Air Lift Ride Control 59516 User manual

For maximum effectiveness and safety,
pleasereadtheseinstructionscompletely
before proceeding with installation.
Failure to read these instructions can result in an
incorrect installation.
MN-282 • (121305) • ECR 7644
INSTALLATION GUIDE
Kit 59516
™

Introduction ....................................... 2
Important Safety Notice .............................................2
Notation Explanation ................................................2
Installation Diagram ................................3
Hardware List .....................................................4
Tools List.........................................................4
Getting Started.....................................4
Important Notes....................................................4
Normal Ride Height .................................................5
Assembling the Installation Tool .......................................5
Installing the RideControl System.....................5
Attaching the Assembly..............................................5
Installing the Air Lines ...............................................7
Aligning the Air Spring...............................................8
Checking for Leaks .................................................8
Fixing Leaks ......................................................8
Maintenance and Servicing ..........................9
Minimum and Maximum Pressure......................................9
Maintenance Guidelines .............................................9
Warranty and Return Policy ..........................9
Replacement Information ............................10
Contact Information ................................10
TABLE OF CONTENTS
1

2MN-282
Introduction
The purpose of this publication is to assist with the installation and maintenance RideControl
air spring kit. The air springs used in RideControl kits are designed and manufactured like
a tire. The air springs have layers of rubber and cords that control the bag’s growth and
funnel it into one direction. The bags do not require a coil spring for control. RideControl
kits utilize a sleeve style air bag that provides up to 2,000 pounds of load-leveling support.
Each sleeve is rated at a maximum of 100 p.s.i.
Itisimportanttoreadandunderstandtheentireinstallationguidebeforebeginninginstallation
orperforming any maintenance,service orrepair.The information hereincludes ahardware
list, tool list, step-by-step installation information, maintenance tips and safety information.
Air Lift Company reserves the right to make changes and improvements to its products and
publications at any time. Contact Air Lift Company at [phone] or visit us online at
www.airliftcompany.com for the latest version of this manual.
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 ination pressure data — is shown on the vehicle’s Safety Compliance
Certication 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
orpossible improper installation whichmayrenderthevehicle unsafe. Notesare usedto help
emphasize areas of procedural importance and provide helpful suggestions. The following
denitions explain the use of these notations as they appear throughout this guide.
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.
Indicates a procedure, practice or hint which is important to highlight.
DANGER
NOTE
WARNING
CAUTION
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Installation Diagram
FORWARD
OUTBOARD
g. 1
¼ Push-in elbow
Nylon nut
Star washer
3/8”-16 X 1.5”
Frame bolt
Upper bracket
Lower bracket
Air sleeve
3/8”-16
Lock nut
3/8” Flat
washer
Flat washer
3/8”-16 Lock nut
½” HHCS bolt
½” Flat washer
3/8” U-bolt
NOTE: The lower
bracket must be
installed with the
flat edge inboard.
Spacer (optional)
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TOOLS LIST
Description..............................................Qty
Hoist or oor jacks................................................1
Safety stands........................................................ 2
Safety glasses...................................................... 1
Torque wrench......................................................1
5/16” open-end or box wrench.............................. 1
7/16” open-end or box wrench.............................. 1
9/16” open-end or box wrench.............................. 1
Crescent wrench...................................................1
Description..............................................Qty
Ratchet with 9/16”, metric, & 1/2” deep well
sockets .................................................................1
3/8” and 5/16” drill bits (very sharp)...................... 2
Heavy duty drill.....................................................1
Hose cutter, razor blade, or sharp knife ............... 1
Air compressor or compressed air source............ 1
Spray bottle with dish soap/water solution ........... 1
Item Part # Description................................Qty
A 58987 Air spring.............................................2
B07475 Upper bracket .....................................2
C03102 Lower bracket .....................................2
D 10591 Installation tool....................................1
E33606 ¼” Elbow.............................................2
F 10583 3/8” U-bolt ...........................................4
G 18414 ½” Flat washer ....................................2
H 17124 Hex head cap screw bolt.....................2
I 01525 Spacer.................................................4
J 18435 3/8”-16 Nyloc nut................................16
Item Part # Description...............................Qty
K 18444 3/8” Flat washer ..................................8
L 18454 Jam nut...............................................1
M 18450 Lock washer........................................2
N 17159 3/8”-16 x 1.5 Frame bolt......................8
O20086 Air line assembly.................................1
P 21230 Valve cap ............................................2
Q 18405 5/16” Flat washer ................................2
R21234 Rubber washer....................................2
S 18411 Star washer.........................................2
T 21233 5/16” Hex nut ......................................4
HARDWARE LIST
Missing or damaged parts? Call Air Lift customer
service at [phone] for a replacement part.
Getting Started
IMPORTANT NOTES
1. Your vehicle may be equipped with a rear brake proportioning valve. Any type of load
assist suspension product could effect brake performance. We recommend that you
check with your dealer before installing this type of product. If your vehicle does not have
a proportioning valve or is equipped with an anti-lock brake system, no adjustment or
modication is required.
2. Before proceeding with installation, measure the opening from the frame rail to the brake
drum or the tire, which ever is closest to frame. The measurement must be a minimum
of 7 inches (g. 2). If spacing is good, remove rear wheels and support frame with safety
stands.
g. 2
7” Minimum
7” Minimum
Brake drum
This kit is designed as an “universal
t” side-mount kit. Some vehicles
may not have sufcient clearance
between the frame and the tire, or
the brake drum and the frame. Before
attempting to install this kit, check to
be sure thre is a MINIMUM clearance
of 7” between the tire and frame or
the brake drum and frame. Clearance
of less than 7” could result in damage
to the tire and/or air spring and void
the warranty.
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Installing the RideControl System
NORMAL RIDE HEIGHT
This is dened as the distance between the bottom edge of the wheel well to the center
point of the wheel with the vehicle in an “as delivered condition” (without a load, i.e. tool box,
camper, etc.) measurements should be taken before beginning the installation. The distance
from the bottom edge of the wheel well to the center point of the wheel should be recorded.
All of our kits are designed to be installed and operated at normal ride height.
1. Raise axle or lower frame until leaf spring is in the normal ride height (no load)
position.
2. Check the distance between the center of the hub and the bottom edge of the wheel well
to ensure that it is at the normal ride height measurement taken above. If not, raise the
frame or lower the axle as necessary to restore the original distance. The vehicle must
be at normal ride height before installing the upper bracket.
ASSEMBLING THE INSTALLATION TOOL
1. Assemble the upper and lower bracket to the alignment tool. This tool is designed to help
you properly install the kit for correct height and alignment. The range of adjustment to
attain the correct mounted height is determined by the upper threaded section of the
tool. The kit may be mounted anywhere in that range (g. 3).
2. Place the upper bracket “legs down” onto the threaded end of the tool resting on the
bottom nylon nut. Then thread a second nylon nut onto the tool to hold the bracket in
place. Leave loose for later adjustment. (g. 3).
3. Use the ½” x 7/8” hex head bolt and at washer to attach the lower bracket to the bottom
of the installation tool with the open edge of the lower bracket toward the legs of the
upper bracket. Leave loose enough to adjust in and out (g. 3).
ATTACHING THE ASSEMBLY
1. Set the assembly on the leaf spring centered over the axle.
2. Using the slot in the lower bracket, push the upper bracket against the frame rail. Use
the nylon nuts on the threaded portion of the installation tool to adjust the upper bracket
so that the anges of the upper bracket are at against the frame rail and at least four
mounting holes are on the at middle section of the frame rail. Do not drill any holes
on the upper or lower radiused edge of the frame rail. You must also allow at least 1.5”
above the upper bracket for air tting clearance. The brackets can be mounted anywhere
within the threaded range of the installation tool.
Upper bracket
Lower bracket
Nylon nut
Flat washer
Hex head bolt
g. 3
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If the upper bracket cannot be positioned in the middle of the frame, when the assembly is
set onto the axle, using the threaded portion of the tool (ie. bracket falls short but is at the
top of the threads) use the optional spacers noted in g. 1 to raise the assembly back up so
the threaded usable portion of the tool can be used to position the bracket correctly on the
frame. Be sure to leave 1.50” above the bracket for valve clearance as stated.
CAUTION
NOTE
3. Attach the lower bracket as shown in g. 4 using the u-bolts, at washers and lock nuts.
Tighten nuts to 20 ft/lbs.
The frame has an indented area directly over the axle. Normally the upper bracket will span
this indented area. If the ange of the upper bracket falls onto or just inside the radiused
edges of the indent, it is ok. Drill and fasten tight to that rounded surface (g. 5).
DO NOT DRILL HOLES INTO THE FRAME UNTIL ANY HYDRAULIC LINES, GAS LINE AND
ELECTRICAL WIRES HAVE BEEN MOVED ASIDE ON BOTH SIDES OF FRAME RAIL.
4. Using the upper bracket as a template, centerpunch one of the lower mounting holes
and drill a 3/8” hole through the frame. Install one of the mounting bolts and LOOSELY
attach the oversized at washer and locknut. Now centerpunch and drill a 3/8” hole at the
other lower mounting hole location. DO NOT insert the mounting bolt at this time (g. 4).
5. You can now remove the installation tool by removing the upper nylon nut, loosening and
removing the tool from the bottom bolt (leave in place), and slightly rotating the upper
bracket to give you enough room to completely remove the tool.
6. Rotate the upper bracket back to the original location and install the frame bolt, oversized
at washer and locknut through the second hole you drilled. Now tighten both of the
installed fasteners to 20 ft/lbs. Drill the other two holes and install the fasteners. Torque
to 20 ft/lbs (g. 6).
OUTBOARD
g. 4
U-bolt
Nyloc nut
Flat washer
3/8” Frame bolt Nyloc nut
Flat washer
g. 5
Upper bracket
Indented area
NOTE
g. 6
Elbow tting Air spring
3/8” Frame bolt
Nylon nut
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7. Install the elbow tting into air port of the air sleeve. The tting is precoated with thread
sealant. Tighten nger tight plus two turns. Use a 7/16” open end wrench being careful
to tighten on the metal hex nut only. Do not overtighten (g. 6).
8. Guide upper thread post/tting through the center mounting hole in the upper bracket (g. 6).
9. Attach the air spring to the lower bracket by carefully hand turning the air spring onto
the lower mounting bolt. LEAVE LOOSE for later adjustment (g. 6).
10. Now install the nylon nut onto the upper thread post of the air spring. LEAVE LOOSE for
nal adjustment (g. 6).
11. Repeat procedure for other side of vehicle.
INSTALLING THE AIR LINES
1. Choose a convenient location for mounting the ination valves. Popular locations for the
ination valve are:
a. The wheel well anges.
b. License plate recess in bumper.
c. Under the gas cap access door.
d. Through license plate itself.
What ever the chosen location is, make sure there is enough clearance around the ination
valves for an air chuck.
2. Drill a 5/16” hole to install the ination valves.
3. Cut the air line assembly in two equal lengths.
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. 7)
4. Place a 5/16” nut and a star washer on the air valve. Leave enough of the ination valve
in front of the nut to extend through the hole and have room for the rubber washer, at
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 (g. 8).
Good Cut Poor Cut
g. 7
g. 8
Air line
Star washer
5/16” Nut
Vehicle body
or bumper
Rubber washer
Valve cap
Flat washer
5/16” nut
CAUTION
NOTE
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5. Push the ination valve through the hole and use the rubber washer, at washer, and
another 5/16” nut. Tighten the nuts to secure the assembly in place (g. 8).
6. Route the air line along the frame to the air tting on the air spring (g. 9). Keep AT
LEAST 6” of clearance between the air line and heat sources, such as the exhaust pipes,
mufer, or catalytic converter. Avoid sharp bends and edges. Use the plastic tie straps
(BB) to secure the air line to xed, 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.
7. Cut off air line leaving approximately 12” of extra air line. A clean square cut will ensure
against leaks (see g. 7). Insert the air line into the air tting. This is a push to connect
tting. Simply push the air line into the 90° swivel tting until it bottoms out (9/16” of air
line should be in the tting).
ALIGNING THE AIR SPRING
1. VERY IMPORTANT - With the top and bottom still loose, inate the air springs to
approximately 10 p.s.i. Use the slots in the brackets to correctly align the air spring
between the upper and lower brackets. This can be accomplished by tapping it inboard
or outboard for proper alignment. There should be symmetrical cushion of air around
the base of the air spring when correctly positioned.
CHECKING FOR LEAKS
1. Inate the air spring to 30 p.s.i. and spray all connections and the ination valves with
a solution of 1/5 liquid dish soap and 4/5 water to check for leaks. Spot leaks easily by
looking for bubbles in the soapy water.
2. After the test, deate the springs to the minimum pressure required to restore the normal
ride height, no less than 5 p.s.i.
3. Check the air pressure again after 24 hours. A 2-4 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 tting:
a. Check the air line connection by deating the spring and removing the line by pulling
the collar against the tting and pulling rmly on the air line. Trim 1” off the end of
the air line. Be sure the cut is clean and square (see g. 7). Reinsert the air line into
the push-to-connect tting.
b. Check the threaded connection by tightening the swivel tting another ½ turn. If it still
leaks, deate the air spring, remove the tting, 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 ination 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 tting.
Option 1
Option 2 g. 9
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DO NOT CUT THE AIR LINE COMPLETELY OFF AS THIS WILL NICK THE BARB AND
RENDER THE FITTING USELESS.
3. If the preceding steps have not resolved the problem, call Air Lift customer service at
[phone] for assistance.
MAINTENANCE GUIDELINES
By following these steps, vehicle owners will obtain the longest life and best results from their
air spring.
1. Check the air pressure weekly.
2. Always maintain normal ride height. Never inate beyond 100 p.s.i.
3. If you develop an air leak in the system, use a soapy water solution to check all air line
connections and the ination valve core, before deating and removing the spring.
4. When increasing load, always adjust the air pressure to maintain 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.
FOR YOUR SAFETY AND TO PREVENT 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
DEPENDENT ON YOUR LOAD AND GVWR.
5. Always add air to the springs in small quantities, checking the pressure frequently. Sleeves
require less air volume than a tire and inate quickly.
6. Should it become necessary to raise the vehicle by the frame, make sure the system is
at a minimum pressure (5 p.s.i.) to reduce tension on the suspension/brake components.
Use of on-board leveling systems do not require deation or disconnection.
NOTE
CAUTION
Maintenance and Servicing
5 p.s.i. 100 p.s.i.
FAILURE TO MAINTAIN CORRECT MINIMUM PRESSURE (OR PRESSURE
PROPORTIONAL TO LOAD), BOTTOMING OUT, OVER-EXTENSION OR RUBBING
AGAINST ANOTHER COMPONENT WILL VOID THE WARRANTY.
Maximum Air PressureMinimum Air Pressure
CAUTION
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 verication.
Warranty and Returns Policy
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10 MN-282
Replacement Information
If you need replacement parts, contact the local dealer or call Air Lift customer service at
[phone]. Most parts are immediately available and can be shipped the same day.
Contact Air Lift Company customer service at [phone], rst 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 [phone], Monday through Friday. For calls from outside
the USA or Canada, our local number is [phone].
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.
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 [phone] in the U.S. and Canada
(elsewhere, [phone]) for a Returned Materials Authorization (RMA) number. Returns
to Air Lift can be sent to: Air Lift Company • 2727 Snow Road • Lansing, MI • 48917.
Productfailuresresultingfromabnormaluseormisuseareexcludedfromthis 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 tness, 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.)
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 EasyStreet and LifeSTYLE & Performance
RideControl

Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or PO Box 80167 • Lansing, MI 48908-0167
Toll Free [phone] • Local [phone] • Fax [phone] • www.airliftcompany.com
Thank you for purchasing Air Lift products — the professional installer’s choice!
Printed in
the USA
Need Help?
Contact our customer service department by calling
[phone], Monday through Friday. For calls
from outside the USA or Canada, our local number
is [phone].
Register your warranty online at
www.airliftcompany.com/warranty