
Leak test before road test — Inflate the air springs to 60 PSI, check all connections for leaks with a soapy water solution. See page 12 for tips on how to spot leaks. All leaks must be eliminated before the vehicle is road tested.
Heat test — Be sure there is sufficient clearance from any heat sources — at least 6” for air springs and air lines. If a heat shield was included in the kit, install it. If there is no heat shield, but one is required, call (800) 248-0892.
Fastener test — Recheck all bolts for proper torque. Axle clamp bar carriage bolt lock nuts should be torqued to 16 ft/lbs. Re-torque after 100 miles.
Road test — The vehicle should be road tested after the preceding tests. Inflate the air springs to 25 PSI (50 PSI if the vehicle is loaded). Drive the vehicle 10 miles and recheck for clearance, loose fasteners and air leaks.
Operating instructions — If professionally installed, the installer should review the Product
Use, Maintenance and Servicing section on page 14 with the owner. Be sure to provide the owner with all of the paperwork which came with the kit.
Technician’s Signature ________________________
Date ______________
MN-773
POST-INSTALLATION CHECKLIST
Overnight leak down test — Recheck air pressure after the vehicle has been used for
24 hours. If the pressure has dropped more than 5 PSI, then there is a leak that must be fixed. Either fix the leak yourself or return to the installer for service.
Air pressure requirements — I understand the air pressure requirements of my air spring system. Regardless of load, the air pressure should always be adjusted to maintain ride height at all times.
Thirty day or 500 mile test — I understand that I must recheck the air spring system after
30 days or 500 miles, whichever comes first. If any part shows signs of rubbing or abrasion, the source should be identified and moved, if possible. If it is not possible to relocate the cause of the abrasion, the air spring may need to be remounted. If professionally installed, the installer should be consulted. Check all fasteners for tightness.
13
LoadLifter 5000
Product Use, Maintenance and Servicing
Minimum Pressure
5 PSI
Maximum Air Pressure
100 PSI
FAILURE TO MAINTAIN CORRECT MINIMUM PRESSURE (OR PRESSURE
PROPORTIONAL TO LOAD), BOTTOMING OUT, OVER-EXTENSION OR RUBBING
AGAINST ANOTHER COMPONENT WILL VOID THE WARRANTY.
NOTE
MAINTENANCE GUIDELINES
By following the steps below, vehicle owners will obtain the longest life and best results from their air springs.
CAUTION
1. Check the air pressure weekly.
2. Always maintain normal ride height. Never inflate beyond 100 PSI.
3. If you develop an air leak in the system, use a soapy water solution (1/5 liquid dish soap and 4/5 water) to check all air line connections and the inflation valve core before deflating and removing the air spring.
FOR YOUR SAFETY AND TO PREVENT POSSIBLE DAMAGE TO YOUR VEHICLE, DO
NOT EXCEED MAXIMUM GROSS VEHICLE WEIGHT RATING (GVWR), AS INDICATED
BY THE VEHICLE MANUFACTURER. ALTHOUGH YOUR AIR SPRINGS ARE RATED AT
A MAXIMUM INFLATION PRESSURE OF 100 P.S.I., THE AIR PRESSURE ACTUALLY
NEEDED IS DEPENDANT ON YOUR LOAD AND GVWR.
4. Loaded vehicles require at least 25 PSI or more. A “loaded vehicle” refers to a vehicle with a heavy bed load, a trailer, or both. As discussed above, never exceed GVWR, regardless of air spring, air pressure, or other load assist. The springs in this kit will support approximately 40 lbs. of load (combined on both springs) for each 1 PSI of pressure. The required air pressure will vary depending on the state of the original suspension. Operating the vehicle below the minimum air spring pressure will void the
Air Lift warranty.
5. When increasing load, always adjust the air pressure to maintain the normal ride height.
Increase or decrease pressure from the system as necessary to attain normal ride height for optimal ride and handling. Remember that loads carried behind the axle (including tongue loads) require more leveling force (pressure) than those carried directly over the axle.
6. Always add air to springs in small quantities, checking the pressure frequently.
7. Should it become necessary to raise the vehicle by the frame, make sure the system is at minimum pressure (5 PSI) to reduce the tension on the suspension/brake components.
Use of on board leveling systems do not require deflation or disconnection.
8. Periodically check the air spring system fasteners for tightness. Also, check the air springs for any signs of rubbing. Realign if necessary.
9. On occasion, give the air springs a hard spray with a garden hose in order to remove mud, sand, gravel or other abrasive debris.
Troubleshooting Guide
1. Leak test the air line connections, the threaded connection into the air spring, and all fittings in the control system.
2. Inspect the air lines to be sure none are pinched. Tie straps may be too tight. Loosen or replace the strap and replace leaking components.
14
MN-773
LoadLifter 5000
3. Inspect the air line for holes and cracks. Replace as needed.
4. Look for a kink or fold in the air line. Reroute as needed.
If the preceding steps do not solve the problem, it is possibly caused by a failed air spring — either a factory defect or an operating problem. Please call Air Lift at (800) 248-0892 for assistance.
Frequently Asked Questions
Q . Will installing air springs increase the weight ratings of a vehicle?
No. Adding air springs will not change the weight ratings (GAWR, GCWR and/or GVWR) of a vehicle. Exceeding the GVWR is dangerous and voids the Air Lift warranty.
Q . Is it necessary to keep air in the air springs at all times and how much pressure will they need?
The minimum air pressure should be maintained at all times. The minimum air pressure keeps the air spring in shape, ensuring that it will move throughout its travel without rubbing or wearing on itself.
Q . Is it necessary to add a compressor system to the air springs?
No. Air pressure can be adjusted with any type of compressor as long as it can produce sufficient pressure to service the springs. Even a bicycle tire pump can be used, but it’s a lot of work.
Q . How long should air springs last?
If the air springs are properly installed and maintained they can last indefinitely.
Q . Will raising the vehicle on a hoist for service work damage the air springs?
No. The vehicle can be lifted on a hoist for short-term service work such as tire rotation or oil changes. However, if the vehicle will be on the hoist for a prolonged period of time, support the axle with jack stands in order to take the tension off of the air springs.
Tuning the Air Pressure
Pressure determination comes down to three things — level vehicle, ride comfort, and stability.
1 . Level vehicle
If the vehicle’s headlights are shining into the trees or the vehicle is leaning to one side, then it is not level (fig. 18). Raise the air pressure to correct either of these problems and level the vehicle.
2 . Ride comfort
If the vehicle has a rough or harsh ride it may be due to either too much pressure or not enough (fig. 19). Try different pressures to determine the best ride comfort.
3 . Stability
Stability translates into safety and should be the priority, meaning the driver may need to sacrifice a perfectly level and comfortable ride. Stability issues include roll control, bounce, dive during braking and sponginess (fig. 20). Tuning out these problems usually requires an increase in pressure.
MN-773
Bad headlight aim
fig. 18
Rough ride
fig. 19
Sway and body roll
fig. 20
15
LoadLifter 5000
Guidelines for Adding Air
1. Start with the vehicle level or slightly above.
2. When in doubt, always add air.
3. For motorhomes, start with 50-100 PSI in the rear because it can be safely assumed that it is heavily loaded.
4. If the front of the vehicle dives while braking, increase the pressure in the front air bags, if equipped.
5. If it is ever suspected that the air bags have bottomed out, increase the pressure (fig. 21).
6. Adjust the pressure up and down to find the best ride.
7. If the vehicle rocks and rolls, adjust the air pressure to reduce movement.
8. It may be necessary to maintain different pressures on each side of the vehicle. Loads such as water, fuel, and appliances will cause the vehicle to be heavier on one side (fig.
22). As much as a 50 PSI difference is not uncommon.
Bottoming out
fig. 21
Warranty and Returns Policy
Unlevel
Level
fig. 22
Air Lift Company warrants its products, for the time periods listed below, to the original retail purchaser against manufacturing defects when used on catalog-listed applications on cars, vans, light trucks and motorhomes under normal operating conditions for as long as
Air Lift manufactures the product. The warranty does not apply to products that have been improperly applied, improperly installed, used in racing or off-road applications, used for commercial purposes, or which have not been maintained in accordance with installation instructions furnished with all products. The consumer will be responsible for removing
(labor charges) the defective product from the vehicle and returning it, transportation costs prepaid, to the dealer from which it was purchased or to Air Lift Company for verification.
Air Lift will repair or replace, at its option, defective products or components. A minimum
$10.00 shipping and handling charge will apply to all warranty claims. Before returning any defective product, you must call Air Lift at (800) 248-0892 in the U.S. and Canada
(elsewhere, (517) 322-2144) for a Returned Materials Authorization (RMA) number.
Returns to Air Lift can be sent to: Air Lift Company • 2727 Snow Road • Lansing, MI •
48917.
Product failures resulting from abnormal use or misuse are excluded from this warranty. The loss of use of the product, loss of time, inconvenience, commercial loss or consequential damages is not covered. The consumer is responsible for installation/reinstallation (labor charges) of the product. Air Lift Company reserves the right to change the design of any product without assuming any obligation to modify any product previously manufactured.
This warranty gives you specific legal rights and you may also have other rights that vary from state-to-state. Some states do not allow limitations on how long an implied warranty lasts or allow the exclusion or limitation of incidental or consequential damages. The above limitation or exclusion may not apply to you. There are no warranties, expressed or implied including any implied warranties of merchantability and fitness, which extend beyond this warranty period. There are no warranties that extend beyond the description on the face hereof. Seller disclaims the implied warranty of merchantability. (Dated proof of purchase required.)
16
MN-773
LoadLifter 5000
(Warranty & Returns Policy continued)
Air Lift 1000 . . . . . . . . . . . . . . . . . . . . Lifetime Limited
RideControl . . . . . . . . . . . . . . . . . . . . Lifetime Limited
LoadLifter 5000* . . . . . . . . . . . . . Lifetime Limited
SlamAir . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifetime Limited
AirCell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifetime Limited
Air Lift Performance** . . . . . . 1 Year Limited
LoadController/Single . . . . . . 2 Year Limited
LoadController/Dual . . . . . . . . . 2 Year Limited
Load Controller (I) . . . . . . . . . . . . 2 Year Limited
Load Controller (II) . . . . . . . . . . . 2 Year Limited
SmartAir . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Year Limited
Wireless AIR . . . . . . . . . . . . . . . . . . . . . . 2 Year Limited
WirelessONE . . . . . . . . . . . . . . . . . . . . . 2 Year Limited
Other Accessories . . . . . . . . . . . . 2 Year Limited
*formerly SuperDuty
**formerly LifeSTYLE & Performance and EasyStreet
Replacement Information
If you need replacement parts, contact the local dealer or call Air Lift customer service at
(800) 248-0892. Most parts are immediately available and can be shipped the same day.
Contact Air Lift Company customer service at (800) 248-0892, first if:
• Parts are missing from the kit.
• Need technical assistance on installation or operation.
• Broken or defective parts in the kit.
• Wrong parts in the kit.
• Have a warranty claim or question.
Contact the retailer where the kit was purchased:
• If it is necessary to return or exchange the kit for any reason.
• If there is a problem with shipping if shipped from the retailer.
• If there is a problem with the price.
Contact Information
If you have any questions, comments or need technical assistance, contact our customer service department by calling (800) 248-0892, Monday through Friday. For calls from outside the USA or Canada, our local number is (517) 322-2144.
For inquiries by mail, our address is PO Box 80167, Lansing, MI 48908-0167. Our shipping address for returns is 2727 Snow Road, Lansing, MI 48917.
You may also contact us anytime by e-mail at [email protected] or on the web at www.airliftcompany.com.
MN-773
17
Need Help?
Contact our customer service department by calling
(800) 248-0892, Monday through Friday. For calls from outside the USA or Canada, our local number is (517) 322-2144.
Register your warranty online at www .airliftcompany .com/warranty
Thank you for purchasing Air Lift products — the professional installer’s choice!
Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or PO Box 80167 • Lansing, MI 48908-0167
Toll Free (800) 248-0892 • Local (517) 322-2144 • Fax (517) 322-0240 • www.airliftcompany.com
Printed in the USA
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