Air Lift LoadLifter 5000

Getting Started

1. Raise the vehicle, remove the wheels, and support the axle with jackstands. Obtain the normal ride height.
2. Remove the jounce bumper and bracket from the side of the frame above the leaf spring (Figure 2). This illustration shows the location on the vehicle's frame above the leaf spring where the jounce bumper and its bracket should be removed.

Assembling the Air Spring

1. Set a roll plate (D) on both ends of the air spring (A). The radiused (rounded) edge of the roll plate will be towards the air spring so that the air spring is seated in both roll plates (Figure 1).
2. Install a 90° swivel air fitting (E) finger tight plus 1 1/2 turns (Figure 1). Do not overtighten.
3. Place the upper bracket (B) onto the top of the bellows and roll plate with the legs facing down.
4. Set the air spring on the lower bracket (C) aligning the two holes in the base of the air spring with the two outer slots in the top of the lower bracket (Figure 1).
5. Loosely attach the upper bracket to the assembly using flat washers (H), lock washers (I), and hex head bolts (L). Remember that the legs face down (Figure 1).
6. Loosely attach the lower bracket to the assembly using flat washers (H), lock washers (I), and hex head bolts (L) (See Figure 1).

Attaching the Lower Bracket

1. Set the assembly over the center spring retainer. Install two spacers (M) between the lower bracket and the spring (Figure 1).
2. Bolt the lower bracket (C) to the spring using two U-bolts (F), four flat washers (H), and four nyloc nuts (G) (Figure 5). Torque to 16 ft.lbs.
3. Trim the inside U-bolt if necessary to keep the bolt from hitting the upper bracket (Figure 3). This illustration shows a U-bolt used for attaching the lower bracket, with an arrow indicating trimming the inside U-bolt to prevent it from interfering with the upper bracket.

Attaching the Upper Bracket

CAUTION: BEFORE DRILLING, CHECK THE BACK-SIDE OF THE FRAME FOR CLEARANCE ISSUES WITH THE BRAKE LINES, GAS LINES, AND ELECTRICAL LINES. ANY OBSTACLES WILL NEED TO BE TEMPORARILY RELOCATED TO CLEAR THE AREA.

1. Position the upper bracket (B) so that it is parallel with the lower bracket and align the assembly vertically and horizontally.

NOTE: Mount the upper bracket as high on the frame as possible. There should be a minimum of 6 inches between the upper and lower brackets (Figure 4). The top two holes may be above or even with the frame. If this is the case, use the two lower holes in the upper bracket for mounting. Figure 4 depicts the upper bracket mounted to the vehicle's frame, emphasizing mounting the bracket as high as possible and maintaining a minimum clearance of 6 inches between the upper and lower brackets. It also shows that the top mounting holes might be above or even with the frame, suggesting the use of lower holes if necessary.

2. Using the upper bracket as a template, center punch and drill one 3/8" locator hole through the frame (Figure 1).
3. Attach a hex washer head frame bolt (K), oversize washer (J), and nyloc nut (G). Do not overtighten. Adjust both sides, X and Y, so that they are the same (Figure 5). Figure 5 shows the lower bracket attached to the axle's leaf springs with U-bolts (F), washers (H), and nuts (G), indicating that the distance between the upper and lower brackets (labeled X and Y) must be 6-8 inches and equal on both sides.
4. Drill the remaining holes. Install the appropriate hardware and torque the nuts to 44 ft.lbs.

Securing the Air Spring to the Brackets

1. Align the bellows (A) in and out so that they are perpendicular to the upper and lower brackets (Figure 5). NOTE: Keep a finger's width between the roll plate (D) and frame (Figure 6). Figure 6 illustrates the air spring assembly secured between the upper and lower brackets, with a note highlighting the importance of keeping a finger's width of clearance between the roll plate (D) and the vehicle's frame.
2. Tighten both upper and lower bellows mounting bolts. Torque to a maximum of 20 ft.lbs.

Relocating the Jounce Bumper

1. The jounce bumper must be relocated under the frame above the axle. First, remove the jounce bumper from the stock bracket.
2. Drill a 3/8" hole above the axle, in the bottom of the frame flange (Figure 7). Figure 7 shows a side view of the vehicle's frame and axle, indicating drilling a 3/8" hole in the bottom of the frame flange above the axle to attach the relocated jounce bumper.
3. Mount the jounce bumper under the frame using O.E.M. hardware. Tighten securely (Figure 8). Drop the axle slightly if necessary to position the jounce bumper between the frame and axle (Figure 8). Figure 8 depicts the jounce bumper mounted under the frame, positioned between the frame and the axle, suggesting dropping the axle slightly if needed to achieve the correct positioning.

Installing the Air Lines

NOTE: When installing the air lines, there must be at least six inches of clearance between the air lines and any heat sources.

1. Choose a convenient location for mounting the inflation valves. Popular locations include: The wheel well flanges; The license plate recess in bumper; Under the gas cap access door; Through license plate (Figure 11). Whatever the chosen location, 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. WHEN CUTTING OR TRIMMING THE AIR LINE, USE A HOSE CUTTER (AIR LIFT P/N 10530), 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 (FIGURE 9). Figure 9 illustrates two methods of cutting air line: a "Good Cut" showing a clean, square cut, and a "Poor Cut" showing a jagged or crimped cut, emphasizing that a clean cut is crucial for preventing leaks, and wire cutters or scissors should not be used.
4. Install the inflation valves as shown in Figure 10. Figure 10 shows the components of the inflation valve assembly being installed, depicting the vehicle body or bumper, the inflation valve (CC), rubber washer (EE), flat washer (DD), and nut (GG), with the air line connected to the valve.
5. 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. Leave at least 2" of slack when securing the air lines to allow for any movement that might pull on the air line (Figure 11). Figure 11 illustrates two options for securing the air lines to the vehicle using provided tie straps, emphasizing maintaining at least 6 inches of clearance from heat sources and leaving approximately 2 inches of slack to accommodate vehicle movement.
6. Cut off air line leaving approximately 12" of extra air line. Insert the air line into the 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 30 p.s.i.
2. Spray all connections and the inflation valves with a solution of 1/5 liquid dish soap and 4/5 water to check for leaks. You should be able to 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 Normal Ride Height, but not less than 10 p.s.i. 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, then:
   • 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. 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, then:
   • 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. 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.
3. If the preceding steps have not resolved the problem, call Air Lift Technical Service at 1-800-248-0892 for assistance.

Before Operating

Installation Checklist (To be completed by installer)

• Clearance test: Inflate the air springs to 60 PSI and ensure there is at least 1½" 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: ______________

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: Regardless of load, the air pressure should always be adjusted to maintain ride height at all times.
• Thirty day or 500 mile test: 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.

Product Use, Maintenance and Servicing

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 the steps below, 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 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.
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

1. 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.
2. 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. The minimum air pressure keeps the air spring in shape, ensuring that it will move throughout its travel without rubbing or wearing on itself.
3. 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 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.
4. Q: How long should air springs last?
   A: If the air springs are properly installed and maintained, they can last indefinitely.
5. 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 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 (Figure 2.1). Raise the air pressure to correct either of these problems and level the vehicle. Figure 2.1 shows a vehicle with headlights aimed too high, indicating a leveling issue.
2. Ride comfort: If the vehicle has a rough or harsh ride, it may be due to either too much pressure or not enough (Figure 2.2). Try different pressures to determine the best ride comfort. Figure 2.2 shows a vehicle with a rough ride.
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 (Figure 2.3). Tuning out these problems usually requires an increase in pressure. Figure 2.3 shows a vehicle experiencing sway and body roll, indicating stability issues.

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 ever suspected that the air bags have bottomed out, increase the pressure (Figure 2.4). Figure 2.4 illustrates a vehicle that appears to be "bottoming out," suggesting a need for more air pressure.
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 will cause the vehicle to be heavier on one side (Figure 2.5). As much as a 50 PSI difference is not uncommon. Figure 2.5 shows a vehicle that is "unlevel" and then "level," illustrating how uneven loads can require different air pressures on each side.

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 that have a working compressor, 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). Dual path systems allow separate control of air springs for different air pressure side-to-side, ideal for uneven or top-heavy loads. Single path systems inflate both springs simultaneously, suitable for evenly distributed loads.

2. Choose wireless or analog control. Wireless offers control from inside or outside the vehicle with easy installation. Analog provides in-cab control and is economically priced.

3. Choose heavy or standard duty compressor. Standard duty is suitable for intermittent use, while heavy duty inflates faster and more quietly for daily use. Visit www.airliftcompany.com for more detailed information on compressor systems.

Warranty and Returns Policy

Air Lift Company warrants its products to the original retail purchaser against manufacturing defects for the time periods listed below, 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, installed, used in racing or off-road applications, used for commercial purposes, or not maintained according to installation instructions. The consumer is responsible for removing the defective product and returning it, transportation costs prepaid, to the dealer or Air Lift Company for verification.

Air Lift will repair or replace defective products or components at its option. A minimum $10.00 shipping and handling charge applies to all warranty claims. Before returning any defective product, call Air Lift at (800) 248-0892 (U.S. and Canada) or (517) 322-2144 (elsewhere) for a Returned Materials Authorization (RMA) number. Returns can be sent to: Air Lift Company, 2727 Snow Road, Lansing, MI 48917.

Product failures from abnormal use or misuse are excluded. Loss of use, time, inconvenience, commercial loss, or consequential damages are not covered. The consumer is responsible for installation/reinstallation labor charges. Air Lift Company reserves the right to change product designs without obligation to modify previously manufactured products.

This warranty grants specific legal rights, and you may have other rights that vary by state. Some states do not allow limitations on implied warranty duration or exclusion of incidental/consequential damages. The above limitations may not apply to you. There are no warranties, expressed or implied, including implied warranties of merchantability and fitness, that extend beyond this warranty period or the description on the face hereof. Seller disclaims the implied warranty of merchantability. (Dated proof of purchase required.)

*formerly SuperDuty
**formerly LifeSTYLE & Performance, EasyStreet

Replacement Information & Contact 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.

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 sales@airliftcompany.com or on the web at www.airliftcompany.com.

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