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

TABLE OF CONTENTS
Installation Diagram ................................... 2
Hardware List and Tools List ............................ 3
Hardware List .............................................................3
Tools List .................................................................3
Introduction .......................................... 4
Important Safety Notice .....................................................4
Notation Explanation ........................................................4
Installing the LoadLifter 5000 Ultimate System ............. 5
Getting Started ............................................................5
Special Appplication Instructions ..............................................5
Assembling the Air Spring Unit ................................................6
Removing the Passenger Side Shock Bracket Rivet ...............................7
Attaching the Lower Bracket..................................................7
Attaching the Upper Bracket..................................................7
Securing the Air Spring to the Brackets .........................................7
Installing the Air Lines ................................. 8
Tips for Installing Air Lines ...................................................9
Securing the Emergency Brake Cable ..........................................9
Before Operating......................................10
Checking for Leaks ........................................................10
Fixing Leaks .............................................................10
Installation Checklist .......................................................11
Post-Installation Checklist...................................................11
Product Use, Maintenance and Servicing .................12
Minimum and Maximum Pressure............................................. 12
Maintenance Guidelines ....................................................12
Tuning the Air Pressure .....................................................13
Guidelines for Adding Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting Guide .................................14
Frequently Asked Questions .................................................14
Limited Warranty and Return Policy ......................17
Replacement Part Information ..........................17
Contact Information ...................................17

2MN-833
LoadLifter 5000 Ultimate
Installation Diagram
g. 1

3
MN-833
LoadLifter 5000 Ultimate
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 fitting .............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” Nylon lock 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
Missing or damaged parts? Call Air Lift customer
service at [phone] for a replacement part.
STOP!
Hardware and Tools Lists
TOOLS LIST
Description.............................................. Qty
Hoist or floor 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
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

4MN-833
LoadLifter 5000 Ultimate
Introduction
NOTE
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. LoadLifter 5000 Ultimate kits are recommended for most 3/4-
and 1-ton pickups and SUVs with leaf springs and provide up to 5,000 pounds of load-
leveling support with air adjustability from 5-100 PSI. The kits are also used in motor
home rear applications and various front applications 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
guidelines and operating tips.
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 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 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
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 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
WARNING
CAUTION

5
MN-833
LoadLifter 5000 Ultimate
GETTING STARTED
1. Raise the vehicle, remove the wheels and obtain normal ride height (Figs. 2 & 3).
Installing the LoadLifter5000 Ultimate System
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 1/4”
from the bottom of the center flange on the side plate and front cross member
(Fig. 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 flange on the B&W side plate
(Fig. 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.
8”
MINIMUM 8”
between tire
and frame
Jack stands
g. 2
g. 3
g. 4

6MN-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 (Fig. 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 (Fig. 6).
2. Install a 90° swivel air fitting finger tight plus 1 1/2 turns (Fig. 6). Do not overtighten.
3. The upper brackets are side specific. The small mounting hole in the upper bracket
faces forward (Fig. 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 (Fig. 6).
Repeat this procedure for the passenger side assembly.
6. Loosely attach the lower bracket to the assembly using flat washers, lock washers,
and hex head bolts. See Fig. 6.
The flange on the lower bracket must face the outside (tire-side) of the vehicle.
NOTE
Remove the upper left rivet to
provide a hold for mounting
the upper bracket.
g. 5
g. 6

7
MN-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 Fig. 5).
ATTACHING THE LOWER BRACKET
1. Set the air spring over the axle (Figs. 7 & 8).
2. Take two spacer bars and slide one under the front leg and one under the rear leg of
the lower bracket (Fig. 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 (Figs. 7 & 8).
Torque to 16 lb.-ft.
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 3/4” 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 lb.-ft. Torque the 3/4” hardware to 90 lb.-ft.
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 lb.-ft.
U-bolt
g. 7
g. 8
g. 9 g. 10

Installing the Air Lines
This section explains how to set up the air spring kit to be controlled with Schrader
valves and a separate compressed air source. An on-board air compressor system allows
for hassle-free control of the air springs. Learn more about Air Lift control systems at
www.airliftcompany.com/products/compressor-systems.
1. Choose a convenient
location for mounting
the inflation valves
(Fig. 11). 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
NOTE 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. 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. 12).
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. Keep
AT LEAST 6” of clearance between the air line and the exhaust system. Avoid sharp
bends and edges. Use zip ties 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).
Wiggle the hose back and forth while inserting to make sure the hose bottoms out in the
fitting to obtain a good seal.
TECH TIP
8MN-833
LoadLifter 5000 Ultimate
g. 11
Air line to
air spring
Hex nut
Hex nut
Valve
Cap
Schrader
valve
Star washer
Rubber washer
Flat
washer
g. 12
Option 1:
Option 2: