Air Lift Air Lift 1000 60713 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.
Kit 60713
™
MN-34 • (111604) • ECR 8475
INSTALLATION GUIDE

TABLE OF CONTENTS
A. Introduction .......................................2
Important Safety Notice .....................................................2
Notation Explanation........................................................2
B. Hardware and Tools Lists............................3
Hardware List .............................................................3
Tools List .................................................................3
C. Installing the Air Lift 1000 Kit.........................3
Getting Started ............................................................3
Marking Hole for Air Line.....................................................4
Installing the Air Spring ......................................................5
D. Installing the Air Lines ..............................6
Tee Air Line Routing ........................................................7
Completing the Installation ...................................................8
Installing the Heat Shield.....................................................8
E. Before Operating...................................8
Installation Checklist ........................................................9
Post-installation checklist ....................................................9
F. Product Use, Maintenance and Servicing .............. 10
Suggested Driving Pressure and Maximum Air Pressure ........................... 10
Operating Tips............................................................ 10
Tuning the Air Pressure .....................................................11
Guidelines for Adding Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
G. Troubleshooting Guide ............................. 12
Frequently Asked Questions .................................................12
Limited Warranty and Returns Policy ................... 16
Replacement Information ............................. 17
Contact Information ................................. 17

Air Lift 1000
2
A. 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, tool list, step-by-step installation information, 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. Check the 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 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
vehicle 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 definitions 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.
NOTE
DANGER
CAUTION
WARNING

Air Lift 1000
MN-34 3
B. Hardware and Tools Lists
Item Part # Description.....................................Qty
A 48171 Air spring.................................................... 2
B 09453 Protector .................................................... 1
C 09567 Protector .................................................... 1
D 20937 Air line assembly........................................ 1
E 10466 Zip ties ....................................................... 4
F 21230 Valve cap ................................................... 2
G 21233 5/16” Hex nut ............................................. 4
H 21234 Rubber washer........................................... 2
I 18411 Star washer................................................ 2
J 18405 5/16” Flat washer ....................................... 2
K 21236 Tee............................................................. 1
L 21455 Valve .......................................................... 2
M 10638 Uni clamps ................................................. 6
HARDWARE LIST TOOLS LIST
Description...................................................... Qty
Hoist or oor jacks.......................................................... 1
Safety stands.................................................................. 2
Safety glasses ................................................................ 1
Air compressor or compressed air source...................... 1
Spray bottle with dish soap/water solution ..................... 1
C. Installing the Air Lift 1000 System
GETTING STARTED
1. Jack up the rear of the vehicle or raise on a hoist. Support the frame with safety
stands.
2. Mark the location of the spring/upper spring mount with a marker so that the spring
can be reinstalled and indexed properly.
3. Remove the shock absorbers from the lower shock mounts on the axle. Lower the
axle or raise the body of the vehicle until the springs can be removed.
OBSERVE TENSION ON BRAKE LINE. DO NOT STRAIN. IF NECESSARY,
TEMPORARILY REMOVE ANY MOUNTING BRACKETS OR CLIPS TO CREATE MORE
SLACK.
CAUTION
4. Remove lower shock mounting nuts and remove bottom of shocks from the control
arm. Leave shocks attached at the top on both right and left side.
5. Remove coil spring on left side by lowering the axle (Fig. C.1)
g. C.1

Air Lift 1000
MARKING HOLE FOR AIR LINE
1. Place air cylinder into coil spring with the air stem facing down (Fig. C.2)
2. Place coil spring and air cylinder assembly on the control arm lower seat.
3. Mark the cylinder air stem location where it comes in contact with the control arm.
4. Remove coil spring and air spring assembly.
5. Center punch and drill 1/4” diameter pilot hole then drill 3/8” diameter nal hole to
allow attachment of the air line to the air cylinder (Fig. C.3).
g. C.2
g. C.3
Control
arm
4

Air Lift 1000
INSTALLING THE AIR SPRING
1. Place the air bag and the top and bottom protectors in the coil spring (Fig. C.4). The
top protector is the thinner one.
2. Install coil spring and air cylinder assembly, placing it on the lower spring seat rst
with air line going through lower protector and control arm (Fig. C.5). Push the top of
coil into upper spring seat.
13. Raise axle back to starting position. Re-attach the shock and torque to manufacturer's
specication.
14. Move the left jack stand under axle and the right jack stand under frame and repeat
steps 4 through 13 to install the right side.
Check exhaust clearance. There must be 3-4 inches between the air bag and the exhaust
or the heat from the exhaust could damage it. If there is insufficient clearance, contact Air
Lift customer service to obtain a heat shield kit.
Thinner air spring
protector (B)
Thicker
air spring
protector (C)
Air spring
(A)
g. C.5
NOTE
MN-34 5
g. C.4

Air Lift 1000
6
A tee air line installation serving both air bags is recommended. If the weight in the
vehicle varies from one side to the other and unequal pressures are needed to level the
load or compensate for axle torque transfer in racing applications, use dual air lines.
Select a location for the inflation valve for each air line in the gas cap well, the trunk,
rear bumper, fender flange or behind the license plate, ensuring that the valve will be
protected and accessible with an air hose. (Fig. D.1)
1. Choose a convenient location for mounting the inflation valves. Popular locations for
the inflation valve are:
a. The wheel well flanges
b. The license plate recess in bumper
c. Under the gas cap access door
d. Through the license plate
Whatever the chosen location, make sure there is enough clearance around the inflation
valves for an air chuck.
2. Drill 5/16” holes to install the inflation valves.
3. If installing dual air lines, cut the air line assembly in two equal lengths.
4. 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 and have room for the rubber
washer, flat washer, and 5/16” nut and cap. There should be enough valve exposed
after installation – approximately 1/2” – to easily apply a pressure gauge or an air
chuck. (Fig. D.2)
D. Installing the Air Lines
NOTE
Option 1:
Option 2:
g. D.1
Air line to
air spring
Star
washer
Vehicle body
or bumper
Hex nut
Hex nut
Rubber
washer
Flat
washer
Valve
Cap
Schrader
valve
g. D.2

Air Lift 1000
MN-34 7
5. Push the inflation valve through the hole and use the rubber washer, flat washer, and
another 5/16” nut to secure it in place. Tighten the nuts to secure the assembly.
6. Route the air line along the frame to the fitting on the air spring (Fig. D.3). Keep
AT LEAST 6” of clearance between the air line and the exhaust system. Avoid sharp
bends and edges. Use plastic tie straps to secure the air line to fixed 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 the air line, leaving approximately 12” of extra air line. A clean square cut will
prevent leaks. Insert the air line into the air fitting. This is a push-to-connect 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).
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. (Fig. D.3)
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 spring seat and spacers.
6. Push the air line onto the stem, covering all the barbs. With the pliers, slide the air line
clamp upward until it fully covers the barbed section.
Use this procedure for all air
line connections:
1. Slide the air line clamp onto
the air line.
2. Push the air line over the
barbed stem.
3. Compress the ears on the
air line clamp with pliers and
slide it forward to fully cover
the barbed section.
1
2
3
g. D.3
CAUTION
CAUTION

Air Lift 1000
8
E. Before Operating
CAUTION
CHECKING FOR LEAKS
1. Inate the air spring to 30 PSI.
2. Spray all connections and the ination valves with a solution of 1/5 liquid dish soap
and 4/5 water. Spot leaks easily by looking for bubbles in the soapy water.
3. After the test, deate the springs to the minimum pressure required to restore the
system to normal ride height. Do not deate to lower than 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 is more than 5 PSI.
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 Fig. b). Reinsert
the air line into the push-to-connect tting.
b. Check the threaded connection by tightening the swivel tting another half 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 and then use a
wrench for an additional two turns.
2. If there is a problem with the ination 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.

Air Lift 1000
MN-34 9
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.
POST-INSTALLATION CHECKLIST
Clearance test — Inflate the air springs to 30 PSI and ensure there is at least 1/2”
clearance around each air spring, 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 30 PSI, check all connections
for leaks with a soapy water solution. See Checking for Leaks 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 Air Lift customer service at [phone].
Fastener test — Recheck all bolts for proper torque. Re-torque after 100 miles.
Road test — The vehicle should be road tested after the preceding tests. Inflate the
air springs to 25 PSI (30 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. Be sure to provide
the owner with all of the paperwork which came with the kit.
INSTALLATION CHECKLIST (To be completed by installer)

Air Lift 1000
10
1. Check the air pressure weekly.
2. Always maintain normal ride height. Never inate beyond 35 PSI or 50 PSI as noted in
above chart.
3. If the system develops an air leak, 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 SAFETY AND TO PREVENT DAMAGE TO THE 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 35 PSI OR 50 PSI, THE AIR PRESSURE
ACTUALLY NEEDED IS DEPENDENT ON LOAD AND GVWR.
5. If using Schrader valves, always add air to the springs in small quantities, checking
the pressure frequently. Cylinders 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 PSI) to reduce tension on the suspension/brake
components.
OPERATING TIPS
1. Inate the air springs to 30 PSI before adding the payload. This will allow the air
cylinder to properly mesh with the coil spring. After the vehicle is loaded, adjust the 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. Air Lift Company recommends a 2 PSI increase
above normal for each 100 pounds additional load on the axle.
F. Product Use, Maintenance and Servicing
CAUTION
5 PSI 35 PSI
Maximum Air PressureMinimum Recommended Pressure

Air Lift 1000
MN-34 11
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 (Fig. F.1). 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 (Fig. F.2). 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 (Fig. F.3). Tuning out these problems
usually requires an increase in pressure.
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. (Fig.
F.4)
5. Adjust the pressure up and down to nd 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
(Fig. F.5). As much as a 15 PSI difference is not uncommon.
Bad headlight aim Sway and
body roll
Rough ride
g. F.1 g. F.3 g. F.2
Bottoming out Unlevel Level
g. F.4 g. F.5

Air Lift 1000
PROBLEM CAUSE SOLUTION
System won’t maintain pressure
overnight.
Improperly installed air line, air line has
holes or cracks.
Leak test the air line connections, the threaded
connection into the air spring, and all ttings in
the control system.
Compressor runs all the time. The compressor relay is defective or there
is a leak in the air lines.
Replace the relay or nd the air leak.
Air spring or tank leak. Fitting seal or air line is compromised. Check to make sure air lines are seated in
connectors. Inspect ttings with soapy water.
Trim hose or re-seal tting. Ensure lines are cut
straight.
Corner won't raise or air leak
develops.
Look for a kink or fold in the air line. Replace any air line that has been kinked.
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 recommended minimum air pressure for the Air Lift 1000 kit is 5 PSI.
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 sufficient 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 indefinitely.
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.
G. Troubleshooting Guide