Air Lift loadlifter 5000 User manual

Kits 57215 |88215 |89215
For maximum effectiveness and safety, please read these instructions
completely before proceeding with installation.
SERIES
Installation
Guide
TM
MN-1046 • (011704) • ERN 8631 Failure to read these instructions can result in an incorrect installation.
Multiple Chevrolet, Dodge, Ford and GMC trucks

IDENTIFYING THE DIFFERENCES BETWEEN KITS
Should you need to contact Air Lift customer service, you will need to know which kit you are inquiring about:
standard LoadLifter 5000, LoadLifter 5000 Ultimate or LoadLifter 5000 Ultimate Plus. The kits are easily
identifiable by looking at the roll plates and air lines.
 Standard LoadLifter 5000 — Zinc-plated steel roll plates and black nylon air lines.
 LoadLifter 5000 Ultimate — Black powder-coated roll plates and black nylon air lines.
 LoadLifter 5000 Ultimate Plus — Stainless steel roll plates, braided stainless steel air lines, stainless steel
air spring mounting hardware.
Air Lift offers two Ultimate Plus upgrade kits:
52300 - Braided stainless steel air line and fittings.
52301 - Stainless steel roll plates, air spring mounting hardware, braided stainless steel air lines and fittings.
LoadLifter 5000 Ultimate
black powder-coated
roll plate
LoadLifter 5000 Ultimate Plus
stainless steel
roll plate
LoadLifter 5000
silver zinc-plated steel
roll plate
LoadLifter 5000 Ultimate
nylon air line
LoadLifter 5000 Ultimate PLUS
braided stainless steel air line
LoadLifter 5000
nylon air line

TABLE OF CONTENTS
TABLE OF CONTENTS
Installation Diagram.......................................2
Hardware and Tools Lists ..................................3
Introduction..............................................4
Important Safety Notice ................................................4
Notation Explanation ...................................................4
Installing the LoadLifter 5000 Series System ..................4
Getting Started .......................................................5
Special Application Instructions ..........................................6
Assembling the Air Spring Unit ...........................................7
Positioning the Brackets ................................................8
Attaching the Lower Bracket.............................................8
Attaching the Upper Bracket.............................................9
Securing the Air Spring to the Brackets ................................... 10
Installing the Air Lines .............................11
Installing Nylon Air Lines ............................................... 11
Installing Braided Stainless Steel Air Lines ................................. 12
Reinstalling the Fender Well Liner ...................13
(Late-Model 4WD Dodge Only)
Before Operating ........................................14
Checking For Leaks .................................................. 14
Fixing Leaks ........................................................ 14
Installation Checklist .................................................. 15
Post-Installation Checklist.............................................. 15
Product Use, Maintenance and Servicing ...................16
Minimum and Maximum Pressure........................................ 16
Maintenance Guidelines ............................................... 16
Tuning the Air Pressure ................................................ 17
Guidelines for Adding Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Troubleshooting Guide ............................. 18
Frequently Asked Questions ............................................ 18
Limited Warranty and Return Policy ........................21
Replacement Information .................................21
Contact Information......................................21

Installation Diagram
C
N
I OR J
K
O
A
M
H
F or G
I
H
B
I OR J
K
O
D
E
OUTBOARD
FORWARD
g. 1
LoadLifter 5000 Series
MN-1046
2

STOP!
Hardware and Tools Lists
TOOLS LIST
KIT 57215
KIT 88215
KIT 89215
Item Part# Description ........................................................ Qty
A 07475 Upper bracket ......................................................... 2
B 03102 Lower bracket ......................................................... 2
F 10594 2” U-bolt ................................................................. 4
G 10583 4.5” U-bolt .............................................................. 4
H 18435 Nylon lock nut ....................................................... 16
L* 13377 Upper bracket spacer ............................................. 4
M 18447 3/8” Flat washer...................................................... 8
N 17159 3/8” x 1.5” Washer-head frame bolt ....................... 8
P* 01525 Spacer bar .............................................................. 4
Q* 17182 1/4” Hex-head cap screw ....................................... 2
R* 20947 Fender well liner spacer.......................................... 2
S* 18419 10/32” Flat washer .................................................. 6
T* 18425 1/4” Nylon lock nut ................................................. 2
EE* 21234 Rubber washer........................................................ 2
TM
TM
ULTIMATE
P L U SP L U S
+
TM
Common Parts Included in All 3 Kits
TM
Item Part# Description ........................................................ Qty
C 58496 Air spring with internal jounce bumper ................... 2
D 11967 Roll plate (black powder coated) ............................ 4
E 21837 Push-to-connect (PTC) fitting ................................. 2
I 18444 3/8” Flat washer.................................................... 16
K 18427 3/8” Lock washer .................................................... 8
O 17203 3/8” x 7/8” Hex-head cap screw............................. 8
AA* 20086 Air line ..................................................................... 1
BB* 10466 Zip tie ...................................................................... 6
CC* 21230 Valve cap................................................................. 2
FF* 18501 M8 Flat washer........................................................ 2
GG* 21233 5/16” Hex nut.......................................................... 4
HH* 18411 Star washer ............................................................. 2
Item Part# Description ........................................................ Qty
C 58437 Air spring ................................................................ 2
D 11951 Roll plate (silver zinc-plated)................................... 4
E 21837 Push-to-connect (PTC) fitting ................................. 2
I 18444 3/8” Flat washer.................................................... 16
K 18427 3/8” Lock washer .................................................... 8
O 17203 3/8” x 7/8” Hex-head cap screw............................. 8
AA* 20086 Air Line .................................................................... 1
BB* 10466 Zip tie ...................................................................... 6
CC* 21230 Valve cap................................................................. 2
FF* 18501 M8 Flat washer........................................................ 2
GG* 21233 5/16” Hex nut.......................................................... 4
HH* 18411 Star washer ............................................................. 2
Unique Parts in Each Kit
Item Part# Description ........................................................ Qty
C 58496 Air spring with internal jounce bumper ................... 2
D 11880 Roll plate (stainless steel)........................................ 4
E 21815 AN-type fitting......................................................... 2
G 17363 3/8”-24 x 3/4” Stainless steel flat-head screw ....... 4
I 18444 3/8” Flat washer...................................................... 8
J 18507 3/8” Stainless steel flat washer............................... 8
K 18504 3/8” Stainless steel lock washer ............................. 8
O 17284 3/8” x 7/8” Stainless steel hex-head cap screw ..... 8
AA* 20987 Stainless steel braided air line ................................ 2
BB* 10466 Zip tie .................................................................... 12
DD* 21709 Schrader valve with cap & nut ................................ 2
FF* 18572 M8 Stainless steel flat washer ................................ 2
HH* 18623 Stainless steel star washer ..................................... 2
II* 21813 PTC to AN adapter fitting ....................................... 2
JJ* 20084 Air line assembly ..................................................... 1
Description............................................................................ Qty
Standard and metric open-end or box wrenches .............................. SET
Adjustable wrench................................................................................... 1
Ratchet .................................................................................................................1
Standard and metric, regular and deep well sockets...................................SET
3/8” and 5/16” drill bits (very sharp)........................................................ 1
Heavy-duty drill ....................................................................................... 1
Center punch........................................................................................... 1
Hammer................................................................................................... 1
Torque wrench.........................................................................................1
Hose cutter, razor blade, or sharp knife ..................................................1
Hoist or floor jacks .................................................................................. 1
Safety stands...........................................................................................1
Safety glasses ......................................................................................... 2
Air compressor or compressed air source .............................................. 1
Spray bottle with dish soap/water solution............................................. 1
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.
* Not pictured in the Installation Diagram
LoadLifter 5000 Series
MN-1046 3

Introduction
The purpose of this publication is to assist with the installation, maintenance and
troubleshooting of the standard LoadLifter 5000, LoadLifter 5000 Ultimate or LoadLifter
5000 Ultimate Plus air spring kits. All LoadLifter 5000 Series kits utilize sturdy,
reinforced, commercial-grade single or double, depending on the kit, convolute bellows.
LoadLifter 5000 Ultimate kits add an internal jounce bumper and black powder-coated
roll plates. LoadLifter 5000 Ultimate Plus kits also have an internal jounce bumper, but
add stainless steel roll plates, air lines and air spring mounting hardware.
The air springs are manufactured like a tire with layers of rubber and cords that control
growth. LoadLifter 5000 series 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.
It is important to read and understand the entire installation guide before beginning
installation or performing any maintenance, service or repair.
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 the vehicle’s owner’s manual and do not exceed the
maximum load listed for this 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.
NOTE
CAUTION
DANGER
WARNING
LoadLifter 5000 Series
MN-1046
4

Installing the LoadLifter 5000 Series System
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. Support the axle with jack stands, remove the wheels and raise or lower to obtain
normal ride height (figs. 2 & 3).
2. There must be 8” clearance between the frame and the rear tire for this kit
to fit (fig. 3).
8”
g. 3
DANGER
g. 2
LoadLifter 5000 Series
MN-1046 5

SPECIAL APPLICATION INSTRUCTIONS
1. 1994 and newer model Dodge 4WD pickups only:
It will be necessary to remove the inner fender well liner on late-model 4WD Dodge
trucks. This is done by carefully driving the pin through the fasteners with a center punch
(fig. 4). These fasteners will be reused along with a special spacer to reattach the liner
and provide clearance for the air spring (See page 13 for reinstallation instructions).
g. 4
2. Ford trucks only:
When installing the upper bracket on an F-250 or F-350, the mounting bolt holes
can line up directly over the indent in the frame. This is an acceptable situation and
is an approved method of installation for the product (fig. 5). Torque the mounting
hardware to specifications, as noted. Do not over torque.
g. 5
Frame
3. For 1999 and later Super Duty F-250 and F-350 trucks:
Remove the bolt that holds the emergency brake cable to the outside of the frame
rail. Reinstall the bolt in the reverse order, with the nut on the inside of the frame rail,
to prevent rubbing against the air spring (fig. 6).
FAILURE TO SWITCH THIS BOLT WILL CAUSE AIR SPRING TO RUPTURE.
g. 6
Emergency brake line
clip
After
Before
Inboard
Inboard
CAUTION
LoadLifter 5000 Series
MN-1046
6

ASSEMBLING THE AIR SPRING UNIT
See fig. 7 below for assembly.
1. Set a roll plate on both ends of the air spring. The radiused (rounded) edge of the roll
plate will be toward the air spring so that the air spring is seated in both roll plates.
2. Install a 90-degree swivel air fitting. It should only be finger tight plus 1 1/2 turns. Do
not overtighten.
3. Place the upper bracket onto the top of the air spring and roll plate with the legs
facing down.
4. Set the air spring on the lower bracket aligning the two holes in the base of the air
spring with the two outer slots in the top of the lower bracket.
5. Loosely attach the upper bracket to the assembly using flat washers, lock washers,
and hex-head bolts. Remember that the bracket legs face down.
6. Loosely attach the lower bracket to the assembly using flat washers, lock washers,
and hex-head bolts.
The flange on the bracket must face the outside (tire side) of the vehicle.
NOTE
g. 7
Upper bracket (A)
90-degree swivel
air tting (E)
Lower bracket (B)
Roll plates (D) Air spring (C)
Hex-head screw (O)
Lock washer (K)
Flat washer (I)
Bracket leg
Flange
Washer-head
frame bolt (N)
LoadLifter 5000 Series
MN-1046 7

POSITIONING THE BRACKETS
1. The air spring must be installed between 5” and 7” from both the upper bracket to the
lower bracket (fig. 8). It is best to position the upper bracket as high as possible.
Failure to mount the air spring at the recommended height can result in the air spring
bottoming out.
The top rear mounting hole may be above the frame rail. If this condition exists, use the two
lower mounting holes to mount the bracket.
2. Set the air spring assembly on the leaf spring over the axle (fig. 8).
3. Position the upper bracket so that at least four bolt holes (two on each side) will be
on the flat section of the frame rail. Keep the edge of drilled holes no closer than 3/4”
from the top or bottom radius of the frame rail.
4. In some cases, it may be necessary to use the optional spacers to achieve the 5”-7”
space. For example, if only the top two holes contact above the lower radius edge of
the frame rail, it may be necessary to move up the spacers under the lower bracket
to achieve mounting height.
If the lower bracket needs to set flat on the leaf spring in order to achieve the correct height and
the stock U-bolts are too high to allow this, it will be necessary to trim the stock U-bolts.
ATTACHING THE LOWER BRACKET
1. If the spacer is not used, attach the lower bracket securely using the provided U-bolts,
flat washers, and lock nuts. Torque nuts to 16 lb.-ft. (22Nm).
2. If the spacer is used, place the spacers legs down on the leaf spring and attach
the lower bracket securely using the provided U-bolts, flat washers, and lock nuts.
Torque nuts to 16 lb.-ft. (22Nm) (fig. 9).
Use shorter U-bolts when attaching to frame contact overload springs (fig. 9).
g. 9
Shorter U-bolt
Trim stock U-bolts
if necessary.
g. 8
Lock nut
Spacer (optional
to achieve proper
mounting height)
Flat washer
Long U-bolt
Distance must be
5”- 7” and equal
on both sides Upper and lower
bracket must be
parallel
Lower
mounting holes
Trim stock U-bolts
if necessary.
NOTE
NOTE
NOTE
Frame contact
overload spring.
LoadLifter 5000 Series
MN-1046
8

ATTACHING THE UPPER BRACKET
BEFORE DRILLING, CHECK THE BACK-SIDE OF THE FRAME FOR CLEARANCE
ISSUES WITH THE BRAKE LINES, GAS LINES, AND ELECTRICAL LINES. ANY
OBSTACLES WILL NEED TO BE TEMPORARILY RELOCATED TO CLEAR THE AREA.
1. Position the upper bracket so that it is parallel with the lower bracket and align the
assembly vertically and horizontally.
2. Using the upper bracket as a template, center punch and drill one 3/8” locator hole
through the frame at one of the top bolt holes (fig. 10).
After achieving the proper alignment, repeat for the opposite side of the bracket.
3. Except for Dodge vehicles, loosely install a washer-head frame bolt, oversized flat
washer, and lock nut (fig. 11).
For Dodge trucks only: The top two, or the bottom two, holes (depending on the
model of the truck) will fall into a horizontal indentation. Spacers are provided to
compensate for the indentation. Loosely install a washer-head frame bolt, two upper
bracket spacers, an oversized flat washer, and a lock nut for such instances (fig. 12).
4. Install a washer-head frame bolt, oversized flat washer, and lock nut.
For Dodge trucks only: It may be necessary to add two of the provided spacers (fig. 12).
g. 11 g. 12
Upper Bracket
Washer head
frame bolt
Lock nut
Oversized at
washer
Frame
Upper bracket
Washer-head
frame bolt
Lock nut
Oversized at
washer
Frame
Spacers
All models, except some late model
Dodge trucks
Dodge trucks with ditch
(ditch can be on top or bottom portion of
the frame, depending on vehicle model)
3/8”
g. 10
CAUTION
NOTE
Ditch
LoadLifter 5000 Series
MN-1046 9

SECURING THE AIR SPRING TO THE BRACKETS
1. Secure the air spring to the upper and lower brackets using an open ended 9/16”
wrench by tightening the two bolts on the top and the two bolts on the bottom of the
spring assembly.
DUE TO THE THICKNESS OF THE LEAF SPRING STACK, TRIM ALL FOUR U-BOLT
ENDS ON EACH SIDE OF THE VEHICLE TO PREVENT BOTTOMING OUT ON THE
UPPER BRACKET (FIG. 14).
2. Check bolts and connectors to ensure that all hardware is secure and repeat the
process for the other side of the vehicle (fig. 14).
5. Remove the clamps and drill the remaining two holes. Install the appropriate hardware
and torque the nuts to 44 lb.-ft. (60Nm).
6. Align the air spring uniformly between the upper and lower brackets and check the air
spring alignment (fig. 13).
U-bolts
g. 14
Move the air spring in
the slots of the upper
and lower brackets to
align. Make sure there
is at least a thumbs
width of clearance
between the uninated
bag and the frame.
Frame
Bag g. 13
CAUTION
LoadLifter 5000 Series
MN-1046
10

LoadLifter 5000 Series
MN-1046 11
Installing the Air Lines
Air lines are routed from the air springs to Schrader valves. LoadLifter 5000 Series air
lines come in two styles: nylon and braided stainless steel. Begin by choosing locations
for the Schrader valves and drill a 5/16” hole, if necessary (fig. 15).
KEEP AT LEAST 6” OF CLEARANCE BETWEEN ALL AIR LINES AND THE EXHAUST
SYSTEM. AVOID SHARP BENDS AND EDGES.
INSTALLING NYLON AIR LINES
1. Cut the air line in half. Make clean, square cuts with a razor blade or hose cutter
(fig. 16). Do not use scissors or wire cutters.
2. Use zip ties to secure the air line to fixed points along the chassis. Do not pinch or kink
the air line. The minimum bend radius for the air line is 1 ” . Leave at least 2” of slack in the
air line to allow for any movement that might pull on the air line.
3. Install the Schrader valve in the chosen location (fig. 17).
Good cut Bad cut
A. Inside fuel tank filler door C. License plate or
B. Inside rear wheel wells rear bumper area
MICHIGAN
XXX-XXX
www.MICHIGAN.gov
A. B. C.
MICHIGAN
XXX-XXX
www.MICHIGAN.gov
If a location for the Schrader valve other than the back of
the vehicle is chosen, it may be necessary to coil the
excess air line. The braided stainless steel air line cannot
be trimmed.
A. Inside fuel
tank filler
door
B. Inside rear
wheel wells
C. License
plate or rear
bumper area*
* For LoadLifter Ultimate Plus kits, the recommended location
for the Schrader valves is the rear bumper area or license plate.
MICHIGAN
XXX-XXX
www.MICHIGAN.gov
A. B. C.
USE IN
Standard,
Ultimate,
7500XL
USE IN
Plus
upgrade kit
USE IN
Plus combo
manuals
MICHIGAN
XXX-XXX
www.MICHIGAN.gov
If a location for the Schrader valve other than the back of the vehicle is
chosen, it may be necessary to coil the excess air line. The braided
stainless steel air line cannot be trimmed.
USE IN
Plus
upgrade kit
Hex nuts
Star washer
Rubber washer
Air Line Setup for Compressor Integration
Air Line Setup Without Compressor System
Vehicle body
or bumper
Hex nuts
Flat washer
Star washer
Rubber washer
Nylon air line
to compressor
system and
Schrader valve
Flat
Flat
Vehicle body
or bumper
Braided stainless steel
air line to air spring
5/16” (8mm)
hole
AN to PTC
fitting
Schrader
valve
Vehicle
body or
bumper
AN
Schrader
valve Air line hex nut
Flat washer
Nylon air line
to air spring
5/16” (8mm) hole
Braided
stainless
steel air line
to air spring
Hex nuts
Flat washer
Star washer
Rubber washer
Schrader
valve
Vehicle
body or
bumper
Nylon air line
to air spring
5/16” (8mm) hole
g. 16
g. 17
g. 15
CAUTION

LoadLifter 5000 Series
MN-1046
12
INSTALLING BRAIDED STAINLESS STEEL AIR LINES
KEEP THE AIR LINE AWAY FROM THE FUEL LINE, BRAKE LINES AND ELECTRICAL
WIRES.
1. Use zip ties to secure
the air line to fixed points
along the chassis every
6” to 8”. Leave at least 2”
of slack to allow for any
movement that might pull
on the air line.
2. Tighten the air line hex
nut finger tight, then use
2 wrenches to turn 1
additional flat (1/6
of one full turn). Do
not overtighten
(figs. 18 or 19). The
easiest way to tighten the
fitting is off the vehicle.
Install the Schrader valve
in the chosen location.
3. Coil and secure any
excess air line in an
area where it will not be
susceptible to damage.
The braided stainless
steel air line cannot be
trimmed.
CAUTION
Hex nuts
Star washer
Rubber washer
Air Line Setup for Compressor Integration
Air Line Setup Without Compressor System
Vehicle body
or bumper
Hex nuts
Flat washer
Star washer
Rubber washer
Nylon air line
to compressor
system and
Schrader valve
Flat
Flat
Vehicle body
or bumper
Braided stainless steel
air line to air spring
5/16” (8mm)
hole
AN to PTC
fitting
Schrader
valve
Vehicle
body or
bumper
AN
Schrader
valve Air line hex nut
Flat washer
Nylon air line
to air spring
5/16” (8mm) hole
Braided
stainless
steel air line
to air spring
Hex nuts
Flat washer
Star washer
Rubber washer
Schrader
valve
Vehicle
body or
bumper
Nylon air line
to air spring
5/16” (8mm) hole
g. 18
g. 19

Rivet locations
g. 22 g. 23
Fender well
LoadLifter 5000 Series
MN-1046 13
1. If this installation was on a late-model 4WD Dodge truck, it is now necessary to
reinstall the inner fender well liner using the original fasteners and provided spacers
to allow for air spring clearance (fig. 20).
2. Place the spacer between the fender well liner and the fender well at the center hole
in the fender well liner (the hole nearest the air spring). Attach using the 1/4” hex-
head cap screw, the 10/32” flat washers, and 1/4” nylon lock nut provided (fig. 21).
Fasten the 1/4” hex-head cap screw with the washer and nut behind the fender well
(fig. 22). Tighten securely.
3. Replace the remaining fender well liner rivets carefully. Push the rivets through the
fender well liner by hand. They should push through completely (fig. 22).
4. From the opposite side, use a rubber mallet and carefully tap the rivet posts back
into the rivets in order to secure them properly (fig. 23). Repeat this process for all
remaining rivets.
NOTE
g. 21
Fender well
Fender well liner
1/4” Nylon lock nut
10/32” Flat washer
Fender well liner spacer
10/32” Flat washer
1/4” Hex-head
cap screw
g. 20
Before After
Reinstalling the Fender Well Liner
— Late Model 4WD DODGE ONLY

CHECKING FOR LEAKS
1. Inflate the air spring to 30 PSI.
2. Spray all connections and the inflation 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, deflate the springs to the minimum pressure required to restore the
system to normal ride height. Do not deflate 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 fitting:
a. Check the air line connection by deflating the spring and removing the line by
pulling the collar against the fitting and pulling firmly on the air line. Trim 1” off
the end of the air line. Be sure the cut is clean and square (see fig. 16). Reinsert
the air line into the push-to-connect fitting.
b. Check the threaded connection by tightening the swivel fitting another half turn.
If it still leaks, deflate the air spring, remove the fitting, 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 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 fitting. Cut the
air line off a few inches in front of the fitting and use a pair of pliers or vice grips
to pull/twist the air line off of the fitting.
DO NOT CUT OFF THE AIR LINE COMPLETELY AS THIS WILL USUALLY NICK THE
BARB AND RENDER THE FITTING USELESS.
3. If the preceding steps have not resolved the problem, call Air Lift customer service at
[phone].
Before Operating
CAUTION
LoadLifter 5000 Series
MN-1046
14

Clearance test — Inflate the air springs to 75-90 PSI and make sure there is at least
1/2” clearance from anything that might rub against each sleeve. Be sure to check
the tire, brakes, frame, shock absorbers and brake cables.
Leak test before road test — Inflate the air springs to 75-90 PSI and check all
connections for leaks. All leaks must be eliminated before the vehicle is road tested.
Heat test — Be sure there is sufficient clearance from 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.
Road test — The vehicle should be road tested after the preceding tests. Inflate the
springs to recommended driving pressures. Drive the vehicle 10 miles and recheck
for clearance, loose fasteners and air leaks.
Operating instructions — If professionally installed, the installer should review the
operating instructions with the owner. Be sure to provide the owner with all of the
paperwork that came with the kit.
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 — It is important to understand the air pressure
requirements of the air spring system. Regardless of load, the air pressure should
always be adjusted to maintain adequate ride height at all times while driving.
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.
INSTALLATION CHECKLIST
POST-INSTALLATION CHECKLIST
INSTALLATION CHECKLIST
POST-INSTALLATION CHECKLIST
LoadLifter 5000 Series
MN-1046 15
INSTALLATION CHECKLIST
POST-INSTALLATION CHECKLIST
INSTALLATION CHECKLIST
POST-INSTALLATION CHECKLIST

MAINTENANCE GUIDELINES
By following the steps below, vehicle owners will obtain the longest life and best results from
their air springs.
1. Check air pressure weekly.
2. Always maintain normal ride height. Never inflate beyond 100 PSI.
3. If the system develops an air leak, use a soapy water solution (1/5 liquid dish soap
and 4/5 water) to check all air line connections and the inflation valve core before
deflating and removing the air spring.
FOR SAFETY AND TO PREVENT POSSIBLE DAMAGE TO THE VEHICLE, DO NOT
EXCEED MAXIMUM GROSS VEHICLE WEIGHT RATING (GVWR), AS INDICATED BY
THE VEHICLE MANUFACTURER. ALTHOUGH THE AIR SPRINGS ARE RATED AT
A MAXIMUM INFLATION PRESSURE OF 100 PSI, THE AIR PRESSURE ACTUALLY
NEEDED IS DEPENDENT ON LOAD AND GVWR.
4. Loaded vehicles require at least 25 PSI. A “loaded vehicle” refers to a vehicle with a
heavy bed load, a trailer or both. Never exceed GVWR, regardless of air spring, air
pressure or other load assist. The springs in this kit will support approximately 40 pounds
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 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.
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 deflation 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 to remove mud,
sand, gravel or other debris.
NOTE
Product Use, Maintenance and Servicing
CAUTIONCAUTION
5 PSI 100 PSI
Maximum Air PressureMinimum Recommended Pressure
5 PSI 100 PSI
Maximum Air PressureMinimum Recommended Pressure
LoadLifter 5000 Series
MN-1046
16
CAUTION
5 PSI 100 PSI
Maximum Air PressureMinimum Recommended Pressure
5 PSI 100 PSI
Maximum Air PressureMinimum Recommended Pressure

LoadLifter 5000 Series
MN-1046 17
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. 24). 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. 25). 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 sacrifice a perfectly level and comfortable ride. Stability issues include roll
control, bounce, dive during braking and sponginess (fig. 26). 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. 27).
5. Adjust the pressure up and down to find 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. 28). As much as a 50 PSI difference is not uncommon.
Bad headlight aim Sway and
body roll
Rough ride
g. 24 g. 26 g. 25
Bottoming out Unlevel Level
g. 27 g. 28

Troubleshooting Guide
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
fittings in the control system.
Air spring or air line leak. Fitting seal or air line is compromised. Check to make sure air lines are seated in
connectors. Inspect fittings with soapy water.
Trim hose or re-seal fitting. 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.
LoadLifter 5000 Series
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18
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 standard, Ultimate and Ultimate Plus, the recommended
minimum air pressure is 5 PSI, but it can safely be run at zero air pressure unladen
(no load).
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.