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-944 • (011411) • ERN 8033
INSTALLATION GUIDE
ADJUSTABLE AIR HELPER SPRINGS
TOW AND HAUL WITH SAFETY AND COMFORTTM
Kit Number
88365

Introduction............................................. 2
Important Safety Notice ................................................2
Notation Explanation ...................................................2
Installation Diagram...................................... 3
Hardware List ........................................................4
Tools List............................................................4
Installing the LoadLifter 5000 Ultimate System............... 4
Getting Started .......................................................4
Assembling the Air Springs ..............................................9
Installing the Assemblies................................................11
Installing the Air Lines ..................................................14
Installing the Heat Shield................................................16
Checking for Leaks ....................................................17
Fixing Leaks .........................................................17
Photos of Finished Assemblies ...........................................18
Before Operating ........................................19
Installation Checklist ...................................................19
Post-Installation Checklist ...............................................19
Product Use, Maintenance and Servicing ...................20
Minimum and Maximum Pressure.........................................20
Maintenance Guidelines ................................................20
Troubleshooting Guide .................................................20
Frequently Asked Questions .............................................21
Tuning the Air Pressure.................................................21
Guidelines for Adding Air................................................22
Choosing the Right On-Board Air Compressor System .......23
Warranty and Returns Policy ..............................24
Replacement Information .................................25
Contact Information......................................25
TABLE OF CONTENTS

2MN-944
LoadLifter 5000 Ultimate
Introduction
The purpose of this publication is to assist with the installation, maintenance and
troubleshootingofthe LoadLifter5000Ultimate airspringkit. LoadLifter5000Ultimate utilizes
sturdy, reinforced, commercial grade single- or double-bellows (depending on the kit). The
bellows are manufactured like a tire with layers of rubber and cords that control growth. An
internaljouncebumper insidethespringabsorbs shock andeliminates harshjarring on rough
roads. The internal jounce bumper replaces the factory bumper and allows the air springs to
safely be run at zero air pressure. LoadLifter 5000 Ultimate kits are recommended for most
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 motorhome
rear kits and some motorhome fronts where leaf springs are used.
Itisimportantto readandunderstand theentireinstallationguide beforebeginninginstallation
orperforming any maintenance, service orrepair. Theinformation hereincludes a hardware
list, tool list, step-by-step installation information, maintenance tips, safety information and
a troubleshooting guide.
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 our website at www.airliftcompany.com.
IMPORTANT SAFETY NOTICE
Theinstallation ofthis kitdoes not alter the GrossVehicle WeightRating (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 ination pressure data — is shown on the vehicle’s Safety Compliance
Certication Label.
Payload: The combined, maximum allowable weight of cargo and passengers that the
vehicle is designed to carry. Payload is GVWR minus the Base Curb Weight.
NOTATION EXPLANATION
Hazard notations appear in various locations in this publication. Information which is
highlighted by one of these notations must be observed to help minimize risk of personal
injuryor possible improper installationwhich may render thevehicle unsafe. Notes areused
to help emphasize areas of procedural importance and provide helpful suggestions. The
following denitions explain the use of these notations as they appear throughout this guide.
INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL
INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE
TO THE MACHINE OR MINOR PERSONAL INJURY.
Indicates a procedure, practice or hint which is important to highlight.
DANGER
NOTE
WARNING
CAUTION

3
MN-944
LoadLifter 5000 Ultimate
Installation Diagram
Left-hand side shown
(driver side)
Right-hand side shown
(passenger side)
NOTE: PROFESSIONAL MECHANICAL
SKILLS ARE NECESSARY IN ORDER
TO COMPLETE THE INSTALLATION
OF THIS KIT.
g. 1

4MN-944
LoadLifter 5000 Ultimate
GETTING STARTED
Inorder toinstall theupper framebrackets (A),it will be necessary toremove thecoil springs
as follows:
1. Lift the vehicle up and support the frame with jack stands. Leave enough room to drop
the axle down low enough to remove the coil springs (g. 2). Remove the rear wheels.
Installing the LoadLifter 5000 Ultimate System
TOOLS LIST
Description..............................................Qty
Hoist or oor jacks................................................1
Safety stands........................................................2
Safety glasses......................................................1
4” grinder or metal cutting tool.............................. 1
Torque wrench......................................................1
Standard open-end combo wrenches...................1
Ratchet.................................................................1
Metric and standard sockets.................................1
Description..............................................Qty
7/32 allen wrench (socket if available)..................1
1/4” and 5/16” drill bits (very sharp)...................... 1
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
Black paint or undercoating.................................. 1
Item Part # Description................................Qty
A 07061 Frame bracket.....................................2
B 07150 Air spring bracket................................2
C1 03017 L.H. lower bracket...............................1
C2 03112 R.H. lower bracket ..............................1
D 58496 Air sring...............................................2
E 11967 Roll plate.............................................4
F 21827 90° swivel tting ..................................2
G 17215 3/8”-24 x 2/4” at head screw .............4
H 17203 3/8”-24 x 2/4” hex head bolt................4
I 18427 3/8” lock washer..................................4
J 18444 3/8” at washer ...................................4
K 17102 5/16”-18 x 3/4” self-tapping screw.......6
L 17361 3/8”-16 x 1.25” Carriage Bolt..............12
Item Part # Description................................Qty
M 17495 M8-1.25” x 20 socket head screw.......2
N 18422 3/8”-16 serrated lock nut....................12
O 18522 M8-1.25” nylon nut..............................2
AA* 20086 Air line assembly.................................1
BB* 10466 Tie strap..............................................6
CC* 21230 Valve cap............................................2
DD* 18501 5/16” at washer .................................2
EE* 21234 Rubber washer....................................2
FF* 18401 Star washer.........................................2
GG* 21233 5/16” hex nut.......................................4
HH* 34365 Heat shield kit .....................................1
*Not shown in g. 1.
HARDWARE LIST
Missing or damaged parts? Call Air Lift customer
service at [phone] for a replacement part.
STOP!
g. 2

5
MN-944
LoadLifter 5000 Ultimate
2. Mark the bottom of the right-hand and left-hand coil springs and lower spring seat
mounts with chalk or a paint marker to make sure the spring is put back the same way
it is removed (g. 3).
3. Remove both lower shock bolts and slowly lower the axle until the springs can be
removed.
Lower the axle carefully and avoid putting stress on the exible brake lines.
4. Remove both jounce bumpers from both sides (g. 4).
5. Grindthe weldsoff thejounce bumpercups thatattach themto thejounce bumperframe
bracket (g. 5). Remove and discard from both sides of the vehicle.
NOTE
g. 3
g. 4
g. 5

6MN-944
LoadLifter 5000 Ultimate
6. Grind the welds removed, down ush to the frame with the grinder. (g. 6).
7. Spraythe framewith blackpaint orundercoating tocover thebare surface,from grinding
the welds ush previously (g. 7). Repeat for both sides.
8. Install the socket head M8 bolt (M) into the frame bracket (A) slot closest to the ange
on the bracket (g. 8). Note: The head points in the same direction as the ange on the
bracket. Cap with the nylon lock nut (O) as shown (g. 9).
g. 6
g. 7
g. 8
A
M

7
MN-944
LoadLifter 5000 Ultimate
9. Only tighten the bolt to where it can still slide in the slot.
10. Set the frame bracket (with the socket head bolt in it), on the frame, with the ange
pointingup. Insert the socket head bolt intothe existing holein the framethat was under
the stock jounce bumper (g. 10).
11. The bracket should sit ush to the bottom of the frame. If there is any leftover weld
holding the bracket off the frame, remove and grind down so the bracket is ush.
12. With the socket head bolt in the hole, push the ange against the side of the frame
(g. 11) and mark the existing hole under the frame with a paint marker (g. 12).
g. 9
g. 10
g. 11
O
M

8MN-944
LoadLifter 5000 Ultimate
If possible, with the bracket in position, use a 21/64 (or closest) centering punch to t into
the hole and center-punch the frame for an exact center of the hole.
13. Center-punch the frame and drill a 1/4” hole (g. 13). Start a 5/16” self-tapping screw
(K) into the hole, making sure it is straight, and tighten it enough to form the threads
needed to set the screw (g. 13). Remove the screw once threads are formed. Repeat
for both sides.
14. Set the bracket back in place on the frame and bolt into position using the self-tapping
screw previously set into the frame. Tighten the screw making sure the washer head
portion of the screw is at to the bracket, and torque to 15 ft-lbs.
15. Make sure the bracket is at to the bottom on the frame, center punch and drill through
the frame with a 1/4” bit using the holes in the side of the ange as a guide (g. 14).
g. 12
g. 13
g. 14
K
TECHNICAL NOTE

9
MN-944
LoadLifter 5000 Ultimate
16. Install two more self-tapping screws (K) in the side, making sure the at head portion of
the bolt is ush to the bracket, and torque to 15 ft-lbs. (g. 15). Repeat for the other side.
17. Once the frame brackets have been installed on both sides, the stock suspension can
be put back together.
18. Set the coil springs back into position using the index marks from the previous step and
raise the axle back up making sure the spring indexes into the top and bottom spring
seats correctly.
19. Install the wheels back on the axle and lower the vehicle back down so the wheels rest
on the ground. Torque the lug nuts to the manufacturers torque specs.
20. Install the lower shock bolts back onto the axle and torque to 135Nm (100 ft-lbs.).
ASSEMBLING THE AIR SPRINGS
1. Set a roll plate (E) onto the air spring (D).
The radius (rounded) edge of the roll plate (E) will be towards the air spring, so that the air
spring is seated inside both roll plates.
2. Install the swivel tting (F) into the top of the air spring nger-tight plus one-and-a-half
turns (g. 16). Repeat for both air springs.
3. Insert four carriage bolts (L) into the upper air spring bracket (B) and set the upper
bracket onto the air spring assembly (g. 17).
4. Attach the upper air spring bracket using two 3/8” hex head bolts (H), two lock washers
(I) and two at washers (J). Torque to no more than 20 ft-lbs. Repeat for the opposite
side. Both upper assemblies shown in gure 18.
NOTE
g. 15
g. 16
Driver-side
bracket
shown
mounted in
place and
ready for the
air spring
assembly.
K
F

10 MN-944
LoadLifter 5000 Ultimate
5. Flip the air spring assemblies upside down and set a roll plate (E) over the air spring
(same as in step one).
6. Position the air spring assemblies so that the ttings are outboard and away from each
other (g. 19).
The nished assemblies will be left and right-hand specic, and the ttings that are on the
top of the air springs should be facing the outside (tire side) of the vehicle once into position.
7. Set the left-hand lower bracket (C1) onto the left side assembly (your left-hand facing
both assemblies) and attach with two 3/8” at head screws (G). Torque to no more than
20 ft-lbs. (g. 19). Attach the right-hand lower bracket (C2) onto the right-side assembly
(your right-hand facing both assemblies). Attach with two 3/8” at head screws (G).
Torque to no more than 20 ft-lbs. (g. 20).
NOTE
g. 17
g. 18
g. 19
B
L
L
H I J
E
E

11
MN-944
LoadLifter 5000 Ultimate
INSTALLING THE ASSEMBLIES
1. Index a 3/8” carriage bolt (L) into the opening on the front of the driver side assembly
as shown (g. 21).
2. Dropthe axleagain togain clearance to put thetwo assembliesinto positionon theaxle.
3. Setthe driverside assemblyinto positionwith the carriage bolt still in theslot (previously
installed). Set into place on the axle making sure the back of the bracket is “hooked”
below the jounce bumper strike plate. Push the assembly forward while lining up the
carriage bolt with the existing hole in the front of the lower jounce bumper strike plate
(gs. 22 and 23). Cap the carriage bolt with a 3/8” serrated lock nut (N), but leave loose
at this time.
g. 20
g. 21
g. 22
Right- side
assembly
(passenger
side) using
lower bracket
(C2).
Left side
assembly
(driver side)
using Lower
Bracket (C1).
L

12 MN-944
LoadLifter 5000 Ultimate
4. Insert another 3/8” carriage bolt (L) through the remaining hole in the front side of the
bracket (g. 24).
5. It will be necessary to use a socket with an extension to reach the inside threads on the
carriage bolt previously set into position (g. 25). It may be helpful to pull the carriage
bolt out slightly so that it can be angled enough to get started on the thread.
g. 23
g. 24
g. 25
Use the slot
in the lower
control arm
mount for the
extension to t
through while
threading the
nut on the
bolt.
L
N
L

13
MN-944
LoadLifter 5000 Ultimate
6. Setthe righthand unitassembly into position in thesame wayindexing thelower bracket
with the tabs under the jounce bumper strike plate and, with the exception of using
the slot for the carriage bolt in the lower bracket, install the carriage bolts in the same
manner. Torque both sides of the lower bracket hardware evenly to 31 ft-lbs. making
sure the tabs are still indexed under the jounce bumper strike plate. Figures 26 and 27
show the assemblies bolted into position.
Fittings should be on the outside (tire side) of the assemblies.
7. Raise the axle back up while aligning the air spring mounting plate’s carriage bolts, with
the frame mounting bracket holes. Cap all carriage bolts, once in position, with 3/8”
serrated lock nuts (N) and torque all the installed nuts to 31 ft-lbs. (g. 28).
NOTE
g. 26
g. 27
g. 28
Left- hand
assembly
shown.
Right-hand
assembly
shown.
N

14 MN-944
LoadLifter 5000 Ultimate
8. Left-side shown with the assembly bolted up to the frame bracket (g. 29).
INSTALLING THE AIR LINES
1. On the passenger side only, place the provided thermal sleeve (HH) on the air line near
the exhaust.
2. Remove the air line heat shield sleeve in the hose heat shield kit and install on the right
side (passenger side) air line where it attaches to the tting on the upper bracket (g. 30).
3. Choose a convenient location for mounting the ination valves. Popular locations for the
ination valve are:
a. The wheel well anges.
b. License plate recess in bumper.
c. Under the gas cap access door.
d. Through license plate itself.
What ever the chosen location is, make sure there is enough clearance around the ination
valves for an air chuck.
4. Drill a 5/16” hole to install the ination valves.
5. Cut the air line assembly (AA) in two equal lengths.
WHENCUTTINGORTRIMMING THEAIRLINE,USE AHOSECUTTER,A RAZORBLADE
ORA SHARP KNIFE.A CLEAN,SQUARE CUT WILLENSURE THATTHE LINEWILLNOT
LEAK. DO NOT USE WIRE CUTTERS OR SCISSORS TO CUT THE AIR LINE. THESE
TOOLS MAY FLATTEN OR CRIMP THE AIR LINE, CAUSING IT TO LEAK AROUND THE
O-RING SEAL INSIDE THE ELBOW FITTING (FIG. 31)
NOTE
CAUTION
g. 29
g. 30
Insert the
air line into
the heat
shield before
attaching to
the right-side
(passenger)
air spring
tting.

15
MN-944
LoadLifter 5000 Ultimate
Good Cut Poor Cut
6. Place a 5/16” hex nut (GG) and a star washer (FF) on the air valve. Leave enough of
the ination valve in front of the nut to extend through the hole and have room for the
rubber washer (EE), at washer (DD), and 5/16” hex nut (GG) and valve cap (CC). There
should be enough valve exposed after installation - approximately 1/2” - to easily apply
a pressure gauge or an air chuck (g. 32).
7. Push the ination valve through the hole and use the rubber washer (EE), at washer
(DD), and another 5/16” hex nut (GG). Tighten the nuts to secure the assembly in place
(g. 32).
8. Route the air line along the frame to the air tting on the air spring (g. 33). Keep AT
LEAST6” of clearance between theair line and heat sources,such as the exhaust pipes,
mufer, or catalytic converter. Avoid sharp bends and edges. Use the plastic tie straps
(BB) to secure the air line to xed, non-moving points along the chassis. Be sure that
the tie straps are tight, but do not pinch the air line. Leave at least 2” of slack to allow
for any movement that might pull on the air line.
g. 31
Vehicle body
or bumper
Air line to
bellows
5/16” Hex nut
Valve cap
5/16” Flat washer
5/16” Hex nut
Rubber washer
Star washer
g. 32
Option 1
Option 2 g. 33
9. Cut off air line, leaving approximately 12” of extra air line. A clean square cut will ensure
that the line will not leak (see g. 31). Insert the air line into the air tting. This is a push-
to-connect tting. Simply push the air line into the 90° swivel tting until it bottoms out
(9/16” of air line should be in the tting).

16 MN-944
LoadLifter 5000 Ultimate
INSTALLING THE HEAT SHIELD
Finished photo of heat shield installed on right-side (passenger) exhaust (g. 34).
1. Bend the tabs on the heat shield to provide a 1/2” dead air space between exhaust pipe
and heat shield (g. 35).
2. Attach the heat shield to the exhaust pipe using the clamps (g. 36). Bend the heat shield
for maximum clearance to the air spring.
Bend tabs up
g. 35
At least 1/2” of
dead air space
Distance from
heat shield to
bellows must
be at least 1/2”
1/2”
g. 36
NOTE
g. 34

17
MN-944
LoadLifter 5000 Ultimate
CAUTION
CHECKING FOR LEAKS
1. Inate the air spring to 30 PSI and spray all connections and the ination valves with
a solution of 1/5 liquid dish soap and 4/5 water to check for leaks. Spot leaks easily by
looking for bubbles in the soapy water.
2. After the test, deate the springs to the minimum pressure required to restore the normal
ride height, no less than 5 PSI.
3. 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 lbs.
FIXING LEAKS
1. If there is a problem with the swivel tting:
a. Check the air line connection by deating the spring and removing the line by pulling
the collar against the tting and pulling rmly on the air line. Trim 1” off the end of
the air line. Be sure the cut is clean and square (see g. 31). Reinsert the air line
into the push-to-connect tting.
b. Check the threaded connection by tightening the swivel tting another 1/2 turn. If
it still leaks, deate the air spring, remove the tting, and re-coat the threads with
thread sealant. Reinstall by hand tightening as much as possible, then use a wrench
for an additional two turns.
2. If there is a problem with the ination valve, then:
a. Check the valve core by tightening it with a valve core tool.
b. Check the air line connection by removing the air line from the barbed type tting.
DO NOT CUT THE AIR LINE COMPLETELY OFF AS THIS WILL NICK THE BARB AND
RENDER THE FITTING USELESS.
3. If the preceding steps have not resolved the problem, call Air Lift customer service at
[phone] for assistance.

18 MN-944
LoadLifter 5000 Ultimate
PHOTOS OF FINISHED ASSEMBLIES
1. Back view of left-side (driver) assembly (g. 37).
2. Back view of right-side (passenger) assembly (g. 38).
g. 37
g. 38