Air Lift 1000 User manual

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.
MN-715 • (041705) • ECR 8760
INSTALLATION GUIDE
Cover illustration
may not depict
actual kit.
Kit 60821
Ford D3 & D4 Chassis
front-wheel and
all-wheel drive

2MN-715
Air Lift 1000

1
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Air Lift 1000
TABLE OF CONTENTS
1
Introduction ................................... 2
Important Safety Notice .............................................2
Notation Explanation ................................................2
Installing the Air Lift 1000 System .....................3
Preparing the Vehicle ...............................................3
Tee Air Line Routing ................................................5
Dual Air Line Routing................................................7
Completing the Installation ...........................................7
Checking for Leaks .................................................8
Fixing Leaks ......................................................8
Maintenance and Servicing ..........................9
Maintenance Guidelines .............................................9
Operating Tips .....................................................9
Troubleshooting Guide ..............................................9
Product Use .......................................10
Frequently Asked Questions ..........................................10
Tuning the Air Pressure ..............................................10
Guidelines for Adding Air .............................................11
Limited Warranty and Return Policy .................. 12
Replacement Part Information ....................... 12
Contact Information ................................12
Kit 60821 Template .................................13

2MN-715
Air Lift 1000
Introduction
The purpose of this publication is to assist with the installation, maintenance and
troubleshooting of the Air Lift 1000 air spring kit.
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, tools 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. Contact Air Lift Company at [phone] or go 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 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 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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Air Lift 1000
Item Part # Description.....................................Qty
A 46135 Air spring.................................................... 2
B 20937 Hose 15’ (4.6m).......................................... 1
C 10466 Zip tie ......................................................... 6
D 21230 Valve cap ................................................... 2
E 21233 5/16” Hex nut ............................................. 4
F 21234 Rubber washer........................................... 2
G 18411 Star washer................................................ 2
H 18501 M8 Flat washer .......................................... 2
I 21236 Tee ............................................................. 1
J 21455 Valve .......................................................... 2
HARDWARE LIST TOOLS LIST
Description...................................................... Qty
Hoist ............................................................................... 1
Floor jack........................................................................ 1
Safety stands.................................................................. 2
Safety glasses ................................................................ 1
Standard sockets/ratchet and wrenches ........................ 1
Drill, drill bits ................................................................... 1
Pliers............................................................................... 1
Air compressor or compressed air source...................... 1
Spray bottle with dish soap/water solution ..................... 1
Installing the Air Lift 1000 System
g. 1
Safety stand
Axle
PREPARING THE VEHICLE
1. Jack up the rear of the vehicle or raise on a hoist. Support the frame with safety stands (g.
1). Disconnect the sway bar at the spindle and remove the lower shock mounting hardware
(g. 2). Lower the axle or raise the body of the vehicle until the suspension is fully extended.
OBSERVE TENSION ON BRAKE LINE/ABS LINE. DO NOT STRAIN.
Almost all of these applications have a hole in the upper spring seat, if you have a “plastic
plug” covering the hole in the upper spring seat, proceed with step 2. If you have an “open
hole” in the spring seat that you can see, move on to step 3 for further instructions.
g. 2
Disconnect Sway Bar
Disconnect Shock
If the upper spring seat has a “plastic plug”
in it covering the hole at the top, proceed
with step 2 to install this kit.
If you have an
open hole at the
top, move on to
step 3.
CAUTION
STOP! Missing or damaged parts? Call Air Lift customer
service at [phone] for a replacement part.
Missing or damaged parts? Call Air Lift customer
service at [phone] for a replacement part.

4MN-715
Air Lift 1000
2. It will be necessary to drill an access hole for the hose through the lower spring seat. Cut out
the hole template on page 13, cut out the circle size that best ts into the lower spring seat
pocket and paste it onto the lower spring seat with a dab of grease. Using the cross as a
guide, center punch and drill a 9/16” (14.5mm) hole (g. 3).
3. Remove the plastic cap from the barbed stem on the end of the air spring. Exhaust the air
from the air spring by rolling it up toward the barbed stem. Replace the cap on the stem to
hold the at shape (g. 4).
4. Insert the attened air spring into the coil spring through the lowest opening of the coil spring
with the stem pointed in the direction determined in step 2 (stem down if a plug is covering
the hole in the spring seat at the top, or up if the hole is open and accessible) (g. 5a or 5b).
5. Push the air spring up within the coil by hand or with a blunt instrument such as a spoon-type
tire iron (g. 5a or 5b).
6. When the air spring is completely within the coil, remove the cap and allow the air spring to
assume it’s “as molded” shape.
7. Push the cylinder to the top or bottom of the coil spring so that the stem will be accessible
allowing for the attachment of the hose. If the hose is routed through the top (had an open
hole) there are holes that are above the modular frame you will need to route the hose
through, to gain access to the upper spring mount hole for the stem. If necessary, use a
coat hanger to route the hose through this opening. Read through the hose installation
instructions rst before proceeding with these next steps.
g. 4
g. 3
Template
from page 13
Bottom View
of Lower Spring
Seat/Control Arm
Center Punch &
Drill 9/16” (14.5mm) Hole
g. 5a
Valve stem is
at the top if the
upper spring
seat hole is
accessible.
g. 5b
Valve stem is
at the bottom
if the upper
spring seat
hole is not
accessible
(has a plug).

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Air Lift 1000
TEE AIR LINE ROUTING
TO PREVENT THE AIR LINE FROM MELTING, MAINTAIN AT LEAST 8” FROM THE
EXHAUST SYSTEM TO THE AIR LINE.
1. Locate the desired tee location on the frame rail or cross member. Determine and cut
an adequate length of air line to reach from the tee to the left and right side air springs.
LEAVE SUFFICIENT AIR LINE SLACK TO PREVENT ANY STRAIN ON THE FITTING
DURING AXLE MOTIONS.
2. Slide an air line clamp onto the air line.
3. Push the air line over one side of the tee until all the barbs are covered. With a pair of
pliers, slide the air line clamp forward until it fully covers the barbed section. Repeat the
entire procedure for the other leg of the tee (g. 6).
4. Route the air line along the cross member and either the lower control arm or the upper
spring seat to the air spring.
5. Insert the air line through the upper spring seat.
A
BC
Use this procedure for all
air line connections:
a. Slide the air line clamp onto
the air line.
b. Push the air line over the
barbed stem.
c. Compress the ears on the
air line clamp with pliers and
slide it forward to fully cover
the barbed section.
g. 6
6. Push the air line onto the stem, covering all the barbs (g. 7). With the pliers, slide the
air line clamp upward until it fully covers the barbed section.
7. Push the remaining air line over the last tting on the tee and route it along the frame to
the desired ination valve location. Attach the air line with zip ties.
8. Select a location for the ination valve in the gas cap well, the trunk, rear bumper, fender
ange or behind the license plate, insuring that the valve will be protected and accessible
with an air hose (g. 8).
g. 7
Stem Air line
CAUTION
CAUTION

6MN-715
Air Lift 1000
9. Drill a 5/16” hole for the ination valve and mount as shown (g. 10). The rubber washer
serves as an outside weather seal.
10. Slide the air line clamp over the air line. Push the air line onto the tting covering all
barbs. Using pliers, slide the air line clamp forward until it fully covers the barbed section
(g. 11).
11. Raise the axle or lower the vehicle body until the air springs lightly touch the upper and
lower spring seats.
g. 11
Be sure to fully cover
the barbed section.
g. 10
Vehicle body
or bumper
Air line
clamp
Hex nut Rubber
washer
Lock
washer
Ination
valve
Flat washer Air line
Hex nut
Option 1
Option 2 g. 8
Good Cut Poor Cut
g. 9
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. 9).
CAUTION

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Air Lift 1000
DO NOT INFLATE AIR SPRINGS BEFORE READING THE MAINTENANCE AND
OPERATION SECTION.
12. Continue to “Completing the Installation.”
DUAL AIR LINE ROUTING
TO PREVENT AIR LINE FROM MELTING, KEEP IT AT LEAST 8” FROM EXHAUST
SYSTEM.
1. Select a location for the ination valves in the rocker panel ange, or rear bumper,
assuring that each valve will be protected and accessible with an air hose.
2. Determine and cut an adequate length of air line to reach from the valve location to the
left side air spring.
LEAVE SUFFICIENT AIR LINE SLACK TO PREVENT ANY STRAIN ON FITTING DURING
AXLE MOTIONS.
3. Insert the air line through the spring seat and spacer.
4. Slide the air clamp onto the cut air line.
5. Push the air line onto the stem, covering all the barbed section (see g. 8). With pliers
slide the air line clamp forward until it fully covers the barbed section.
6. Repeat process for the right side.
7. Drill a 5/16” hole for the inating valves and mount as illustrated. The rubber washer is
for an outside weather seal (see g. 10).
8. Route the air line along the control arm and frame to the ination valve location and cut
off the excess.
9. Slide a clamp onto the air line and push the air line over the tting, covering all the barbs.
With pliers slide the air line clamp forward until it fully covers the barbed section (see g.
11).
10.Raise the axle or lower body until the air springs lightly touch the upper and lower spring
seat.
DO NOT INFLATE AIR SPRINGS BEFORE READING THE MAINTENANCE AND
OPERATION SECTION.
COMPLETING THE INSTALLATION
1. Attach the sway bar and lower shock mounts. Tighten securely.
2. If you used step 2 on page 4 (had a plastic plug covering the upper spring seat hole)
for your hose installation, raise and lower the suspension up and down while viewing
the hose/barbed cylinder interface, if hose/barb rubs on the lower spring seat it will be
necessary to grind this area out for more clearance. The hose/barb area of the cylinder
cannot rub on the lower spring seat.
3. Inate the air springs to 35 PSI (2.4BAR). Test for air leaks by applying soap to 4/5 water
to all valve cores, ttings and connections.
4. Recheck air pressure after 24 hours. A 2-4 PSI (.14-.28BAR) loss after initial pressure
has dropped more than 5 PSI (.34BAR), retest for leaks.
It may be necessary to leave the maximum pressure in the system overnight for the rst
few nights to stretch the cylinder out inside the coil spring.
NOTE
CAUTION
CAUTION
CAUTION
CAUTION

8MN-715
Air Lift 1000
CAUTION
CHECKING FOR LEAKS
1. Inflate the air spring to 30 PSI (2.07BAR).
2. Spray all connections and the inflation valves with a soapy water solution. 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 (.34BAR).
4. Check the air pressure again after 24 hours. A 2 - 4 PSI (.14-.28BAR) loss after initial
installation is normal. Retest for leaks if the loss is more than 5 PSI (.34BAR).
FIXING LEAKS
1. 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 tting. Cut the air
line off a few inches in front of the tting and use a pair of pliers or vice grips to pull/
twist the air line off of the tting.
DO NOT CUT OFF THE AIR LINE COMPLETELY AS THIS WILL USUALLY NICK THE
BARB AND RENDER THE FITTING USELESS.
2. If the preceding steps have not resolved the problem, call Air Lift customer service at
[phone].

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Air Lift 1000
Minimum Air Pressure Maximum Air Pressure
5 PSI (.34BAR) 35 PSI (2.41BAR)
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 and Servicing
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 at least the recommended minimum air pressure to prevent the air
spring from being pinched. Never inate beyond the maximum air pressure.
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 air spring.
4. Always add air to springs in small quantities, checking the pressure frequently. Air springs
require less air volume than a tire and inate quickly.
OPERATING TIPS
1. Inate your air springs to 35 PSI (2.41BAR) before adding the payload. This will allow
the air cylinder to properly mesh with the coil spring. After the vehicle is loaded, adjust
your air pressure down to level the vehicle and for ride comfort.
2. When carrying a payload it will be helpful to increase the tire ination pressure in proportion
to any overload condition. We recommend a 2 PSI (.14BAR) increase above normal for
each 100 pounds (45kg) additional load on the axle.
DO NOT EXCEED THE VEHICLE MANUFACTURERS’ MAXIMUM GROSS VEHICLE
WEIGHT RATING.
Troubleshooting Guide
1. Leak test the air line connections, threaded connection of the elbow into the air spring, and
the ination valves. See “Fixing Leaks” on page 8 for repair.
2. Check for dirt debris in the valve core.
3. 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.
4. Inspect the air line for holes and cracks. Replace as needed.
5. Look for a kink or fold in the air line. Reroute as needed.
If the preceding steps do not solve the problem, it is most likely caused by a failed air spring
— either a factory defect or an operating problem. Please call Air Lift at [phone] for
assistance or a replacement air spring.
CAUTION

10 MN-715
Air Lift 1000
Product Use
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
sufcient 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 indenitely.
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 (g. 12). 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 (g. 13). 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 sacrice a perfectly level and comfortable ride. Stability issues include roll control,
bounce, dive during braking and sponginess (g. 14). Tuning out these problems usually
requires an increase in pressure.
g. 12 g. 13
Bad headlight aim Rough ride
Sway and body roll
g. 14

11
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Air Lift 1000
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 (3.45-6.9BAR) 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 (g. 15).
6. Adjust the pressure up and down to nd 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 (g.
16). As much as a 50 PSI (3.45BAR) difference is not uncommon.
g. 15 g. 16
Bottoming out Unlevel Level

12 MN-715
Air Lift 1000
Replacement Part Information
If replacement parts are needed, 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] 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
Mailing address P.O. Box 80167
Lansing, MI 48908-0167
Shipping address 2727 Snow Road
for returns Lansing, MI 48917
Phone Toll free: [phone]
International: [phone]
Email [e-mail]
Web address www.airliftcompany.com
Limited Warranty and Return Policy
Air Lift Company provides a limited lifetime warranty to the original purchaser of its
Load Support products, that the products will be free from defects in workmanship
and materials when used on cars and trucks as specied by Air Lift Company and
under normal operating conditions, subject to the requirements and exclusions set
forth in the full Limited Warranty and Return Policy that is available online at
www.airliftcompany.com/warranty.
For additional warranty information contact Air Lift Company customer service.

13
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Air Lift 1000
Kit 60821 Template

14 MN-715
Air Lift 1000
Notes

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Air Lift 1000
Notes

16 MN-715
Air Lift 1000
Notes

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Air Lift 1000
Notes

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
JJC-0517
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