Air Lift LoadLifter 7500 XL User manual

MN-1033 • (032004) • ECR 9273
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.
Installation
Guide
Ford Super Duty
Kit 57596
Representative vehicle image

A. Installation Diagrams ............................... 2
B. Hardware and Tools Lists............................ 3
Hardware List .........................................................3
Tools List.............................................................3
C. Introduction ....................................... 4
Notation Explanation ...................................................4
D. Installing the LoadLifter 7500 XL System ..............5
Getting Started ........................................................5
Installing the Braces ....................................................6
Retaining Clip L-Bracket Installation on Brace................................7
Driver’s (Left) Side Brace Installation .......................................8
Passenger’s (Right) Side Brace Installation .................................10
Air Spring and Bracket Assembly......................................... 11
Attaching the Assemblies to the Frame ....................................16
Attaching the Lower Bracket to the Axle ...................................19
E. Installing the Air Lines ..............................23
Installing the Heat Shield ............................................... 23
F. Finished Installation Photos .........................24
G. Before Operating ..................................25
Installation Checklist................................................... 25
H. Maintenance and Use Guidelines .....................25
Minimum and Maximum Pressure ........................................ 25
Limited Warranty and Return Policy ...................25
Table of Contents

MN-1033
222
A. Installation Diagrams
L
R
K
RT
YX
ZW
W
Q OR CC
X
P
H
S
UV
E
V
SS
RR II
F
M
O
I
J
DD
DD
I
AA
A
JJ
VU
B
BB
G
V
U
Z
W
EE OR GG
EE
N OR CC
C
U
V
S
H
RR
V
SS
II
D
M
O
O
O
I
J
DD
DD
I
AFF
HH
AA
V
U
B
JJ
BB
G
V
U
JJ
JJ
HH
FF
BB
HH
FF
WW
L
R
K
RT
YX
ZW
W
Q OR CC
X
P
H
S
UV
E
V
SS
RR II
F
M
O
I
J
DD
DD
I
AA
A
JJ
VU
B
BB
G
V
U
Z
W
EE OR GG
EE
N OR CC
C
U
V
S
H
RR
V
SS
II
D
M
O
O
O
I
J
DD
DD
I
AFF
HH
AA
V
U
B
JJ
BB
G
V
U
JJ
JJ
HH
FF
BB
HH
FF
WW
* NOTE: If the vehicle has a fifth-wheel hitch
installed that has side plates along the frame, use
the existing hardware that was removed. If not, use
the 1/2” hardware supplied and recommended in
this kit and in the directions in this installation guide.
Passenger’s
(right) side
Driver’s
(left) side
g. A.1
LoadLifter 7500 XL
2

MN-1033 333
B. Hardware and Tools Lists
TOOLS LIST
Description.............................................. Qty
Metric & standard open-end box wrenches........... set
Ratchet with metric & standard sockets ................ set
Standard hex keys.................................................. set
Drill and 5/16" drill bit................................................ 1
Torque wrench........................................................... 1
Hose cutter, razor blade or sharp knife ..................... 1
Hoist or floor jack ...................................................... 1
Safety stands............................................................. 2
Safety glasses ........................................................... 1
Air compressor or compressed air source ................ 1
Spray bottle with dish soap/water solution............... 1
HARDWARE LIST
Item Part # Description.................................................QTY
A 03964 Lower bracket main plate .................................. 2
B 03998 Lower bracket cup............................................. 2
C 07975 Upper brace, RH................................................ 1
D 07965 Upper bracket, RH............................................. 1
E 07676 Upper brace, LH ................................................ 1
F 07666 Upper bracket, LH ............................................. 1
G 01851 Clamp bar .......................................................... 2
H 13966 Spacer ............................................................... 2
I 11897 Roll plate............................................................ 4
J 58120 Air spring ........................................................... 2
K 10886 L-bracket ........................................................... 1
L 17135 1/4"-20 x 1" Hex-cap screw.............................. 1
M 17140 3/8"-16 x 2" Carriage bolt ................................. 2
N 17161 1/2"-13 x 1 1/2" Hex-cap screw........................ 1
O 17361 3/8"-16 x 1 1/4" Carriage bolt ........................... 4
P 17177 M8-1.25 x 25mm Hex-cap screw...................... 1
Q 17412 1/2"-13 x 1 1/4" Hex-cap screw........................ 1
R 18419 #12 Flat washer ................................................. 2
S 18422 3/8"-16 Serrated flange lock nut ....................... 2
T 18425 1/4"-20 Nylon lock nut....................................... 1
U 18435 3/8"-16 Nylon lock nut...................................... 12
V 18444 3/8" Flat washer................................................ 16
W 18485 1/2" Flat washer................................................. 3
X 18501 M8 Flat washer .................................................. 2
Y 18522 M8-1.25 Nylon lock nut ..................................... 1
Z 18505 1/2"-13 Serrated flange lock nut ....................... 2
Item Part # Description.................................................QTY
AA 11717 U-bolt................................................................. 2
BB 17113 5/16"-18 x 1" Carriage bolt ............................... 3
CC 17271 1/2"-13 x 3" Hex-cap screw.............................. 2
DD 17387 3/8"-16 x 10" Carriage bolt ............................... 4
EE 18207 1/2" Thick flat washer........................................ 2
FF 18433 5/16" Flat washer............................................... 7
GG 18556 3/4" Flat washer................................................. 1
HH 18613 5/16"-18 Thin nylon lock nut ............................. 2
II 21830 90 degree Swivel elbow fitting........................... 2
JJ 17215 3/8"-24 x 3/4" Flat-head screw ......................... 4
KK 20086* Air line ............................................................... 1
LL 10466* Zip tie................................................................. 6
MM 21230* Valve cap ........................................................... 2
NN 18501* 5/16" Flat washer............................................... 2
OO 21234* Rubber washer .................................................. 2
PP 18411* Star washer........................................................ 2
QQ 21233* 5/16" Hex nut..................................................... 4
RR 17203 3/8"-24 x 7/8" Hex-cap screw........................... 4
SS 18427 3/8" Lock washer............................................... 4
TT 17103* 5/16"-18 x 1" Hex-cap screw............................ 2
UU 18438* 5/16"-18 Nylon lock nut..................................... 3
VV 22640* High-temp zip tie ............................................... 1
WW 26333 Modified P-clamp .............................................. 1
XX 11901* Emergency brake cable secondary bracket ..... 1
YY 11908* Emergency brake cable primary bracket .......... 1
* Not shown in the Installation Diagrams
STOP!
LoadLifter 7500 XL
3
STOP! Missing or damaged parts? Call Air Lift customer
service at [phone] for a replacement part.

MN-1033
4
C. Introduction
NOTE
The purpose of this publication is to assist with the installation, maintenance and
troubleshooting of the LoadLifter 7500 XL air spring kit. LoadLifter 7500 XL 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 7500 XL kits are recommended for most 3/4- and 1-ton
pickups and SUVs with leaf springs and provide up to 7,500 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. 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.
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
CAUTION
WARNING
LoadLifter 7500 XL
4
DANGER
CAUTION
WARNING

MN-1033 5
g. D.1
g. D.2
g. D.3
GETTING STARTED
1. Raise the vehicle and support it in a way, using safety stands or equivalent, that the
axle can be safely lowered away from the frame. This will need to be done in order for
the air spring assembly to be put into position between the axle and frame (Fig. D.1).
2. Remove the jounce bumpers from under the frame, over the axle (Figs. D.2 & D.3).
Use a wire brush and some penetrating oil on the jounce bumper to help in its removal. The
socket size for the nut is typically 15mm.
D. Installing the LoadLifter 7500 XL System
NOTE
LoadLifter 7500 XL
5

MN-1033
6
Set left side brace
inside the frame (E)
Frame Rail
g. D.4
g. D.5
g. D.6
3. If necessary, disconnect the wiring harness from the driver’s (left) side frame rail to gain
clearance for the upper brace (Fig. D.4). Also, push out the harness connector that
holds the electrical lines going to the gas/DEF tank in or out of the tank bracket. This
will improve socket/bolt access required for installing and tightening the frame brace
(Fig. D.5).
4. If the truck has a fifth-wheel hitch already installed, other than the standard factory
Reese hitch, remove the hardware that bolts the side bracket (plates) to the outside
of the frame above the axle.
INSTALLING THE BRACES
Gas engine models have emission lines on the inside of the frame. If the truck has
emission lines running along the inside of the frame rail (Fig. D.6), relocate those lines as
follows:
1. Carefully push the line holder out of the frame above the axle and save for reuse.
Remove any emissions/fuel line retaining clips and electrical wire loom retaining clips
forward or rearward of the axle to aid in positioning the lines once the upper brace
has been installed (Figs. D.6 & D.7).
If equipped, this
emissions/fuel line
retaining clip must
be pulled away
from the frame in
order to install the
upper frame brace
(E).
Push this
electrical harness
connector out
of the gas/DEF
tank bracket for
better access to
mounting hole/slot
in frame.
Remove the line
holders from
the gas/DEF
tank bracket for
easier access to
the upper brace
hardware.
LoadLifter 7500 XL
6

MN-1033 7
g. D.7
g. D.8
RETAINING CLIP L-BRACKET INSTALLATION ON BRACE
1. In order to reattach the previously removed emissions line, attach the provided
L-bracket (K) to the back frame brace using the 1/4"-20 x 1" bolt (L), flat washers (R)
and 1/4"-20 nylon lock nut (T) supplied (Fig. D.5). Placing this L-bracket depends on
where the line holder is on the wiring or the emissions line that was previously pulled
from the frame. Set the driver’s (left) side frame brace (E) against the frame and
insert the 8mm-1.25 x 25mm hex-cap screw (P) with an M8 flat washer (X) through
the brace and into the hole in the side of the frame from which the line holder was
removed (Fig. D.8). This will hold the line in place. Note which side the line holder
is in, in respect to the back leg of the brace. Is it forward or behind the back leg of
the brace? Where the line holder lines up is the side where the L-bracket is to be
installed (Figs. D.7 & D.8).
2. Pull the brace back out and attach the L-bracket onto the brace with the hardware
noted above, in the proper location previously found (Figs. D.9 & D.10). Make sure
the L-bracket faces up and tighten securely.
Image shows
lines clear on
the frame,
opening it up
for the brace
installation.
Brace being
temporarily held
in place by the M8
bolt and washer.
L-bracket is shown
in location already.
Note: The side
the line holder is
on depends on
the location of the
factory retaining
clip.
g. D.9 g. D.10
LoadLifter 7500 XL
7
No matter what side the L-bracket is
on, make sure it is installed so the flat
side points up when tightening.
Attach the L-bracket to the brace in
the position previously found using
the hardware specified.

MN-1033
8
DRIVER’S (LEFT) SIDE BRACE INSTALLATION
1. Set the left upper brace (E) into the driver’s side frame rail. The brace has a small hole
that will line up with an existing hole in the frame. Insert the M8-1.25 x 25mm hex-
cap screw (P) with an M8 flat washer (X) through the brace and frame (Figs. D.11 &
D.12) and cap with a M8 flat washer (X) and M8-1.25 nylon lock nut (Y). Leave loose
at this time.
BE SURE NOT TO PINCH THE PREVIOUSLY MOVED WIRING OR LINES INSIDE THE
LEFT FRAME RAIL.
2. If the truck has no fifth-wheel hitch or if it has the standard equipment Reese fifth-
wheel hitch that was purchased on the truck from Ford, in the frame there is a slot
that is forward of the 8mm bolt just installed, insert the 1/2"-13 x 1 1/4" hex-cap
screw (Q) and 1/2" flat washer (W) through the brace and frame (from the inside out).
Cap with a 1/2" flat washer (W) and a 1/2"-13 serrated flange lock nut (Z) (Figs. D.11,
D.13 & D.14). Do not tighten at this time.
OR
g. D.12
g. D.13
Attach the
bracket to the
frame using the
8mm hardware
noted.
Driver’s (left) side
brace shown
with supplied
hardware in
place. Existing
fifth-wheel
hardware which
may have been
removed may
look different.
g. D.11
LoadLifter 7500 XL
8
CAUTION

MN-1033 9
NOTE
g. D.14
If the truck has an aftermarket fifth-wheel hitch that has an outer bracket (plate)
running along side of the frame and it used this slot to secure the bracket with
existing hardware, install the original fifth-wheel hardware previously removed in
the Getting Started section from the fifth-wheel installation for securing the brace
(Fig. D.11). Do not tighten at this time.
OR
If the truck has an aftermarket fifth-wheel hitch that has an outer bracket (plate)
running along side of the frame and it does not have any attaching hardware on the
side where the slot in the frame is, it will be necessary to drill a 1/2" hole through the
plate using the slot in the frame as a template. Drill the hole as far to the rear of the
slot as possible.
CLEAR ANY ELECTRICAL OR HARD LINES FROM THE AREA SO AS NOT TO DAMAGE
THEM IN ANY WAY WHEN DRILLING THE HOLE.
It may be necessary to mark and remove the outer bracket (plate) from the side of the frame
in order to drill the hole correctly. Reattach once the hole is drilled.
3. Insert a 1/2"-13 x 3" hex-cap screw (CC) with a 1/2" flat washer (W) through the
brace, frame and fifth-wheel plate previously drilled. Cap with a 1/2" flat washer (W)
and a 1/2"-13 serrated flange lock nut (Z) (Fig. D.14). Leave loose at this time.
Rear view of driver’s (left) side shown
Existing jounce
bumper hole
1/2”-13 serrated
flange locknut (Z)
1/2” flat washer (W)
REAR OF
VEHICLE
FRONT OF
VEHICLE
Ford standard
Reese equipped
fifth-wheel hitch
bracket along the
outside of the
frame.
NOTE: Also use if
there is NO fifth-
wheel hitch on
the vehicle.
g. D.14
LoadLifter 7500 XL
9
CAUTION

MN-1033
10
g. D.16
g. D.17
For the passenger's (right)
side, before inserting the
upper brace hardware,
make sure that the 1/2”
thick flat washer (EE) or
(GG) is installed in between
the brace and frame (see
Step 2). Note: The 1/2”
thick flat washer (EE) is
not a half inch thick. It has
a 1/2” hole and is a thick
washer.
Passenger's
(right) side
upper brace
shown with
hardware
supplied in
place.
FRONT OF
VEHICLE
REAR OF
VEHICLE
PASSENGER'S (RIGHT) SIDE BRACE INSTALLATION
1. Set the right upper brace (C) into the passenger's (right) side frame rail (Figs. D.15,
D.16 & D.17).
*& ** See footnote in Fig. A.1
EE or GG
g. D.15
II
Inside view of passenger’s (right) side frame shown
LoadLifter 7500 XL
10

MN-1033 11
NOTE
NOTE
NOTE
g. D.18
2. For trucks with no fifth-wheel or the OEM purchased Reese fifth-wheel hitch, insert
the 1/2"-13 x 1 1/2" hex-cap screw (N) and 1/2" thick flat washer (EE) through the
brace, between the brace and the frame add the 1/2" thick flat washer (EE) then
through the frame (from the inside out). Note: The 1/2" thick flat washer (EE) is not
a half inch thick. It has a 1/2" hole and is a thick washer. Cap with a 1/2" flat washer
(W) and a 1/2"-13 serrated flange lock nut (Z) (Figs. D.14 & D.15). Do not tighten at
this time.
OR
If the truck has an aftermarket fifth-wheel hitch that has an outer bracket (plate)
running along side of the frame and it used this slot to secure the bracket to the
frame with existing hardware, re-install the original hardware previously removed in
the Getting Started section. However, add the 1/2” thick flat washer (EE) or 3/4” flat
washer (GG) depending on whether the existing hardware is in between the brace
and the frame (Fig. D.15).
The 1/2” thick flat washer (EE) is not a half inch thick. It has a 1/2” hole and is a thick
washer. Do not tighten at this time.
OR
If the truck has an aftermarket fifth-wheel hitch that has a bracket (plate) running
along side of the frame and it does not have any attaching hardware on the side
where the slot in the frame is, it will be necessary to drill a 1/2” hole through the plate
using the slot in the frame as a template.
It may be necessary to mark and remove the bracket (plate) from the side of the frame in
order to drill the hole correctly. Reattach once the hole is drilled.
Insert a 1/2”-13 x 3” hex-cap screw (CC) with a 1/2” thick flat washer (EE) through
the brace, between the brace and the frame add the 1/2” thick flat washer (EE) then
through the frame and fifth-wheel plate previously drilled. NOTE: The 1/2” thick flat
washer (EE) is not a half inch thick. It has a 1/2” hole and is a thick washer. Cap with
a 1/2” flat washer (W) and a 1/2”-13 serrated flange lock nut (Z) (Fig. D.14). Leave
loose at this time.
AIR SPRING AND BRACKET ASSEMBLY
1. Set roll plates (I) over the top and bottom of the air springs (J) (Figs. A.1 & D.18).
The radiused (rounded) edge of the roll plate (I) will be toward the air spring so that the air
spring is seated inside both roll plates.
2. Install the swivel elbow fitting (II) into the top of the air spring finger-tight. Tighten the
swivel fitting one and a half turns.
Set roll plate (I)
over the air spring
and install the
fitting (II) as stated.
Repeat for the
other air spring.
I
II
LoadLifter 7500 XL
11

MN-1033
12
g. D.19
g. D.20
g. D.22 g. D.23
3. Insert a 5/16"-18 x 1" carriage bolt (BB) through the square hole in the lower bracket
cup (B). Make sure to insert the carriage bolt on the flanged side of the bracket. Set
the assembly onto the lower bracket main plate (A) making sure the lower bracket
cup (B) is on the flanged side of the bracket (Fig. D.19).
4. Flip the assembly over and cap the 5/16"-18 x 1" carriage bolt with a 5/16” flat
washer (FF) and 5/16” thin nylon lock nut (HH) (Fig. D.20). Tighten the nut only tight
enough so that the cup still swivels on the lower bracket main plate (Fig. D.21).
5. Insert one of the 3/8”-16 x 10” carriage bolts (DD) into the lower bracket assembly
previously assembled (Fig. D.22). Determine which holes correspond with either side
(Fig. D.23).
A
BB
B
Bottom of lower bracket.Top of lower bracket.
Passenger’s (right) side,
use this hole
HH
FF
DD
Driver’s (left) side,
use this hole
g. D.21
LoadLifter 7500 XL
12

MN-1033 13
The air fitting
must be on
this side of the
assembly.
Driver’s
(left) side
The 3/8"-16 x 10"carriage bolts will be behind the axle once the assembly is installed on
the axle.
6. The lower bracket assembly has two sets of air spring mounting holes, one for the
driver’s (left) side, the other for the passenger’s (right) side. Insert one 5/16"-18 x 1"
carriage bolt (BB) into the square hole as shown for the driver's (left) side assembly
(Fig. D.24). Using the corresponding holes in the lower bracket designated (Figs. D.24
& D.25), attach the air spring to the bracket using the 3/8"-24 x 3/4" flat-head screws
(JJ) and torque to no more than 20 lb.-ft. (27Nm).
7. Figures D.26 & D.27 shows the driver’s (left) side and passenger’s (right) side
assemblies.
Passenger’s (right) side air
spring mounting holes shown
in relation to the 3/8"-16 x
10" carriage bolt previously
installed. When installing on
the air spring, make sure the
bracket edge facing you is on
the fitting side of the air spring.
Driver’s (left) side air spring
mounting holes shown in
relation to the 3/8"-16 x
10" carriage bolt previously
installed. When installing on
the air spring, make sure the
bracket edge facing you is on
the fitting side of the air spring.
Passenger’s
(right) side
This slot
should be on
the opposite
side of the
air line fitting
on the air
spring once
mounted.
NOTE
g. D.24
g. D.25
g. D.26 g. D.27
LoadLifter 7500 XL
13

MN-1033
14
g. D.29
g. D.30
Cut a small section of cardboard and fold it in half. When assembling the upper bracket
to the air spring, set this cutout under the carriage bolt between the roll plate and upper
bracket to hold the carriage bolt in place. This will make it easier to tighten the mounting
hardware once in place on the frame (Fig. D.28).
8. Set the lower bracket assembly aside. Pick up the driver's side (F) and passenger's
(right) side (D) upper brackets (Fig. D.29). Insert two 3/8”-16 x 1 1/4" carriage bolts
(O) up through the bottom of the driver's (left) side (F) and passenger's (right) side
(D) upper brackets (Figs. D.29 & D.30), through the two square holes that are on
the corresponding side. Also, insert one 3/8"-16 x 2" carriage bolt (M) through the
remaining hole. The head of this carriage bolt will be hidden once the upper bracket
is mounted to the air spring.
TECH TIP
O
F
M
g. D.28
O
D
Driver’s
(left) side
Passenger’s
(right) side
Driver’s (left) side Passenger’s (right) side
LoadLifter 7500 XL
14

MN-1033 15
9. Set the driver’s (left) side upper bracket onto the driver’s (left) side air spring
assembly previously assembled, using the holes in the upper bracket designated
(Fig. D.29), and attach to the air spring with two 3/8" flat washers (V), 3/8" lock
washers (SS) and 3/8"-24 x 7/8" hex-cap screws (RR). Torque no more than
20 lb.-ft. (27Nm). (Figs. D.30, D.31 & D.32).
10.Repeat the above process on the passenger's (right) side assembly (Fig. D.32).
11.Set the spacers (H) over both 3/8”-16 x 2” carriage bolts (M) (Figs. D.31, D.32 &
D.34).
The hole in the flat spacer (H) is offset. Install the spacer so that the wide portion faces the
outside of the vehicle (Figs. D.31 & D.34).
g. D.31 g. D.32
g. D.33
g. D.34
NOTE
V, SS, RR
F
H - wide portion of spacer points outward
D
V, SS, RR
Passenger's (right) sideDriver's (left) side
Attach the
upper bracket
to the air spring
assembly
with two 3/8”
flat washers
(V), 3/8” lock
washers (SS),
and 3/8”-24 x
7/8” hex-head
cap screws
(RR).
Spacer (H) set
on bracket in
position. The
wide side of the
spacer faces the
outside of the
vehicle.
M
H
V
SS
MRR
LoadLifter 7500 XL
15

MN-1033
16
12. Figure D.35 shows the assemblies complete and ready to install.
ATTACHING THE ASSEMBLIES TO THE FRAME
1. Drop the axle or raise the frame to make room to put the assemblies into position.
2. Set the driver’s (left) side assembly onto the jounce bumper strike plate (Fig. D.36).
Make sure the 3/8"-16 x 10" carriage bolt (DD) on the bottom bracket goes
outside the hard brake line on the back side of the axle. Raise the axle just enough
to insert the 3/8"-16 x 2" carriage bolt (M) (that is installed in the upper bracket)
through the existing jounce bumper hole in the bottom of the frame. At the same
time, line up the upper brace into the remaining two carriage bolts in the assembly’s
upper bracket (Fig. D.37). Do this just enough for the carriage bolts to hold the
assembly into postion in the frame, while resting on the jounce bumper strike plate
(Fig. D.36).
g. D.35
The long carriage
bolt must go
outside the hard
brake/ABS line on
the driver’s (left)
side.
Raise the axle up
while aligning the
3/8"-16 x 2" carriage
bolt (M) through the
frame and the two
3/8"-16 x 1 1/4"
carriage bolts (O) in
the upper bracket,
through the brace.
Existing
jounce
bumper
strike
plate g. D.36
g. D.37
O
Driver’s
(left) side
assembly
Passenger’s
(right) side
assembly
LoadLifter 7500 XL
16

MN-1033 17
3. Set the passenger's (right) side assembly into position on the jounce bumper strike
plate the same way the left side was positioned (Fig. D.38). Note: the long carriage
bolt goes outside of the hard brake line on the passenger's (right) side.
4. Make sure the thick spacer (H) is parallel to the frame and bracket (Fig. D.39). Finish
raising the axle or lowering the frame until the spacer contacts the frame on both
sides.
5. Install the 3/8"-16 serrated flange lock nut (S) on the 3/8"-16 X 2" carriage bolt (M)
that went through the existing jounce bumper hole and tighten securely on both sides
(Fig. D.40).
BE SURE NOT TO PINCH THE PREVIOUSLY MOVED WIRING OR LINES INSIDE THE
LEFT FRAME RAIL.
g. D.38
g. D.39
g. D.40
Make sure the
spacer (H) is
parallel to both the
frame and upper
bracket. Raise axle
or lower frame until
the spacer touches
the frame on both
sides.
Install the 3/8"-16
serrated flange lock nut
(S) onto the 3/8"-16 x 2"
carriage bolt (M) that goes
through the flange on the
frame and tighten.
The long carriage
bolt goes on the
outside (backside)
of the hard brake/
ABS line on the
passenger's (right)
side.
H
S
M
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CAUTION

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18
6. Cap the 3/8"-16 x 1 1/4" carriage bolts (O) with 3/8" flat washers (V) and 3/8"-16
nylon lock nuts (U) on both sides and torque to 15 lb.-ft. (20Nm) (Fig. D.41).
7. With the spacers (H) on the upper brackets tight to the bottom of the frame and the
braces tight to the upper brackets, tighten the 8mm (driver’s [left] side only) and 1/2"
or 3/4" hardware previously installed, that hold the braces to the frame (Fig. D.42).
Tighten both sides.
If possible, use a thin socket. It helps to pull back the driver's (left) side mounting hardware
(Q or CC) as far back in the slot as possible while tightening.
8. Once the driver’s (left) side 1/2" or 3/4" hardware has been tightened, push the wiring
harness connector – which was removed in the Getting Started section – back into
the gas/DEF tank mounting hole. If the connector broke during disassembly, zip tie it
to the bracket (Figs. D.4 & D.5).
9. If equipped with the emissions line previously loosened from the frame, insert the line
holder post into the L-bracket (K) attached to the back leg of the upper left brace (E)
(Fig. D.43). It may be necessary to move the line holder post forward or back on the
lines to line up correctly with the L-bracket hole. Reattach any line holders removed
forward or behind the axle, if possible, that were removed to aid in positioning the
upper bracket.
g. D.42
g. D.43
g. D.41
Cap the 3/8"-16
x 1 1/4" carriage
bolts (O) with 3/8"
flat washers (V)
and 3/8"-16 nylon
lock nuts (U), then
torque to 15 lb.-ft.
(20Nm). Repeat
for the other side.
Tighten the M8
hardware and the
1/2"(or 3/4" if
from the fifth-wheel
hitch hardware) and
tighten securely.
Repeat for the
hardware on the
opposite side.
U
V
O
Insert the line
holder previously
removed into the
L-bracket installed
on the upper
brace as shown.
NOTE
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