Air Lift LoadLIFTER5000 User manual
Kit No. 57362
Please read these instructions completely bere proceeding with installation
Air Spring Kit Parts List
Item P/N Description Quantity
A
D
G
L
M
N
cc
DD
GG
Z
1
Technical Support
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2
Technical Support
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I. Assembling the Unit
1. Set a roll plate (D) on both ends of the air spring (A). 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
(Figure 2).
2. Install 90 degree elbow fitting (E) to the top of the air spring.
Tighten finger-tight plus 1 and 1/2 turns. Be careful to only
tighten on the metal hex nut. Do not over tighten.
3. Set the upper bracket (B) over the top of the air spring. Attach
the upper bracket using two 3/8" bolts (F), two lock
washers (G), and two flat washers (H). Tighten securely
(Figure 2).
4. Set the lower bracket (C) on to the bottom of the air spring.
NOTE: The bracket will be offset to the outside of the vehicle
(Figure 3). Attach using two 3/8" bolts (F), two lock
washers (G), and two flat washers (H). Leave loose at this
time for later adjustment (Figure 2).
II. Removing the Jounce Bumper
1. Drill or cut the rivets off of the side of the frame that hold the
jounce bumper bracket on.
2. Remove the jounce bumper bracket from the side of the frame.
Drive the rivets out of the holes that are in the frame (Figure
4). CAUTION: There are lines on the inside of the frame on
the passenger's (right) side. Use extreme caution to avoid
damaging these lines in any way during the removal
process.
3. Drill the two bottom holes out with a 1/2" drill bit. If unable
to drill from the outside in, then drill the holes from the inside
of the frame out.
Tools Needed
IMPORTANT: Your vehicle may be equipped with a rear brake proportioning valve. Any type of load assist product could
affect brake performance. We recommend that you check with your dealer before installing this type of product. If your
vehicle DOES NOT have a rear brake proportioning valve or is equipped with an anti-lock type brake system, installation
of a load assist product will have NO EFFECT ON BRAKE SYSTEM PERFORMANCE.
IMPORTANT: Failure to maintain correct minimum pressure (or pressure proportional to load), bottoming out,
overextension, or rubbing against another component will void the warranty.
DANGER: 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.
1/2", 9/16" Open-end or box wrenches
Adjustable wrench
Ratchet with 9/16", 1/2" deep well sockets
5/16" Drill bits (very sharp)
Heavy duty drill
Torque wrench
Hose cutter, razor blade, or sharp knife
Hoist or floor jacks
Safety stands
Safety glasses
Air compressor, or compressed air source
Spray bottle with dish soap/water solution
Figure 2
Figure 3
OUTBOARD
3
Technical Support
1-800-248-0892
III. Installing the Assembly
1. Set the assembly on the leaf spring and insert two 1/2" carriage
bolts (L) through the bottom holes in the upper bracket and then
through the frame. Install a flat washer (M) and nylon lock nut
(N) to each bolt. Refer to Figure 1. Leave loose for
adjustment.
2. Insert two 3/8" frame bolts (I) through the top holes in the
upper bracket and frame. Secure using two flat washers (H)
and two nylon lock nuts (K) to the inside of the frame (Fig. 1).
3. Tighten all upper bracket mounting hardware at this time.
4. Insert four 3/8" bolts (J) and four flat washers (H) into the
holes on the lower bracket (Figure 1).
5. Slide two clamp bars (O) onto the bolts hanging from the lower
bracket and attach using four flat washers (H) and four nylon
lock nuts (N). Refer to Figure 1.
6. The lower bracket is slotted for in and out alignment of the air
spring. Align the air spring so that it is parallel and perpendicular
to the top and bottom. When aligned, tighten all mounting
hardware, including the lower air spring hardware to the specified
torque value found on page 5.
IV.Installing the Air Lines
1. Choose a convenient location for mounting the inflation valves
and drill a 5/16" hole to install the inflation valves. Popular
locations for the inflation valve are: the wheel well flanges, license
plate recess in bumper, under the gas cap access door, or
through license plate itself. NOTE: What ever the chosen
location is, make sure there is enough clearance around the
inflation valves for an air chuck.
2. Cut the air line assembly (AA) in two equal lengths. CAUTION: When cutting or trimming the air line, use a hose
cutter (Air Lift P/N 10530), 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.
3. Place a 5/16" nut (GG) and a star washer (FF) 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 (EE), flat washer (DD), and 5/16" nut (GG) and
cap (CC). There should be enough valve exposed after installation - approximately 1/2" (13mm) - to easily
apply a pressure gauge or an air chuck (Figure 5).
4. Push the inflation valve through the hole and use the rubber washer (EE), flat washer (DD), and another 5/16"
nut (GG) to secure it in place. Tighten the nuts to secure the assembly in place (Figure 5).
5. Route the air line along the frame to the air fitting on the air spring. Keep at least 6" (150mm) of clearance
between the air line and heat sources, such as the exhaust pipes, muffler, or catalytic converter. Avoid sharp
bends and edges. Use the plastic zip ties (BB) to secure the air line to fixed, non-moving points along the chassis.
Be sure that the zip ties are tight, but do not pinch the air line. Leave at least 2" (50mm) of slack to allow for any
movement that might pull on the air line.
6. Cut off air line leaving approximately 12" (300mm) of extra air line. A clean square cut will ensure against leaks.
Insert the air line into the air fitting. This is a push to connect fitting. Simply push the air line into the 90 degree
swivel fitting until it bottoms out (9/16" of air line should be in the fitting).
Figure 4
Air Line to
Bellows
FF
Vehicle body
or bumper
GG
GG
EE
DD
CC
Remove Rivets
Figure 5
4
Technical Support
1-800-248-0892
V. Checking for Leaks
1. Inflate the air spring to 30 PSI (2.1BAR)
2. Spray all connections and the inflation valves with a solution of dish soap and water to check for leaks. You should
be able to 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 Normal Ride Height, but not less
than 10 PSI (.7BAR).
4. IMPORTANT: Check the air pressure again after 24 hours. A 2 to 4 PSI (.1-.3BAR) loss after initial installation
is normal. Retest for leaks if the loss is more than 5 lbs.
VI. Fixing Leaks
1. If there is a problem with the swivel fitting, then:
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" (25mm) off the end of the air line. Be sure the cut is clean and square.
Reinsert the air line into the push-to-connect fitting.
b. Check the threaded connection by tightening the swivel fitting another 1/2 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, then use a wrench for an additional two turns.
2. If there is a problem with the inflation 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 fitting. CAUTION: Do not cut it off.
As this will usually nick the barb and render the fitting useless. Cut air line off a few inches in front of the fitting
and use a pair of pliers or locking pliers to pull/twist the air line off the fitting.
3. If the preceding steps have not resolved the problem, call Air Lift Technical Service at 1-800-248-0892 for assistance.
VII. Troubleshooting Guide
Problems maintaining air pressure, without on-board compressor.
1. Leak test the air line connections and threaded connection of the elbow into the air spring. See Section VI to repair.
2. Leak test the inflation valve for leaks at the air line connection or dirt or debris in the valve core. See Section VI to
repair.
3. Inspect air lines to be sure it is not pinched. Zip ties may be too tight. Loosen or replace strap. Replace leaking
components.
4. Inspect air line for holes and cracks. Replace as needed.
5. A kink or fold in the air line. Reroute as needed.
You have now tested for all of the most probable leak conditions that can be easily fixed. At this point the problem is
most likely a failed air spring - either a factory defect or an operating problem. Please call Air Lift at 1-800-248-0892 for
assistance or a replacement air spring.
5
Technical Support
1-800-248-0892
VIII. Checklist
Protectyourwarrantyonthisproductandpreventunnecessarywearbyensuringthefollowingcheckshavebeenmade:
Section I – Installation (To be completed by the installer):
Section II - Post Installation Checklist (To be completed by the owner):
1. Clearance Test - Inflate the air springs to 60 PSI (4BAR) and ensure there is at least 1/2 " (13mm)
clearance around each sleeve from anything that might rub against them. Be sure to check the tire,
brake drum, frame, shock absorbers and brake cables.
2. Leak Test Before Road Test – Inflate the air springs to 60 PSI (4BAR), check all connections for leaks
with a soapy water solution. See page 4 of the manual for tips on how to spot leaks. All leaks must be
eliminated before the vehicle is road tested.
3. Heat Test – Be sure there is sufficient clearance from heat sources - at least 6" (150mm) 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 1-800-0892.
4. Fastener Test – Recheck all bolts for proper torque.
100 lb.-ft.
44 lb.-ft.
Torque Guide:
1/2" Carriage Bolts
3/8" Frame Bolts
U-bolt Lock Nuts 16 lb.-ft.
5. Road Test – The vehicle should be road tested after the preceding tests. Inflate the springs to 25 PSI
(1.7BAR) (50 PSI [3.5BAR] if vehicle is loaded). Drive the vehicle 10 miles (16km) and recheck for
clearance, loose fasteners and/or air leaks.
6. Operating Instructions – If professionally installed, the installer should review the operating instructions
on page 6 with the owner. Be sure to provide the owner with all of the paperwork that came with the kit.
1. Overnight Leakdown Test – Recheck air pressure after vehicle has been used for 24 hours. If pressure
has dropped more than 5 PSI (.4BAR) then, you have a leak that must be fixed. Either fix the leak
yourself (see page 4) or return to the installer for service.
2. Air Pressure Requirements – I understand that the air pressure requirements of my air spring system are
as follows:
Minimum ___________ Maximum ___________
Regardless of load, the air pressure should always be adjusted so that the Ride Height is maintained at all
times.
3. Thirty Day or 500 Mile (800km) Test. I understand that I must recheck the air spring system after 30 days
or 500 miles (800km), 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.
6
Technical Support
1-800-248-0892
Ext. 2
IX. Maintenance and Operations
By following these steps, 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 inflate beyond 100 PSI (7BAR).
3. If you develop an air leak in the system, use a soapy water solution to check all air line connections and the inflation
valve core before deflating and removing the air spring.
4. 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.
5. IMPORTANT: For your safety and to prevent possible damage to your vehicle, do not exceed maximum Gross
VehicleWeight Rating (GVWR), as indicated by the vehicle manufacturer. Although your air springs are rated at a
maximum inflation pressure of 100 PSI (7BAR). The air pressure actually needed is dependent on your load and
GVWR, which may be less than 100 PSI (7BAR). Check your vehicle owners manual and do not exceed the
maximum load listed for your vehicle.
6. Always add air to springs in small quantities, checking the pressure frequently. Air springs require less air
volume than a tire and inflate quickly.
7. Should it become necessary to raise the vehicle by the frame, make sure the system is at minimum pressure (10
PSI
[.7BAR]
) to reduce the tension on the suspension/brake components. Use of on–board leveling systems
do not require deflation or disconnection.
20 PSI (1.4BAR) 100 PSI (7BAR)
Failure to maintain correct minimum pressure (or pressure proportional to load), bottoming
out, over-extension, or rubbing against another component will void the warranty.
Maximum Air PressureMinimum Air Pressure
“The Choice of the Professional Installer”
For Technical Assistance call 1-800-248-0892
Thank you for purchasing Air Lift Products
Mailing Address: Street Address:
AIR LIFT COMPANY AIR LIFT COMPANY
P.O. Box 80167 2710 Snow Rd.
Lansing, MI 48908-0167 Lansing, MI 48917
Local Phone: (517) 322-2144
Fax: (517) 322-0240
http://www.airliftcompany.com
Product Use Information
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 time and how much pressure will they need?
The minimum air pressure should be maintained at all times. The minimum air pressure keeps the air spring in shape,
ensuring that it will move throughout its travel without rubbing or wearing on itself.
Q. Is it necessary to add a compressor system to the air springs?
No.Airpressurecanbeadjustedwithanytypeofcompressoraslongasitcanproducesufcientpressuretoservice
the springs. Even a bicycle tire pump can be used, but it’s a lot of work.
Q. How long should air springs last?
Iftheairspringsareproperlyinstalledandmaintainedtheycanlastindenitely.
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
Ifthevehicle’sheadlightsareshiningintothetreesorthevehicleisleaningtooneside,thenitisnotlevel(g.1).
Raise the air pressure to correct either of these problems and level the vehicle.
2. Ride comfort
Ifthevehiclehasaroughandharshrideitmaybeduetoeithertoomuchpressureornotenough(g.2).Trydifferent
pressures to determine the best ride comfort.
3. Stability
Stabilitytranslatesintosafetyandshouldbethepriority,meaningthedrivermayneedtosacriceaperfectlylevel
andcomfortableride.Stabilityissuesincluderollcontrol,bounce,diveduringbrakingandsponginess(g.3).Tuning
out these problems usually requires an increase in pressure.
Continued on pg. 2
Bad headlight aim Rough ride Sway and body roll
g. 1 g. 3
g. 2
Thank you for purchasing Air Lift products! For technical support, please call (800) 248-0892.
Air Lift Company • P.O. Box 80167, MI 48908-0167 • (517) 322-2144 • Fax: (517) 322-0240 • www.airliftcompany.com
Guidelines for adding air:
1. Startwiththevehiclelevelorslightlyabove.
2. Whenindoubt,alwaysaddair.
3. Formotor homes,startwith50-100PSI (3.5-7BAR)intherearbecauseitcanbesafelyassumedthatitisheavily
loaded.
4. If the front of the vehicle dives while braking, increase the pressure in the front air bags, if equipped.
5. Ifitiseversuspectedthattheairbagshavebottomedout,increasethepressure(fig.4).
6. Adjustthepressureupanddowntofind thebestride.
7. If the vehicle rocks and rolls, adjust the air pressure to reduce movement.
8. It may be necessary to maintain different pressures on each side of the vehicle. Loads such as water, fuel,
andapplianceswillcausethevehicletobeheavierononeside(fig.5).Asmuchasa50PSI (3.5BAR)
differenceisnot uncommon.
Continued from pg. 1
g. 5
g. 4
Bottoming out Unlevel Level
Air Lift Company provides a limited lifetime warranty to the original purchaser of its load support products, that the products will be free
from defects in workmanship and materials when used on cars and trucks as specified by Air Lift Company and under normal operating
conditions, subject to the requirements and exclusions set forth in the full Limited Warranty and Return Policy that is available at
www.airliftcompany.com/warranty.
For additional warranty information contact Air Lift Company customer service.
Warranty and Returns Policy
California: WARNING: Cancer and Reproductive Harm – www.P65Warnings.ca.gov
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