Air Lift LoadLifter 5000 Ultimate 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-833 • (031403) • ECR 7916
INSTALLATION GUIDE
ADJUSTABLE AIR HELPER SPRINGS
TOW AND HAUL WITH SAFETY AND COMFORTTM
Kit Number
88291

Introduction............................................. 2
Important Safety Notice ................................................2
Notation Explanation ...................................................2
Installation Diagram ...................................... 3
Hardware List ........................................................3
Tools List ............................................................4
Installing the LoadLifter 5000 Ultimate System ............... 4
Getting Started .......................................................4
Special Applications Instructions.......................................... 4
Assembling the Air Spring Unit ...........................................5
Removing the Passenger Side Shock Bracket Rivet. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Attaching the Lower Bracket .............................................6
Attaching the Upper Bracket .............................................6
Securing the Air Spring to the Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installing the Air Lines ..................................................7
Securing the Emergency Brake Cable .....................................8
Checking for Leaks ....................................................8
Fixing Leaks .........................................................8
Before Operating ........................................ 9
Installation Checklist ...................................................9
Post-Installation Checklist ...............................................9
Product Use, Maintenance and Servicing ...................10
Minimum and Maximum Pressure.........................................10
Maintenance Guidelines ................................................10
Troubleshooting Guide .................................................10
Frequently Asked Questions .............................................11
Tuning the Air Pressure.................................................11
Guidelines for Adding Air................................................12
Choosing the Right On-Board Air Compressor System .......13
Warranty and Returns Policy ..............................14
Replacement Information .................................15
Contact Information ......................................15
TABLE OF CONTENTS

2MN-833
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.
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 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.
DANGER
NOTE
WARNING
CAUTION

3
MN-833
LoadLifter 5000 Ultimate
Installation Diagram
g. 1
HARDWARE LIST
Item Part # Description................................Qty
A 58496 Air spring.............................................2
B 07437 Driver side upper bracket....................1
C 07438 Passenger side upper bracket ............1
D 11967 Roll plate.............................................4
E 03102 Lower bracket ....................................2
F 21837 1/8’-1/4” Swivel elbow tting ...............2
G 10466 Zip ties ................................................6
H 18405 5/16” Flat washer ................................2
I 18411 5/16” Lock washer...............................2
J 21230 Valve cap ............................................2
K 21233 Hex nut................................................4
L 21234 Rubber washer....................................2
M 20086 Air line ............................................... 16”
N 17203 3/8” Bolt...............................................8
O 18427 3/8” Lock washer.................................8
P 18444 3/8” Flat washer .................................20
Q 10583 3/8” x 3.5 x 4.5 U-bolt..........................4
R 01426 3” Spacer bar ......................................4
S 10594 3/8”-16 x 2 U-bolt ................................4
T 18435 3/8” Nyloc nut.....................................10
U 17159 3/8” Washer head bolt.........................2
V 18447 5/16” x 3/8” Large washer...................2
W 10465 Line clamp...........................................1

4MN-833
LoadLifter 5000 Ultimate
GETTING STARTED
1. Raise the vehicle, remove the wheels and obtain normal ride height (g. 2 and g. 3).
Installing the LoadLifter5000 Ultimate System
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
SPECIAL APPLICATION INSTRUCTIONS
1. For B&W hitch applicatons:
a. On B&W part number 1199R, with the hitch in the 49” position only, trim ¼” from the
bottom of the center ange on the side plate and front cross member (g. 4). Also,
grind a slight chamfer on the back of the front mounting leg of the upper brackets to
clear the bend radius of the large ange on the B&W side plate (g. 4).
1199R ONLY: Grind the lower edge
of this tab down to accommodate the
upper mounting bracket for this kit.
1199R ONLY: Grind the edge of this
tab down to allow the upper bracket to
butt ush against the B&W bracket. g. 4
g. 3
8”
MINIMUM 8”
between tire
and frame
g. 2
Jack stands

5
MN-833
LoadLifter 5000 Ultimate
2. On 2005 models it will be necessary to remove the top rear shock bracket rivet (on the
passenger side only) to mount the upper bracket (g. 5).
3. With the B&W hitch bracket in the position described in step 1, proceed with the air spring
installations.
4. Remove the emergency brake cable bracket and corresponding hardware attached to
the lower spring retainer. Save the bolt for later use.
ASSEMBLING THE AIR SPRING UNIT
1. Set a roll plate on both ends of the air spring. 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 (g.
6).
2. Install a 90° swivel air tting nger tight plus 1 ½” turns (g. 6). Do not overtighten.
3. The upper brackets are side specic. The small mounting hole in the upper bracket faces
forward (g. 6).
4. Place the driver side upper bracket on top of the bellow and roll plate with the legs facing
down.
5. Set the air spring on the driver side lower bracket and align the two holes in the base of
the air spring with the two outer slots in the top of the lower bracket (g. 6). Repeat this
procedure for the passenger side assembly.
6. Loosely attach the lower bracket to the assembly using at washers, lock washers, and
hex head bolts. See g. 6.
The ange on the lower bracket must face the outside (tire-side) of the vehicle.
g. 6
NOTE
g. 5
Remove the upper left rivet to
provide a hold for mounting
the upper bracket.

6MN-833
LoadLifter 5000 Ultimate
REMOVING THE PASSENGER SIDE SHOCK BRACKET RIVET
1. Remove the rear, top shock mounting rivet on the passenger side of the vehicle to provide
a mounting hole for the upper bracket (see g. 5).
ATTACHING THE LOWER BRACKET
1. Set the air spring over the axle (g. 7 and g. 8).
2. Take two spacer bars and slide one under the front leg and one under the rear leg of
the lower bracket (g. 8).
3. Depending on whether the vehicle has frame contact overloads or a regular leaf stack,
attach the lower bracket to the leaf using the provided u-bolts (g. 7 and g. 8). Torque
to 16 ft/lbs.
ATTACHING THE UPPER BRACKET
1. For B&W hitch applications:
a. Align the two large holes with the existing B&W hitch frame brackets. Use the existing
¾” hardware supplied by B&W to attach the bracket.
2. Align the upper bracket so that it is parallel to the lower bracket. Torque the 3/8” hardware
to 40 ft.lbs. Torque the ¾” hardware to 90 ft/lbs.
g. 7
SECURING THE AIR SPRING TO THE BRACKETS
1. The upper bracket is slotted so that the air spring can be adjusted forward and back.
The bottom bracket is slotted so that the air spring can be adjusted in and out.
2. Using the slots in the top and bottom brackets, adjust the air spring so that it is
perpendicular to both surfaces. Tighten top and bottom mounting hardware to no more
than 10 ft/lbs.
g. 8
g. 9 g. 10
U-bolt

7
MN-833
LoadLifter 5000 Ultimate
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. 11)
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. 12).
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. 12).
6. Route the air line along the frame to the air tting on the air spring (g. 3). 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
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.
CAUTION
NOTE
Option 1
Option 2
Good Cut Poor Cut
g. 11 g. 12
g. 13

8MN-833
LoadLifter 5000 Ultimate
7. Cut off air line leaving approximately 12” of extra air line. A clean square cut will ensure
against leaks (see g. 11). 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).
SECURING THE EMERGENCY BRAKE CABLE
1. Attach the supplied clamp around the emergency brake cable and secure it to the lower
bracket using the previously removed stock bolt. Tighten securely (g. 14).
2. Cut the existing emergency brake cable bracket close to the cable (g. 14).
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. 11). 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.
DO NOT CUT THE AIR LINE COMPLETELY OFF AS THIS WILL NICK THE BARB AND
RENDER THE FITTING USELESS.
CAUTION
Install supplied clamp
aroundtheemergency
brake cable, securing
to the lower bracket.
g. 14
Cut off existing
brake bracket
close to the
brake cable.

9
MN-833
LoadLifter 5000 Ultimate
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 xed. Either x 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 60 PSI and ensure there is at least ½” 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.
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______________
Before Operating
INSTALLATION CHECKLIST (To be completed by installer)

10 MN-833
LoadLifter 5000 Ultimate
Product Use, Maintenance and Servicing
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 inate 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 ination valve core before
deating 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 deation 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
ttings 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.
NOTE
CAUTION
5 PSI 100 PSI
Maximum Air Pressure
Minimum Recommended Pressure

11
MN-833
LoadLifter 5000 Ultimate
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?
For LoadLifter 5000 Ultimate, the recommended minimum air pressure is 5 PSI, but it
can safely be run at zero air pressure.
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. 2.1). 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 (g. 2.2). 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 (g. 2.3). Tuning out these problems usually
requires an increase in pressure.
g. 2.1
Bad headlight aim Sway and
body roll
g. 2.3
Rough ride g. 2.2

12 MN-833
LoadLifter 5000 Ultimate
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 (g. 2.4).
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 (g.
2.5). As much as a 50 PSI difference is not uncommon.
g. 2.4
Bottoming out g. 2.5
Unlevel Level

13
MN-833
LoadLifter 5000 Ultimate
Choosing the Right On-Board Air Compressor System
Add an on-board air compressor sytem to inate and deate 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 ination (see
illustrations at right)
2. Choose wireless or analog control
•Wireless: Control your air springs from
inside or outside the vehicle. Easiest
installation - no wires to the cab.
•Analog: In-cab control of your air springs.
Economically priced.
3. Choose heavy or standard duty compressor
•Standard duty: A standard duty compressor
will work well for most customers who use
their system on an intermittent basis.
•Heavy duty: For daily use, consider
the heavy duty compressor - it inates
faster and more quietly than the standard
compressor. Single path systems Two springs will
inate at the same time. Good for loads
that are evenly distributed from left-to-
right or front-to-back.
Dual path systems Air springs are
controlled separately to allow for different
air pressure from side-to-side. Perfect for
uneven or top-heavy loads.
WIRELESS
DUAL PATH
SINGLE PATH
ANALOG
DEFLATE
RIGHT
DEFLATE
LEFT
INFLATE
BOTH
WirelessAIR
TM
WirelessONE
TM
LoadCONTROLLER
TM
Dual
Single
LoadCONTROLLER
TM
DEFLATE
BOTH
INFLATE
BOTH
• Easy installation
• Includes heavy
duty compressor
Compact,
economically priced
control.
Compact,
economically priced
control.
• Easy installation
• Includes standard
duty compressor
P/N Standard Duty Compressor
25850; P/N Heavy Duty mpressor 25854
P/N Standard Duty Compressor
25852; P/N Heavy Duty Compressor 25856
P/N 25870
P/N 72000