Air Lift loadlifter 5000 User manual

INSTALLATION GUIDE
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-381 • (111811) • ECR 9053
Cover
illustration
may not depict
actual kit.
Kit 57216
& 57128

MN-381 1
LoadLifter 5000
TABLE OF CONTENTS
Installation Diagram...................................... 2
Hardware and Tools Lists ................................. 3
Hardware List ........................................................3
Tools List ............................................................3
Introduction............................................. 4
Notation Explanation ...................................................4
Installing the LoadLifter 5000 System ....................... 5
Getting Started .......................................................5
Raising the Vehicle ....................................................6
Removing the Jounce Bumper ...........................................6
Assembling the Air Spring Unit ........................................... 6
Attaching the Lower Bracket.............................................9
Attaching the Upper Bracket.............................................9
Installing the Frame Brace............................................... 9
Installing the Air Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installing the Heat Shield................................................11
Installation Checklist ...................................................12
Maintenance and Use Guidelines ..........................12
Minimum Recommended and Maximum Air Pressure .........................12
Limited Warranty and Return Policy ........................12

MN-381
2
LoadLifter 5000
Installation Diagram
INBOARD
FORWARD
OPTION, see Figures 4-6
A
B
C D
E
F
G
N
O
H
H
I
I
I
H
J
K
J
J
J
J
K
K
J
J
M
M
N
O
O
OO
E
P
KIT 57216
KIT 57128
NOTE: No roll plates are used.
g. 1

MN-381 3
LoadLifter 5000
Item Description ..............................................Qty
A Air Spring........................................................... 2
B Upper Bracket ................................................... 2
C Lower Bracket (Left) .......................................... 1
D Lower Bracket (Right)........................................ 1
E Roll Plate (not in 57128) .................................... 4
F Frame Brace...................................................... 2
G Elbow Fitting...................................................... 2
H 3/8”-24 x 7/8”Bolt............................................. 8
I 3/8” Lock Washer.............................................. 8
J 3/8” Flat Washer............................................... 24
K 3/8” Oversized Flat Washer............................... 6
L 3/8”-16 x 3/4” Bolt ............................................ 2
M 3/8”-16 x 1 1/2” Bolt ......................................... 8
N 3/8”-16 x 6” Carriage Bolt................................. 4
O 3/8” Nylon Lock Nut ......................................... 12
Item Description ............................................. Qty
P Axle Clamp ........................................................ 2
Q Heat Shield*....................................................... 1
R Clamp*............................................................... 2
S Thermal Sleeve.................................................. 1
Air Line Assembly Parts
AA Air Line Assembly.............................................. 1
BB Zip Tie* .............................................................. 6
CC Valve Caps* ....................................................... 2
DD 5/16” Stainless Steel Flat Washer*.................... 2
EE Rubber Washer* ................................................ 2
FF Stainless Steel Star Washer* ............................. 2
GG 5/16” Hex Nut* .................................................. 4
(* not shown in Figure 1)
Description...........................................................Qty
STD and Metric Open-end or box wrenches .................. 1
Adjustable Wrench .......................................................... 1
Ratchet with 3/8”, 9/16”, and 1/2” deep well sockets .... 1
3/8” and 5/16” drill bits (very sharp)................................ 1
3/8” Nut Driver................................................................. 1
Heavy Duty Drill............................................................... 1
Torque Wrench ................................................................ 1
Hose Cutter, Razor Blade, or Sharp Knife....................... 1
Hoist or Floor Jacks ........................................................ 1
Safety Stands .................................................................. 2
Safety Glasses................................................................. 1
Air Compressor, or Compressed Air Source ................... 1
Spray Bottle with Dish Soap/Water Solution................... 1
HARDWARE LIST
TOOL LIST
Missing or damaged parts? Call Air Lift customer
service at [phone] for a replacement part.
STOP!
Hardware and Tools Lists

MN-381
4
LoadLifter 5000
DANGER
WARNING
The purpose of this publication is to assist with the installation and maintenance of the
LoadLifter 5000 air spring kits. All LoadLifter 5000 kits utilize sturdy, reinforced, commercial-
grade single or double, depending on the kit, convolute bellows. They also incorporate an
internal jounce bumper.
The air springs are manufactured like a tire with layers of rubber and cords that control
growth. LoadLifter 5000 kits provide up to 5,000 pounds (2,268kg) of load-leveling support
with air adjustability from 5-100 PSI (.34-7BAR).
It is important to read and understand the entire installation guide before beginning
installation or performing any maintenance, service or repair.
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.
Introduction
CAUTION

MN-381 5
LoadLifter 5000
Installing the LoadLifter 5000 System
g. 2
NOTE This instruction manual is for kits 57216 and 57128. The only difference between the
two kits is the air spring. The drawings depict a double convolute bellow, as found in kit
57216. But all instructions and illustrations apply to kit 57128 as well, which uses a single
convolute bellow.
The air springs will last much longer if they are not the suspension limiter in either
compression or extension. The air spring compresses to 2.8” (71mm) and extends to
9.1” (231mm). Regardless of load, the air pressure should always be adjusted so that the
Normal Ride Height is maintained at all times. The shock absorber is usually the limiter
on extension. If this is not the case, then the use of limiting straps should be considered,
in particular for vehicles that are used off-road.
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. The 57216 kit requires a minimum of 7 1/4” (184mm) from the top of the jounce
bumper strike plate to the bottom of the frame rail. Before installation is begun, check
for sufficient clearance. If the measurement is less than 7 1/4” (184mm), then use kit
57128 (Fig. 2).
2. Determine the normal ride height. The normal ride height is the distance between the
bottom edge of the wheel well and the center of the hub with the vehicle in the “as
delivered” condition. In some cases, normal ride height is not perfectly level.
a. Remove unusual loads and examine your vehicle from the side to ensure it is on
a level surface.
b. If necessary (in cases where your leaf springs are sagging badly), use a jack to
raise the rear end so that the vehicle achieves the original “as delivered” ride
height.
CAUTION
This measurement must be
7 1/4” (184mm) or greater.
If less than 7 1/4” (184mm)
use kit 57128.

MN-381
6
LoadLifter 5000
g. 3
3. Measure the distance between the center of the hub and the bottom edge of the
wheel well (Fig. 3). This is the normal ride height. Enter the measurement below:
NORMAL
RIDE HEIGHT: __________ inches/millimeters
NOTE: The measurement
from one end of the arrow to
the other end is the Normal
Ride Height.
RAISING THE VEHICLE
1. Raise the vehicle and remove the wheels.
2. Check the distance between the center of the hub and the bottom edge of the wheel
to ensure that it is at the normal ride height previously recorded. If not, raise the
frame or lower the axle as necessary to restore the original distance.
a. If the vehicle is raised with an axle contact hoist, then place axle stands under
the frame and lower the axle as needed.
b. If the vehicle is raised with a frame contact hoist, then place axle stands under
the axle and raise the frame as needed.
c. If the vehicle is raise with a jack and supported with axle stands on the frame,
then use a floor jack to lower the axle.
REMOVING THE JOUNCE BUMPER
1. Remove the jounce bumper by prying it off of the jounce bumper bracket.
2. Remove the jounce bumper bracket from the frame rail. It may be bolted or riveted. If
riveted, it can be removed by center punching and drilling out the rivets, chiseling or
grinding it off, or cutting if off with a torch.
ASSEMBLING THE AIR SPRING UNIT
1. The lower brackets (C and D) are designated left (driver’s) side (indicated by the “L”
stamped on it) and right (passenger’s) side (indicated by the stamped “R”).
2. It will be necessary to use either the 3/8”-16 x 3/4” bolt (L) or the 3/8”-16 x 1 1/2” (M)
in combination with flat washers (J) and a nylon lock nut (O) as a spacer stack so that
the lower bracket sits flat on the axle housing/jounce bumper pad.
3. Set the lower bracket on the axle housing to determine the appropriate spacer stack
up.

MN-381 7
LoadLifter 5000
g. 4
g. 5
g. 6
NOTE As a general rule, 1/2 and 3/4 ton trucks and some 1 ton trucks with single rear wheels
take the stack in Figure 4. Most 1 ton single rear wheels and some 1 ton dual rear wheel
trucks take the stack in Figure 5. Most 1 ton dual rear wheel trucks take the stack in
Figure 6.
For 1/2- and 3/4- ton trucks
and some 1-ton trucks
with single rear wheels. O
L
For most 1-ton trucks
with single rear wheels
and some 1-ton trucks
with dual rear wheels.
O
J
M
For most 1-ton trucks
with dual rear wheels.
O
J
J
M

MN-381
8
LoadLifter 5000
4. Due to manufacturing tolerances, the shock mounting bracket may stop the lower
bracket from sitting completely flat on the axle housing/jounce bumper pad. This may
occur on only one side of the vehicle. In such instances, it will be necessary to use a
grinder to trim the shock bracket until it is flat with the top of the axle housing (Fig. 7).
g. 7
g. 8
5. After determining and installing the appropriate stackup, insert one carriage bolt (N)
into the forward hole of the lower bracket (Fig. 8).
6. Set a roll plate (E) on both ends of the double convolute air spring (Fig. 1). Kit 57128
with the single convolute air spring does not require roll plates.
7. Set the air spring assembly onto the lower bracket. The spacer assembly on the
lower bracket must be positioned on the same side as the air port on the top of the
air spring.
8. Attach the lower bracket to the air spring using two bolts (H), two lock washers (I),
and two flat washers (J) (Fig. 1).
9. Attach the upper bracket (B) to the air spring using two bolts (H), two lock washers
(I), and two flat washers (J). Be sure that the tall vertical leg of the upper bracket is
opposite of the air fitting port (Fig. 1).
10.Repeat assembly for other side.

MN-381 9
LoadLifter 5000
Use hole in upper bracket as a
template to center punch and drill
g. 9
ATTACHING THE LOWER BRACKET
1. Set the assembly on the axle with the tall, wide vertical leg of the upper bracket on
the outside of the frame rail. The lower bracket spacer sets just inboard of the jounce
bumper pad on the axle housing.
2. Some models may require prying the brake line slightly away from the axle so that the
axle clamp will not pinch the brake line.
3. Insert a carriage bolt (N) into the rearward hole in the lower bracket. Attach the
bracket using the axle clamp (P), flat washers (J), and lock nuts (O). Torque to
20 lb.-ft. (27Nm).
ATTACHING THE UPPER BRACKET
1. Align the air spring vertically and horizontally and clamp the upper bracket to the
frame rail using locking pliers or c-clamp.
BEFORE DRILLING, BE SURE TO CHECK THE BACK SIDE OF THE FRAME RAIL FOR
BRAKE LINES, GAS LINES, OR ELECTRICAL LINES THAT MAY BE IN THE WAY. IT IS
NECESSARY TO MOVE ANY INTERFERING LINES PRIOR TO DRILLING.
2. Use the upper bracket as a template to center punch and drill a 3/8” hole through the
outboard side of the frame rail and upper bracket (Fig. 9).
3. Install one bolt (M), one flat washer (J), one oversized flat washer (K), and a lock nut
(O). Torque to 44 lb.-ft. (60Nm) and leave clamp in place.
4. Do not use the existing jounce bumper holes in the frame rail. Instead, use the holes
in the upper bracket as a template along the bottom of the frame rail and center
punch and drill two 3/8” holes through the holes in the upper bracket. Do not attach
to the frame rail at this time. Remove the clamp or locking pliers.
INSTALLING THE FRAME BRACE
1. It may be necessary to cut or trim off the plastic locator studs (on ’97 and newer
models) before installing the frame brace.
2. Install the frame brace (F) with the access holes toward the bottom of the frame rail.
This is a tight fit and may require tapping with a hammer or mallet.
3. Align the access holes with the holes already drilled in the bottom of the frame. Using
a large screw driver or punch through the already drilled hole, push the frame brace
forward or backward until the holes are aligned.
CAUTION

MN-381
10
LoadLifter 5000
4. Install a bolt (M), flat washer (J), oversized flat washer (K), and a lock nut (O). Hold the
lock nut with a 9/16” open end wrench through the access hole and tighten the bolt
to 44 lb.-ft. (60Nm). Repeat for other mounting hole (Fig. 10).
O
K
J
M
J
M
g. 10
5. Install the air fitting into the air spring assembly. The threads are precoated with
sealant. Tighten finger tight plus 1 1/2 turns, being careful to tighten only on the
metal hex nut. Do not over tighten.

MN-381 11
LoadLifter 5000
g. 12
g. 11
g. 13
Installing the Air Lines
Vehicle body
or bumper
Hex nuts
Flat washer
Star washer
Rubber washer
Schrader
valve
Vehicle
body or
bumper
5/16” hole
Nylon air line
to air spring
Hex nuts
Flat washer
Star washer
Rubber washer
Schrader
valve
Vehicle
body or
bumper
5/16” hole
Nylon air line
to air spring
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.
USE IN
Standard LL5000
CAUTION
Choose the locations for
the Schrader valves and
drill a 5/16 ” (8mm) hole, if
necessary (Fig. 11).
1. Cut the air line in half.
Make clean, square cuts
with a razor blade or
hose cutter (Fig. 12). Do
not use scissors or wire
cutters.
KEEP AT LEAST 6” (152MM)
OF CLEARANCE BETWEEN
ALL AIR LINES AND THE
EXHAUST SYSTEM. AVOID
SHARP BENDS AND
EDGES.
2. Use zip ties to secure
the air line to fixed points
along the chassis. Do not
pinch or kink the air line.
Leave at least 2” (50mm)
of slack in the air line to
allow for any movement
that might pull on the air
line. The minimum bend
radius for the air line is 1”
(25mm).
3. Install the Schrader valve
in the chosen location
(Fig. 13).
Good cut Bad cut
g. 14
Exhaust
resonator
Bend
tabs
Double hose
clamps if
necessary
1/2” (13mm)
dead air space
between shield
and exhaust
INSTALLING THE HEAT SHIELD
1. Attach the metal heat shield to the exhaust where it is closest to the passenger's (right)
side air spring. Slide the air line thermal sleeve over the air line and position it where the
air line is closest to the exhaust. (Fig. 14).

MN-381
12
LoadLifter 5000
INSTALLATION CHECKLIST
Clearance test — Inflate the air springs to 40-60 PSI (2.8-4.1BAR) and make sure
there is at least 1/2” (13mm) 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 40-60 PSI (2.8-4.1BAR) 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” (152mm)
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 (16km) 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.
1. Check air pressure weekly.
2. Always maintain normal ride height. Never inflate beyond 100 PSI (7BAR).
3. If the system develops an air leak, use a soapy water solution 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) OR PAYLOAD RATING, AS
INDICATED BY THE VEHICLE MANUFACTURER.
ALTHOUGH THE AIR SPRINGS ARE RATED AT A MAXIMUM INFLATION PRESSURE OF
100 PSI (7BAR), THE AIR PRESSURE ACTUALLY NEEDED IS DEPENDENT ON LOAD AND
GROSS VEHICLE WEIGHT RATING.
Maximum Air PressureMinimum Recommended Pressure
100 PSI (7BAR)5 PSI (.34BAR)
Maintenance and Use Guidelines
Limited Warranty and Return Policy
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.
CAUTION
CAUTION

Air Lift Company • 2727 Snow Road • Lansing, MI 48917 or PO Box 80167 • Lansing, MI 48908-0167
Toll Free [phone] • Local [phone] • Fax [phone] • www.airliftcompany.com
Thank you for purchasing Air Lift products — the professional installer’s choice!
Printed in the USA
JJC-1118
Need Help?
Contact our customer service department by calling
[phone], Monday through Friday. For calls
from outside the USA or Canada, our local number
is [phone].
Register your warranty online at
www.airliftcompany.com/warranty
California: WARNING: Cancer and Reproductive Harm – www.P65Warnings.ca.gov