Air Lift LoadLifter 5000 88216 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-831 • (021306) • ECR 7668
INSTALLATION GUIDE
ADJUSTABLE AIR HELPER SPRINGS
TOW AND HAUL WITH SAFETY AND COMFORTTM
safety, please read these instructions
completely before proceeding with
Failure to read these instructions can result in an
Kit Numbers
88216 &
88128

1
MN-831
LoadLifter 5000 Ultimate
Introduction............................................. 2
Important Safety Notice ................................................2
Notation Explanation ...................................................2
Installation Diagram ...................................... 3
Hardware List ........................................................4
Tools List ............................................................4
Installing the LoadLifter 5000 Ultimate System ............... 5
Getting Started .......................................................5
Raising the Vehicle ....................................................6
Removing the Jounce Bumper ........................................... 6
Assembling the Air Spring Unit ...........................................6
Attaching the Lower Bracket .............................................9
Attaching the Upper Bracket .............................................9
Installing the Frame Brace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installing the Air Lines ..................................................10
Installing the Heat Sheild................................................12
Checking For Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Fixing Leaks .........................................................12
Before Operating ........................................13
Installation Checklist ...................................................13
Post-Installation Checklist ...............................................13
Product Use, Maintenance and Servicing ...................14
Minimum and Maximum Pressure......................................... 14
Maintenance Guidelines ................................................14
Troubleshooting Guide ................................................. 15
Frequently Asked Questions .............................................15
Tuning the Air Pressure.................................................15
Guidelines for Adding Air................................................16
Choosing the Right On-Board Air Compressor System .......17
Warranty and Returns Policy ..............................18
Replacement Information .................................19
Contact Information ......................................19
TABLE OF CONTENTS

2MN-831
LoadLifter 5000 Ultimate
Introduction
The purpose of this publication is to assist with the installation, maintenance and
troubleshooting of the LoadLifter 5000 Ultimate air spring kit.LoadLifter 5000 Ultimate
utilizes sturdy, reinforced, commercial grade single or double, depending on the kit, convolute
bellows.The bellows are manufactured like a tire with layers of rubber and cords that
control growth.An internal jounce bumper inside the spring absorbs shock and eliminates
harsh jarring on rough roads.The internal jounce bumper replaces the factory bumper and
allows the air springs to safely be run at zero air pressure.LoadLifter 5000 Ultimate kits
are recommended for most ¾ and 1 ton pickups and SUVs with leaf springs and provide
up to 5,000 lbs.of load leveling support with air adjustability from 5-100 PSI.The kits are
also used in motorhome rear kits and some motorhome fronts where leaf springs are used.
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 tips, safety information and
a troubleshooting guide.
Air Lift Company reserves the right to make changes and improvements to its products and
publications at any time.For the latest version of this manual, contact Air Lift Company at
[phone] or visit our website at www.airliftcompany.com.
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
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
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

3
MN-831
LoadLifter 5000 Ultimate
Installation Diagram
INBOARD
FORWARD
OPTION, see Figures 4-6
A
B
C D
E
F
G
N
O
H
H
I
I
I
H
J
K
J
J
J
J
K
K
J
J
M
M
N
O
O
OO
E
P
KIT 88216
A
KIT 88128
NOTE: No roll plates are used.
g. 1

4MN-831
LoadLifter 5000 Ultimate
Item Description ..............................................Qty
ABellow................................................................ 2
BUpper Bracket.................................................... 2
CLower Bracket (Left) .......................................... 1
DLower Bracket (Right)........................................ 1
ERoll Plate (not in 88128).................................... 4
FFrame Brace...................................................... 2
GElbow Fitting...................................................... 2
H3/8”-24 x 7/8” Bolt.............................................. 8
I3/8” Lock Washer .............................................. 8
J 3/8” Flat Washer............................................... 24
K3/8” Oversized Flat Washer............................... 6
L3/8”-16 x 3/4” Bolt.............................................. 2
M3/8”-16 x 1.5” Bolt.............................................. 8
N3/8”-16 x 6 Carriage Bolt ................................... 4
O3/8” Nylock Nut................................................. 12
Item Description ............................................. Qty
PAxle Clamp ........................................................ 2
QHeat Shield*....................................................... 1
RClamp*............................................................... 2
SThermal Sleeve ................................................. 1
Air Line Assembly Parts
AA Air Line Assembly.............................................. 1
BB Tie Strap*........................................................... 6
CC Valve Caps*....................................................... 2
DD 5/16” Flat Washer*............................................. 2
EE Rubber Washer*................................................ 2
FF Small Star Washer* ........................................... 2
GG 5/16” Hex Nut*................................................... 4
(* not shown in Figure 1)
Description...........................................................Qty
7/16”, 9/16” open-end or box wrenches........................... 1
Crescent Wrench............................................................. 1
Ratchet with 3/8”, 9/16”, and 1/2” deep well sockets....... 1
3/8” and 5/16” drill bits (very sharp)................................. 1
3/8” Nut Driver ................................................................. 1
Heavy Duty Drill............................................................... 1
Torque Wrench................................................................ 1
Hose Cutter, Razor Blade, or Sharp Knife....................... 1
Hoist or Floor Jacks......................................................... 1
Safety Stands .................................................................. 1
Safety Glasses ................................................................ 1
Air Compressor, or Compressed Air Source ................... 1
Spray Bottle with Dish Soap/Water Solution ................... 1
HARDWARE LIST
TOOL LIST
Missing or damaged parts? Call Air Lift customer
service at [phone] for a replacement part.
STOP!

5
MN-831
LoadLifter 5000 Ultimate
Installing the LoadLifter 5000 Ultimate System
DANGER
g. 2
NOTE This instruction manual is for kits 88216 and 88128. The only difference between the two kits
is the bellows. The drawings depict a double convolute bellow, as found in kit 88216. But all
instructions and illustrations apply to kit 88128 as well, which uses a single convolute bellow.
The air springs will last much longer if they are not the suspension limiter in either compressor
or extension. The air spring compresses to 2.8” and extends to 9.1”. Regardless of load, the
air pressure should always be adjusted so that the Normal Ride Height is maintained at all
times. The shock absorber is usually the limiter on extension. If this is not the case, then the
use of limiting straps should be considered, in particular for vehicles that are used off-road.
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.
GETTING STARTED
1. The 88216 kit requires a minimum of 7.25” from the top of the jounce bumper strike plate
to the bottom of the frame rail. Before installation is begun, check for sufcient clearance.
If the measurement is less than 7.25”, then use kit 88128 (Figure 2).
Frame
Axle
Jounce Bumper
Strike Plate
2. Determine the Normal Ride Height.The Normal Ride Height is the distance between
the bottom edge of the wheel-well and the center of the hub with the vehicle in the “as
delivered” condition. In some cases, Normal Ride Height is not perfectly level.
a. Remove unusual loads and examine your vehicle from the side to ensure it is on a level
surface.
b. If necessary (in cases where your leaf springs are sagging badly), use a jack to raise
the rear end so that the vehicle achieves the original “as delivered” ride height.

6MN-831
LoadLifter 5000 Ultimate
g. 3
3. Measure the distance between the center of the hub and the bottom edge of the wheel
well (Figure 3). This is the Normal Ride Height. Enter the measurement below:
NORMAL
RIDE HEIGHT: __________ inches
NOTE: The measurement
from one end of the arrow to
the other end is the Normal
Ride Height.
RAISING THE VEHICLE
1. Raise the vehicle and remove the wheels.
2. Check the distance between the center of the hub and the bottom edge of the wheel to
ensure that it is at the normal ride height previously recorded.If not, raise the frame or
lower the axle as necessary to restore the original distance.
a. If the vehicle is raised with an axle contact hoist, then place axle stands under the frame
and lower the axle as needed.
b. If the vehicle is raised with a frame contact hoist, then place axle stands under the axle
and raise the frame as needed.
c. If the vehicle is raise with a jack and supported with axle stands on the frame, then use
a oor jack to lower the axle.
REMOVING THE JOUNCE BUMPER
1. Remove the jounce bumper by prying it off of the jounce bumper bracket.
2. Remove the jounce bumper bracket from the frame rail.It may be bolted or riveted.If
riveted, it can be removed by center punching and drilling out the rivets, chiseling or
grinding it off, or cutting if off with a torch.
ASSEMBLING THE AIR SPRING UNIT
1. The lower brackets (C and D) are designated left/driver side (indicated by the “L” stamped
on it) and right/passenger side (indicated by the stamped “R”).
2. It will be necessary to use either the 3/8” x 3/4” (L) bolt or the 3/8” x 1.5” (M) in combination
with at washers (J) and a nylock nut (O) as a spacer stack so that the lower bracket
sits at on the axle housing/jounce bumper pad.
3. Set the lower bracket on the axle housing to determine the appropriate spacer stack up.

7
MN-831
LoadLifter 5000 Ultimate
g. 4
g. 5
g. 6
NOTE As a general rule, 1/2 and 3/4 ton trucks and some 1 ton trucks with single rear wheels take
the stack in Figure 4. Most 1 ton single rear wheels and some 1 ton dual rear wheel trucks
take the stack in Figure 5. Most 1 ton dual rear wheel trucks take the stack in Figure 6.
For ½ and ¾ ton trucks
and some 1 ton trucks
with single rear wheels.
O
L
For most 1 ton trucks
with single rear wheels
and some 1 ton trucks
with dual rear wheels.
O
J
M
For most 1 ton trucks
with dual rear wheels.
O
J
J
M

8MN-831
LoadLifter 5000 Ultimate
4. Due to manufacturing tolerances, the shock mounting bracket may stop the lower bracket
from sitting completely at on the axle housing/jounce bumper pad. This may occur on
only one side of the vehicle.In such instances, it will be necessary to use a grinder to
trim the shock bracket until it is at with the top of the axle housing (Figure 7).
g. 7
g. 8
5. After determining and installing the appropriate stackup, insert one carriage bolt (N) into
the forward hole of the lower bracket (Figure 8).
6. Set a roll plate (E) on both ends of the double convolute bellow (Figure 1).Kit 88128
with the single convolute bellow does not require roll plates.
7. Set the bellow assembly onto the lower bracket.The spacer assembly on the lower
bracket must be positioned on the same side as the air port on the top of the air spring.
8. Attach the lower bracket to the bellow using two bolts (H), two lock washers (I), and two
at washers (J) (Figure 1).
9. Attach the upper bracket (B) to the bellow using two bolts (H), two lock washers (I), and
two at washers (J). Be sure that the tall vertical leg of the upper bracket is opposite of
the air tting port (Figure 1).
10.Repeat assembly for other side.