Air Lift LoadLifter 5000 Installation Guide

Introduction

This publication provides assistance with the installation, maintenance, and troubleshooting of the LoadLifter 5000 air spring kit. The LoadLifter 5000 features sturdy, reinforced, commercial-grade single or double convolute bellows, designed to control growth like a tire. These kits are recommended for most 3/4- and 1-ton pickups and SUVs with leaf springs, offering up to 5,000 pounds of load leveling support with air adjustability from 5-100 PSI.

It is crucial to read and understand this entire installation guide before beginning installation or performing any maintenance, service, or repair. This guide 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 airliftcompany.com.

Important Safety Notice

The installation of this kit does not alter the Gross Vehicle Weight Rating (GVWR) or payload of the vehicle. Always check your vehicle's owner's manual and do not exceed the maximum load listed for your vehicle.

• Gross Vehicle Weight Rating (GVWR): The maximum allowable weight of the fully loaded vehicle, including passengers and cargo. This information, along with other weight limits, tire 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 are used to highlight information that must be observed to minimize the risk of personal injury or improper installation. Notes emphasize procedural importance and offer helpful suggestions.

• DANGER: Indicates immediate hazards that will result in severe personal injury or death.
• WARNING: Indicates hazards or unsafe practices that could result in severe personal injury or death.
• CAUTION: Indicates hazards or unsafe practices that could result in damage to the machine or minor personal injury.
• NOTE: Indicates a procedure, practice, or hint that is important to highlight.

Installation Diagram

The diagram illustrates the components for both the left-hand (driver side) and right-hand (passenger side) installations. Key components are labeled with letters (A-N, AA-GG) corresponding to the hardware list.

NOTE: Professional mechanical skills are necessary to complete the installation of this kit.

Hardware List

*Not shown in fig. 1.

STOP! Missing or damaged parts? Call Air Lift customer service at (800) 248-0892 for a replacement part.

Tools List

Installing the LoadLifter 5000 System

Getting Started

To install the upper frame brackets (A), the coil springs must be removed. Follow these steps:

1. Lift the vehicle and support the frame with jack stands. Ensure there is enough clearance to lower the axle sufficiently to remove the coil springs (Fig. 2). Remove the rear wheels.
2. Mark the bottom of the right-hand and left-hand coil springs and lower spring seat mounts with chalk or a paint marker to ensure correct reinstallation (Fig. 3).
3. Remove both lower shock bolts and slowly lower the axle until the springs can be removed. Lower the axle carefully to avoid stressing the flexible brake lines.
4. Remove both jounce bumpers from both sides (Fig. 4).
5. Grind off the welds securing the jounce bumper cups to the jounce bumper frame bracket (Fig. 5). Remove and discard the cups from both sides of the vehicle.
6. Grind the removed welds flush to the frame with the grinder (Fig. 6).
7. Spray the frame with black paint or undercoating to cover the bare surface created by grinding the welds flush (Fig. 7). Repeat for both sides.
8. Install the socket head M8 bolt (M) into the frame bracket (A) slot closest to the flange. Ensure the bolt head points in the same direction as the flange. Cap with the nylon lock nut (O) (Fig. 8 & 9). Tighten the bolt only enough so it can still slide in the slot.
9. Position the frame bracket (with the socket head bolt) onto the frame with the flange pointing up. Insert the socket head bolt into the existing hole in the frame that was under the stock jounce bumper (Fig. 10).
10. The bracket should sit flush to the bottom of the frame. If any weld is holding the bracket off the frame, remove and grind it down until the bracket is flush.
11. With the socket head bolt in the hole, push the flange against the side of the frame (Fig. 11) and mark the existing hole under the frame with a paint marker (Fig. 12).
12. TECHNICAL NOTE: If possible, use a 21/64" (or closest) centering punch to fit into the hole and center-punch the frame for an exact center.
13. Center-punch the frame and drill a 1/4" hole (Fig. 13). Start a 5/16" self-tapping screw (K) into the hole, ensuring it is straight, and tighten it enough to form the threads. Remove the screw once threads are formed. Repeat for both sides.
14. Position the bracket back onto the frame and secure it using the self-tapping screw. Tighten the screw, ensuring the washer head is flat to the bracket, and torque to 15 lb.-ft.
15. Ensure the bracket is flat to the bottom of the frame. Center-punch and drill through the frame with a 1/4” bit, using the holes in the side of the flange as a guide (Fig. 14).
16. Install two more self-tapping screws (K) into the side, ensuring the flat head portion is flush to the bracket, and torque to 15 lb.-ft. (Fig. 15). Repeat for the other side. The driver-side bracket is shown mounted in place, ready for the air spring assembly.
17. Once the frame brackets are installed on both sides, reassemble the stock suspension.
18. Position the coil springs back using the index marks and raise the axle, ensuring the springs are correctly indexed into the top and bottom spring seats.
19. Install the wheels back onto the axle and lower the vehicle until the wheels rest on the ground. Torque the lug nuts to the manufacturer's specifications.
20. Install the lower shock bolts back onto the axle and torque to 135 Nm (100 lb.-ft.).

Assembling the Air Springs

1. Place a roll plate (E) onto the air spring (D). The radius (rounded) edge of the roll plate should be towards the air spring, ensuring it is seated inside both roll plates.
2. Install the swivel fitting (F) into the top of the air spring, finger-tight plus one-and-a-half turns (Fig. 16). Repeat for both air springs.
3. Insert four carriage bolts (L) into the upper air spring bracket (B) and place the upper bracket onto the air spring assembly (Fig. 17).
4. Attach the upper air spring bracket using two 3/8” hex head bolts (H), two lock washers (I), and two flat washers (J). Torque to no more than 20 lb.-ft. Repeat for the opposite side. Both upper assemblies are shown in Figure 18.
5. Flip the air spring assemblies upside down and place a roll plate (E) over the air spring (as in step one).
6. Position the air spring assemblies so the fittings are outboard and away from each other (Fig. 19). The fittings should be on the outside (tire side) of the assemblies when in position.
7. Attach the left-hand lower bracket (C1) to the left side assembly (your left-hand facing both assemblies) using two 3/8” flat head screws (G). Torque to no more than 20 lb.-ft. (Fig. 19). Attach the right-hand lower bracket (C2) to the right-side assembly (your right-hand facing both assemblies) using two 3/8" flat head screws (G). Torque to no more than 20 lb.-ft. (Fig. 20).

Installing the Assemblies

1. Index a 3/8" carriage bolt (L) into the opening on the front of the driver side assembly as shown (Fig. 21).
2. Lower the axle again to provide clearance for positioning the assemblies on the axle.
3. Position the driver side assembly with the carriage bolt still in the slot. Ensure the back of the bracket is “hooked” below the jounce bumper strike plate. Push the assembly forward while aligning the carriage bolt with the existing hole in the front of the lower jounce bumper strike plate (Figs. 22 & 23). Cap the carriage bolt with a 3/8" serrated lock nut (N), but leave it loose for now.
4. Insert another 3/8” carriage bolt (L) through the remaining hole in the front side of the bracket (Fig. 24).
5. Use a socket with an extension to reach the inside threads on the carriage bolt. It may be helpful to pull the carriage bolt out slightly so it can be angled to start threading (Fig. 25). Use the slot in the lower control arm mount for the extension to fit through while threading the nut on the bolt.
6. Position the right-hand unit assembly similarly, indexing the lower bracket with the tabs under the jounce bumper strike plate. Install the carriage bolts in the same manner, using the slot in the lower bracket for the carriage bolt. Torque both sides of the lower bracket hardware evenly to 31 lb.-ft., ensuring the tabs are indexed under the jounce bumper strike plate. Figures 26 and 27 show the assemblies bolted into position. Fittings should be on the outside (tire side) of the assemblies.
7. Raise the axle back up, aligning the air spring mounting plate's carriage bolts with the frame mounting bracket holes. Once in position, cap all carriage bolts with 3/8" serrated lock nuts (N) and torque all installed nuts to 31 lb.-ft. (Fig. 28).

Installing the Air Lines

1. On the passenger side only, place the provided thermal sleeve (HH) on the air line near the exhaust.
2. Remove the air line heat shield sleeve from the hose heat shield kit and install it on the right side (passenger side) air line where it attaches to the fitting on the upper bracket (Fig. 30). Insert the air line into the heat shield before attaching to the right-side (passenger) air spring fitting.

This section explains how to set up the air spring kit to be controlled with Schrader valves and a separate compressed air source. An on-board air compressor system allows for hassle-free control of the air springs. Learn more about Air Lift control systems at www.airliftcompany.com/products/compressor-systems.

Choosing Inflation Valve Location

Choose a convenient location for mounting the inflation valves (Fig. 31). Popular locations include:

• The wheel well flanges
• The license plate recess in the bumper
• Under the gas cap access door
• Through the license plate

NOTE: Whatever the chosen location, ensure there is enough clearance around the inflation valves for an air chuck.

1. Drill 5/16" holes to install the inflation valves.
2. Cut the air line assembly into two equal lengths.
3. 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, accommodating the rubber washer, flat washer, and the second 5/16" nut and cap. Ensure sufficient valve is exposed after installation.
4. Push the inflation valve through the hole and use the rubber washer, flat washer, and another 5/16” nut to secure it. Tighten the nuts to secure the assembly.
5. Route the air line along the frame to the fitting on the air spring. Maintain at least 6" of clearance between the air line and the exhaust system. Avoid sharp bends and edges. Use zip ties to secure the air line to fixed points along the chassis. Ensure tie straps are tight but do not pinch the air line. Leave at least 2" of slack for movement.
6. Cut the air line, leaving approximately 12” of extra air line. A clean, square cut prevents leaks. Insert the air line into the air fitting; this is a push-to-connect fitting. Wiggle the hose back and forth while inserting to ensure it bottoms out in the fitting for a good seal.

TECH TIP: Wiggle the hose back and forth while inserting to make sure the hose bottoms out in the fitting to obtain a good seal.

Tips for Installing Air Lines

When cutting air lines, use a sharp knife or hose cutter and make clean, square cuts (Fig. 33). Do not use scissors or wire cutters, as they may deform the air line and cause leaks. Do not cut lines at an angle.

• Do not bend the 1/4" hose at a radius less than 1" or the 3/8" hose at a radius less than 1 1/2".
• Do not put side load pressure on the fitting. The hose should be straight for 1” beyond the fitting before bending.
• Inspect the hose for scratches that run lengthwise before installation. Contact Air Lift customer service at (800) 248-0892 if the air line is damaged.

Watch a video demonstrating proper air line cutting at air-lift.co/cuttingairline.

Installing the Heat Shield

1. Bend tabs to provide a dead air space between the exhaust pipe and the heat shield (Fig. 34). Attach the heat shield to the exhaust pipe using the clamps. Bend the heat shield for maximum clearance to the air spring.

Finished Installation Photos

Photos show the completed installation from the back view of the left-side (driver) assembly (Fig. 35) and the right-side (passenger) assembly (Fig. 36).

Before Operating

Checking for Leaks

1. Inflate the air spring to 30 PSI.
2. Spray all connections and inflation valves with a solution of 1/5 liquid dish soap and 4/5 water. Look for bubbles to identify leaks.
3. Deflate the springs to the minimum pressure required for normal ride height. Do not deflate below 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 exceeds 5 PSI.

Fixing Leaks

1. If there is a problem with the swivel fitting:
   • Check the air line connection by deflating the spring and removing the line. Trim 1" off the end of the air line, ensuring a clean, square cut. Reinsert the air line into the push-to-connect fitting.
   • Check the threaded connection by tightening the swivel fitting another half turn. If leaks persist, deflate the air spring, remove the fitting, re-coat the threads with thread sealant, and reinstall. Hand-tighten as much as possible, then use a wrench for an additional two turns.
2. If there is a problem with the inflation valve:
   • Check the valve core by tightening it with a valve core tool.
   • Check the air line by removing it from the barbed type fitting. Cut the air line a few inches in front of the fitting and use pliers or vice grips to pull/twist the air line off the fitting. CAUTION: DO NOT CUT OFF THE AIR LINE COMPLETELY, AS THIS MAY NICK THE BARB AND RENDER THE FITTING USELESS.
3. If problems persist, contact Air Lift customer service at (800) 248-0892.

Installation Checklist

• Clearance test: Inflate air springs to 75-90 PSI and ensure at least 1/2" clearance from anything that might rub against the sleeve (tires, brakes, frame, shocks, brake cables).
• Leak test before road test: Inflate air springs to 75-90 PSI and check all connections for leaks. Eliminate all leaks before road testing.
• Heat test: Ensure at least 6" clearance from heat sources for air springs and air lines. If a heat shield was included, install it. If not, and one is required, contact Air Lift customer service at (800) 248-0892.
• Fastener test: Recheck all bolts for proper torque.
• Road test: After preceding tests, inflate springs to recommended pressures. Drive 10 miles and recheck for clearance, loose fasteners, and air leaks.
• Operating instructions: If professionally installed, review operating instructions with the owner and provide all accompanying paperwork.

Post-Installation Checklist

• Overnight leak down test: Recheck air pressure after 24 hours of use. If pressure dropped more than 5 PSI, fix the leak or return to the installer.
• Air pressure requirements: Understand that air pressure should always be adjusted to maintain adequate ride height, regardless of load.
• Thirty-day or 500-mile test: Recheck the air spring system after 30 days or 500 miles. If any part shows signs of rubbing or abrasion, identify and move the source if possible. If abrasion cannot be relocated, the air spring may need remounting. Consult the installer if professionally installed. Check all fasteners for tightness.

Product Use, Maintenance and Servicing

Minimum and Maximum Pressure

Maintenance Guidelines

Follow these steps for longest life and best results from your air springs:

1. Check air pressure weekly.
2. Always maintain normal ride height. Never inflate beyond 100 PSI.
3. If the system develops an air leak, 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.
4. CAUTION: FOR SAFETY AND TO PREVENT POSSIBLE DAMAGE TO THE VEHICLE, DO NOT EXCEED MAXIMUM GROSS VEHICLE WEIGHT RATING (GVWR). THE AIR SPRINGS ARE RATED AT A MAXIMUM INFLATION PRESSURE OF 100 PSI, BUT THE ACTUAL PRESSURE NEEDED DEPENDS ON LOAD AND GVWR.
5. Loaded vehicles require at least 25 PSI. A “loaded vehicle” refers to a vehicle with a heavy bed load, a trailer, or both. Never exceed GVWR, regardless of air spring, air pressure, or other load assist. The springs in this kit support approximately 40 pounds of load (combined on both springs) for each 1 PSI of pressure. Required air pressure varies with the original suspension. Operating below the minimum air spring pressure voids the Air Lift warranty.
6. When increasing load, adjust air pressure to maintain normal ride height. Adjust pressure as necessary for optimal ride and handling. Loads carried behind the axle (including tongue loads) require more leveling force than those carried directly over the axle.
7. Add air to springs in small quantities, checking pressure frequently.
8. If the vehicle needs to be raised by the frame, ensure the system is at minimum pressure (5 PSI) to reduce tension on suspension/brake components. On-board leveling systems do not require deflation or disconnection.
9. Periodically check air spring system fasteners for tightness and air springs for signs of rubbing. Realign if necessary.
10. Occasionally, spray the air springs with a garden hose to remove mud, sand, gravel, or other debris.

Tuning the Air Pressure

Pressure determination involves three factors: level vehicle, ride comfort, and stability.

1. Level vehicle: If headlights are not level or the vehicle leans, adjust air pressure to correct (Fig. 37).
2. Ride comfort: A rough or harsh ride may be due to too much or too little pressure (Fig. 38). Experiment with different pressures for best comfort.
3. Stability: Stability is crucial for safety. Stability issues include roll control, bounce, dive during braking, and sponginess (Fig. 39). Tuning out these problems usually requires increased pressure.

Guidelines for Adding Air

1. Start with the vehicle level or slightly above.
2. When in doubt, add air.
3. If the front of the vehicle dives while braking, increase pressure in the front air bags (if equipped).
4. If air bags appear to have bottomed out, increase pressure (Fig. 40).
5. Adjust pressure up and down to find the best ride.
6. If the vehicle rocks and rolls, adjust air pressure to reduce movement.
7. Different pressures may be needed on each side of the vehicle. Loads like water, fuel, or appliances can cause uneven weight distribution (Fig. 41). A difference of up to 50 PSI is not uncommon.

Troubleshooting Guide

Frequently Asked Questions

Q. Will installing air springs increase the weight ratings of a vehicle?
A. No. Adding air springs does not change weight ratings (GAWR, GCWR, and/or GVWR). 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?
A. For LoadLifter 5000, the recommended minimum air pressure is 5 PSI. It can safely be run at zero air pressure when unladen.

Q. Is it necessary to add a compressor system to the air springs?
A. No. Air pressure can be adjusted with any compressor that can produce sufficient pressure. A bicycle pump can be used, but it is labor-intensive.

Q. How long should air springs last?
A. If properly installed and maintained, air springs can last indefinitely.

Q. Will raising the vehicle on a hoist for service work damage the air springs?
A. No. The vehicle can be lifted on a hoist for short-term service work like tire rotation or oil changes. However, for prolonged periods on the hoist, support the axle with jack stands to relieve tension on the air springs.

Limited Warranty and Return Policy

Air Lift Company provides a limited lifetime warranty to the original purchaser of its Load Support products, ensuring they are free from defects in workmanship and materials when used on cars and trucks as specified by Air Lift Company and under normal operating conditions. The full Limited Warranty and Return Policy is available online at www.airliftcompany.com/warranty.

For additional warranty information, contact Air Lift Company customer service.

Replacement Part Information

If replacement parts are needed, 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.
• Technical assistance is needed for installation or operation.
• Parts in the kit are broken or defective.
• Incorrect parts were received.
• A warranty claim or question exists.

Contact the retailer where the kit was purchased if:

• The kit needs to be returned or exchanged for any reason.
• There is a problem with shipping if the item was shipped from the retailer.
• There is a problem with the price.

Contact Information

Mailing address:
P.O. Box 80167
Lansing, MI 48908-0167

Shipping address for returns:
2727 Snow Road
Lansing, MI 48917

Phone:
Toll free: (800) 248-0892
International: (517) 322-2144

Email:
service@airliftcompany.com

Web address:
www.airliftcompany.com

Need Help?

Contact Air Lift Company customer service department by calling (800) 248-0892. For calls from outside the USA or Canada, dial (517) 322-2144.

Thank you for purchasing Air Lift products — the professional installer's choice!

Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or P.O. 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
JJC-0217