LoadLifter 5000 Kit 57101

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, manufactured like a tire with layers of rubber and cords to control growth. These kits are recommended for most 3/4 and 1-ton pickups and SUVs with leaf springs, offering up to 5,000 lbs. of load leveling support with air adjustability from 5-100 PSI. They are also suitable for motor home rear kits and some motor home fronts where leaf springs are used.

It is crucial to read and understand the 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 instructions, maintenance guidelines, and operating tips.

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, 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 calculated as GVWR minus the Base Curb Weight.

Notation Explanation

Hazard notations appear throughout this publication. Information highlighted by these notations must be observed to minimize the risk of personal injury or improper installation that could render the vehicle unsafe. Notes are used to emphasize procedural importance and provide 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

A diagram illustrating the mounting of the LoadLifter 5000 air spring system. It shows the air spring positioned between a vehicle's frame rail (labeled "Frame") and its leaf spring assembly near the axle (labeled "Axle"). Components include the upper bracket attached to the frame, the air spring, and the lower bracket attached to the leaf spring. Arrows indicate "FORWARD" and "INBOARD" directions relative to the vehicle.

Hardware List

(* not shown in Figure 1)

Tool List

Installing the LoadLifter 5000 System

IMPORTANT: Your vehicle may be equipped with a rear brake proportioning valve. Any type of load assist product could affect brake performance. It is recommended that you check with your dealer before installing this type of product. If your vehicle DOES NOT have a rear brake proportioning valve or is equipped with an anti-lock type brake system, installation of a load assist product will have NO EFFECT ON BRAKE SYSTEM.

⚠️ DANGER: COMPRESSED AIR CAN CAUSE INJURY AND DAMAGE TO THE VEHICLE AND PARTS IF IT IS NOT HANDLED PROPERLY. FOR YOUR SAFETY, DO NOT TRY TO INFLATE THE AIR SPRINGS UNTIL THEY HAVE BEEN PROPERLY SECURED TO THE VEHICLE.

Assembling the Air Spring Assembly

Refer to Figure 1.

1. Consult your User's Manual to determine the normal ride height of your vehicle.
2. Loosely attach the 90° elbow fitting (D) to the top of the air spring. Tighten finger tight plus 1 and 1/2 turns. Be careful to tighten on the metal hex nut only. DO NOT OVERTIGHTEN.
3. Loosely attach the upper bracket (B) to the air spring (A) with two 3/8" bolts (E), two 3/8" lock washers (F), and two 3/8" flat washers (G).
4. Attach the air spring to the lower bracket (C) with two 3/8" bolts (E), two 3/8" lock washers (F), and two 3/8" flat washers (G). Leave loose at this time.

Attaching the Lower Bracket

Refer to Figure 1.

1. Insert two 3/8" carriage bolts (I) through the lower bracket. Attach the lower bracket to the leaf spring forward of the axle by securing the carriage bolts to a clamp bar (O) underneath the leaf spring.
2. Secure the carriage bolts with two 3/8" flat washers (G) and 3/8" nyloc nuts (H). Tighten all nuts to 20 ft.lbs.

Attaching the Upper Bracket

Refer to Figure 1.

1. Position the upper bracket (B) on the frame rail so that it is aligned front-to-rear and inboard-to-outboard. Upper and lower brackets are slotted for adjustment. The short end of the upper bracket must be positioned so that it is touching the underside of the frame rail (Figure 2).
2. Put the upper bracket into position on the frame rail and drill one 1/2" hole in the side of the frame rail (Figure 3).

⚠️ CAUTION: DO NOT DRILL HOLES IN THE FRAME BEFORE CHECKING FOR HYDRAULIC LINES, GAS LINES AND/OR ELECTRICAL WIRES THAT MAY HAVE TO BE MOVED OUT OF THE WAY TO EITHER SIDE OF THE FRAME.

Figure 2: A close-up illustration of a vehicle's frame rail and the upper bracket. It highlights that the shorter end of the upper bracket must be positioned flush against the underside of the frame rail for correct alignment.

Figure 3: A diagram showing a vehicle's frame rail with an upper bracket positioned on it. A drill is depicted indicating the location to center punch and drill a 1/2 inch hole into the side of the frame rail for mounting the bracket.

3. Recheck the alignment. Using the slots in the lower bracket, align the air spring so that it is square, vertically and horizontally, to the upper bracket.
4. Tighten the air spring mounting bolts to 20 ft.lbs. Attach the upper bracket using one 1/2"-13 x 1.5" bolt (J), one 1/2" flat washer (K), one 1/2" lock washer (L), and one 1/2" hex nut (M). Only one bolt is required to secure the bracket to the frame.

Installing Other Air Spring

1. Installation for one air spring is now complete. Continue by repeating the steps in Assembling the Air Assembly, Attaching the Lower Bracket, and Attaching the Upper Bracket for the other side.
2. Proceed to Installing the Air Lines when the second air spring is installed.

Installing the Air Lines

1. Choose a convenient location for mounting the inflation valves. Popular locations include wheel well flanges, stowage areas, or under the body flange. Ensure there is enough clearance around the inflation valves for an air chuck.
2. Drill a 5/16" hole to install the inflation valves.
3. Cut the air line assembly (AA) in two equal lengths. ⚠️ CAUTION: 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, AS THESE TOOLS MAY FLATTEN OR CRIMP THE AIR LINE, CAUSING LEAKAGE AROUND THE O-RING SEAL INSIDE THE ELBOW FITTING.
4. Place a 5/16” nut (GG) and a star washer (FF) on the air valve. Leave enough of the valve in front of the nut to extend through the hole and have room for the rubber washer (EE), flat washer (DD), and a second 5/16" nut (GG) and cap (CC). Approximately 1/2" of the valve should be exposed after installation for easy access with a pressure gauge or air chuck (Figure 4).
5. Push the inflation valve through the hole and use the rubber washer (EE), flat washer (DD), and another 5/16" nut (GG) to secure it in place. Tighten the nuts to secure the assembly (Figure 4).

Figure 4: An illustration detailing the installation of an inflation valve. It shows the valve passing through a hole in the vehicle body or bumper, secured by nuts and washers (including a rubber washer and flat washer). The air line connects to the valve's fitting, with a cap shown. The diagram indicates approximately 1/2 inch of the valve should extend outward for access.

6. Route the air line along the frame to the air fitting on the air spring (Figure 5). Keep at least 6" of clearance between the air line and heat sources, such as exhaust pipes, mufflers, or catalytic converters. Avoid sharp bends and edges. Use the plastic tie straps (BB) to secure the air line to fixed, non-moving points along the chassis. Ensure tie straps are tight but do not pinch the air line. Leave at least 2" of slack for movement.

Figure 5: A diagram illustrating two options for routing the air line from the inflation valve to the air spring. It shows the air line running along the vehicle's chassis, with a note to maintain at least 6 inches of clearance from heat sources like the exhaust. Plastic tie straps are shown for securing the line.

7. On the exhaust side only, place the provided thermal sleeve (P) on the air line near the exhaust.
8. Cut off air line, leaving approximately 12" of extra air line. A clean square cut will ensure against leaks. Insert the air line into the push-to-connect air 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).

Checking For Leaks

1. Inflate the air spring to 60 p.s.i. and spray all connections and the inflation valves with a solution of 1/5 liquid dish soap and 4/5 water to check for leaks. Leaks will be spotted by looking for bubbles in the soapy water.
2. After the test, deflate the springs to the minimum pressure required to restore the Normal Ride Height, but not less than 20 p.s.i.

IMPORTANT: Check the air pressure again after 24 hours. A 2 to 4 p.s.i. 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. Ensure the cut is clean and square. Reinsert the air line into the push-to-connect fitting.
   • b. Check the threaded connection by tightening the swivel fitting another 1/2 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, then use a wrench for an additional two turns.
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 connection by removing the air line from the barbed type fitting.

⚠️ CAUTION: DO NOT CUT IT OFF. AS THIS WILL USUALLY NICK THE BARB AND RENDER THE FITTING USELESS. CUT AIR LINE OFF A FEW INCHES IN FRONT OF THE FITTING AND USE A PAIR OF PLIERS OR VISE-GRIPS TO PULL/TWIST THE AIR LINE OFF THE FITTING.

Before Operating

Installation Checklist (To be completed by installer)

• ✔️ Clearance test: Inflate the air springs to 60 PSI and ensure there is at least 1/2" clearance around each bellow, away from anything that might rub against them. 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. All leaks must be eliminated before the vehicle is road tested.
• ✔️ Heat test: Ensure sufficient clearance from any heat sources (at least 6" for air springs and air lines). If a heat shield was included, install it. If no heat shield is present 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: Road test the vehicle 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 with the owner. Provide the owner with all accompanying paperwork.

Technician's Signature: ________________________ Date: ______________

Post-Installation Checklist

• ✔️ Overnight leak down test: Recheck air pressure after 24 hours of use. If pressure dropped more than 5 PSI, a leak must be fixed.
• ✔️ Air pressure requirements: Regardless of load, air pressure should always be adjusted to maintain ride height.
• ✔️ 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 relocation is not possible, the air spring may need remounting. Consult the installer if professionally installed. Check all fasteners for tightness.

Product Use, Maintenance and Servicing

⚠️ CAUTION: FAILURE TO MAINTAIN CORRECT MINIMUM PRESSURE (OR PRESSURE PROPORTIONAL TO LOAD), BOTTOMING OUT, OVER-EXTENSION OR RUBBING AGAINST ANOTHER COMPONENT WILL VOID THE WARRANTY.

Maintenance Guidelines

By following these steps, vehicle owners will obtain the longest life and best results from their air springs.

1. Check the air pressure weekly.
2. Always maintain normal ride height. Never inflate beyond 100 PSI.
3. If an air leak develops, 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.

⚠️ CAUTION: 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. 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 as necessary to attain normal ride height for optimal ride and handling. 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, ensure the system is at minimum pressure (40 PSI) to reduce tension on suspension/brake components. Use of on-board leveling systems does 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 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 ensure none are pinched. Tie straps may be too tight; loosen or replace the strap and replace leaking components.
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 may be caused by a failed air spring (factory defect or 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?
  A: 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?
  A: The minimum air pressure should be maintained at all times. This keeps the air spring in shape, ensuring it moves throughout its travel without rubbing or wearing on itself.
• Q: Is it necessary to add a compressor system to the air springs?
  A: No. Air pressure can be adjusted with any type of compressor that can produce sufficient pressure. Even a bicycle tire pump can be used, though it requires significant effort.
• 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 for short-term service work (e.g., tire rotation, oil changes). However, for prolonged periods on a hoist, support the axle with jack stands to take tension off the air springs.

Tuning the Air Pressure

Pressure determination is based on three factors: level vehicle, ride comfort, and stability.

1. Level vehicle: If the vehicle's headlights are shining into the trees or it is leaning to one side, it is not level (Figure 2.1). Raise the air pressure to correct these issues and level the vehicle.
2. Ride comfort: A rough or harsh ride may be due to too much or too little pressure (Figure 2.2). Experiment with different pressures to find the best ride comfort.
3. Stability: Stability translates to safety and should be the priority, potentially requiring a sacrifice in ride comfort. Stability issues include roll control, bounce, dive during braking, and sponginess (Figure 2.3). Tuning out these problems usually requires an increase in pressure.

Figure 2.1: Illustration of a truck with its front end lifted high and headlights pointing upwards, indicating an unlevel condition.

Figure 2.2: Illustration of a vehicle experiencing significant bouncing and jarring, representing a rough ride.

Figure 2.3: Illustration of a vehicle leaning heavily to the side during a turn, depicting sway and body roll.

Guidelines for Adding Air

1. Start with the vehicle level or slightly above.
2. When in doubt, always add air.
3. If the front of the vehicle dives while braking, increase the pressure in the front air bags, if equipped.
4. If it is suspected that the air bags have bottomed out, increase the pressure (Figure 2.4).
5. Adjust the pressure up and down to find the best ride.
6. If the vehicle rocks and rolls, adjust the air pressure to reduce movement.
7. It may be necessary to maintain different pressures on each side of the vehicle. Loads such as water, fuel, and appliances can cause the vehicle to be heavier on one side (Figure 2.5). A difference of as much as 50 PSI is not uncommon.

Figure 2.4: Illustration showing a vehicle's suspension compressed to its lowest point, indicating the air springs have bottomed out.

Figure 2.5: An illustration comparing three vehicle states: one leaning to the left, one leaning to the right, and one perfectly level.

Choosing the Right On-Board Air Compressor System

Add an on-board air compressor system to inflate and deflate your air springs with the touch of a button – from inside or outside of the vehicle.

• For convenient, on-the-go control of your air springs, add an Air Lift on-board air compressor system.
• Air Lift on-board air compressor systems eliminate the search for gas stations with working compressors, saving you time, energy, and money.
• All systems include a compressor, controller, and all parts needed for easy installation.

1. Choose single or dual path inflation (see illustrations below).

2. Choose wireless or analog control:

• Wireless: Control your air springs from inside or outside the vehicle. Easiest installation – no wires to the cab.
• Analog: In-cab control of your air springs. Economically priced.

3. Choose heavy or standard duty compressor:

• Standard duty: A standard duty compressor works well for most customers who use their system on an intermittent basis.
• Heavy duty: For daily use, consider the heavy duty compressor – it inflates faster and more quietly than the standard compressor.

Dual path systems: Air springs are controlled separately, allowing for different air pressure from side-to-side. Perfect for uneven or top-heavy loads.

Single path systems: Two springs inflate at the same time. Good for loads that are evenly distributed from left-to-right or front-to-back.

Wireless Systems

• WirelessAIR™ (Our Premium System!)
  • Easy installation
  • Includes heavy duty compressor
  • P/N 72000
• WirelessONE™
  • Easy installation
  • Includes standard duty compressor
  • P/N 25870

Analog Systems

• LoadCONTROLLER™ Dual
  • Compact, economically priced control.
  • P/N Standard Duty Compressor 25850; P/N Heavy Duty Compressor 25854
• LoadCONTROLLER™ Single
  • Compact, economically priced control.
  • P/N Standard Duty Compressor 25852; P/N Heavy Duty Compressor 25856

Warranty and Returns Policy

Information regarding the warranty and returns policy is typically found in a separate section or document. Please refer to the official Air Lift documentation for details.

Replacement Information

For replacement parts or further assistance, please contact Air Lift directly or consult your authorized dealer.

Contact Information

For inquiries, support, or to order replacement parts, please contact:

Air Lift Company
1245 North 7th Street
St. Joseph, MI 49085
Phone: (800) 248-0892
Website: www.airliftcompany.com