Air Lift 1000 User manual

BY
MN-295
(01511)
NPR1641
1. Jack up front end of vehicle. Support frame with jack
stands and let the suspension drop down.
2. Remove stock shocks.
3. Locate 1” hole that is in outer frame rail (hole is
stamped from factory). Clean area of all grease and
dirt for a proper welding surface (Figure 1).
4. If necessary, trim fender panel for adequate clearance
of the shock mount.
5. With the shock mount in place, weld both the horizontal
and vertical edges. This should be done by a qualified
welder.
6. Assemble upper shock pin (5/8” mounting stud) into
shock mount (Figure 1A).
7. Cut out template and hold on lower control arm to
locate the hole location for bottom pin.
8 . Center punch and then drill 5/8” hole in lower control
arm. Bolt in lower shock pin.
9. Insert the large diameter end of the tall spacer supplied
in kit through the hole in bottom spring seat and hold in
top of the spring, insert large 1/2 thick spacer between
coils under tall spacer (Figure 2). Insert the carriage
bolt and large washer up through both spacers. Using
small washer and 3/8” nut, install on carriage bolt and
hand tighten the spacers together as one assembly,
this will hold them together and make it easier to install
into the upper spring seat (Figure 3).
Figure 1
SHOCK RELOCATION KIT P/N 31510
FRONT-88-Newer Chevy/GMC 1 Ton Dually Lowered
Top Shock Mount
1" Hole In Frame
5/8" Hole
Lower Control Arm
Springs
* IMPORTANT *
WELDING PRECAUTIONS
1. AIR LIFT STRONGLY RECOMMENDS THAT THIS KIT BE PROFESSIONALLY INSTALLED BYA CERTIFIED
WELDER.
2. Prior to welding, the battery cables should be disconnected at the battery, Thoroughly clean the area to be
used as the ground connection as well as the area to be welded.
3. Before welding the brackets, inspect the area to be welded for electrical wiring, brake lines, fuel lines, proximity
to fuel tank, and/or any other components that should not be exposed to excessive heat. These items must be
removed, re-positioned, and/or properly shielded.
4. After the welding is completed and the area is cool to the touch, carefully re-position and inspect all wiring, fuel
lines, brake lines, etc. for any possible damage.
5. Some sort of corrosion protection should be applied to the welded area.
WASHERS
NUT
WASHERS
RUBBER
BUSHING
(SHOCK) MOUNTING
PIN
NUT TORQUE
TO 50 FT. LBS
BRACKET
0R
FRAME
Figure 1A

2
10. Guide the assembly through upper shock bolt hole
and attach with large washer (with 3/8” hole) and
3/8” nut. Hand tighten only at this time (Figure 3).
11. Remove black cap and squeeze air out of cylinder
and fold into a hot dog bun shape. Put black cap on
to retain deflated shape. Insert into lower spring
seat hole with stem down and push all the way into
spring (Figure 4). Slide thin spacer into spring at
bottom of cylinder and pull cap off so cylinder will
obtain its as molded shape.
12. Install air line clamp onto air line and install air line
onto the barbed stem of cylinder. With pliers slide
the air line clamp until it fully covers barbed section
of stem (Figure 3A).
13. With air line installed on the cylinder, route airline
forward on inside of A-Arm. There are hose clips
and bolts supplied in the kit to attach air line to the
lower A-Arm. Locate and drill 3/8” hole. Attach the
clip to theA-Arm using the 3/8-16X1” bolts and nuts
supplied in kit (Figure 8). If air line is routed near a
high heat source (headers, manifold, etc.) use the
thermal sleeves supplied in effected areas.
Tee air line installation recommended unless weight in
vehicle varies from one side to the other and unequal
pressures are needed to level the load. Dual air lines are
used in this case.
TEE AIR LINE ROUTING
TO PREVENT AIR LINE FROM MELTING, KEEP IT AT
LEAST EIGHT INCHES FROM EXHAUST SYSTEM.
A. Locate desired tee location on the frame rail or
cross member.
B. Route along cross member from the lower spring
seat to tee location. Attach with plastic straps or
wire.
CAUTION: LEAVE SUFFICIENT AIR LINE SLACK TO
PREVENT ANY STRAIN ON FITTING DURING AXLE
MOTIONS.
C. Cut off excess air line and slide air line clamp onto
the air line. Push the air line over one side of the tee
until all the barbs are covered. Repeat procedure
for other leg of tee.
D. With pliers slide the air line clamp forward until it
fully covers the barbed section. Repeat for the air
line from the other air cylinder (Figure 3A).
E. Select a location for the inflation valve assuring that
the valve will be protected and accessible with an air
hose.
Figure 2
Large Flat Washer
(with large od hole)
Carriage
Bolt
Large
1/2" thick
Spacer
Tall
Spacer
Small
Flat
Washer
Large Flat Washer
(with small od hole)
38" Nut
3/8" Nut
THIS
END
DOWN
THIS
END
UP
Vehicle
Frame
Upper Shock
Mount Hole
Figure 3
A
B
C
Use this procedure for all air line connections:
A. Slide air line clamp onto the air line
B. Push the air line over the barbed stem.
C. Compress the ears on the air line clamp
with pliers and slide it forward to fully cover
the barbed section.
Figure 3A

3
F. Push the remaining air line over the last fitting on tee
and route along frame to desired inflation valve
location. Attach with plastic straps or wire.
G. Drill a 5/16” hole for inflation valve and mount as in
illustration. Rubber washer is for outside weather
seal (Figure 6).
H. Slide air line clamp over the air line. Push air line
onto fitting covering all barbs, with pliers slide the air
line clamp forward until it fully covers the barbed
section.
I. Read procedure for all air line connections (Figure
3A).
J. Continue with step #14.
DUAL AIR LINE ROUTING
TO PREVENT AIR LINE FROM MELTING, KEEP IT AT
LEAST EIGHT INCHES FROM EXHAUST SYSTEM.
A. Select a location for the inflation valves assuring
that each valve will be protected and accessible with
an air hose.
B. Drill 5/16” hole for inflation valves and mount as
illustrated. Rubber washer is for outside weather
seal (Figure 6).
CAUTION: LEAVE SUFFICIENT AIR LINE SLACK TO
PREVENT ANY STRAIN ON VALVE STEM DURING
NORMAL AXLE MOTIONS.
C. Route air line along control arm and frame to
inflation valve location and cut off excess air line.
Attach with plastic straps or wire.
D. Slide air line clamp onto the air line and push the air
line over the fitting, covering all the barbs. With
pliers slide the air line clamp forward until it fully
covers the barbed section (Figure 3A).
E. Repeat process for the other side.
F. Continue with step #14.
DO NOT INFLATE AIR CYLINDERS BEFORE READING
MAINTENANCE/OPERATION TIPS.
14. Install shocks (Figure 7).
15. Raise axle or lower body until air cylinders lightly
touch lower spring protector and upper spacer.
Fig.5 MN 185
Figure 5
Fig.4 MN 185
Hex Nut
Rubber
Washer
Flat
Washer
Lock
Washer
Hex Nut
Inflation
Valve
Air Line
Vehicle Bumper
or Body
Air Line
Clamp
Figure 6

4
MINIMUM AIR PRESSURE
10 P.S.I. MAXIMUM AIR PRESSURE
60 P.S.I.
Thank you for purchasing Air Lift Products
AIR LIFT COMPANY
P.O. BOX 80167
Lansing, MI 48908-0167
FOR TECHNICAL ASSISTANCE CALL 1-800-248-0892
Caution: DO NOT EXCEED THE VEHICLE MANUFACTURERS MAXIMUM GROSS VEHICLE WEIGHT RATING.
Printed in the USA
MAINTENANCE TIPS:
1. Check pressure weekly!
2. Always maintain at least 10 p.s.i. air pressure to prevent chafing or coil pinch.
3. If you develop an air leak in the system, use a soapy/water solution to check all air line connections
and the valve core before removing cylinder.
FAILURE TO MAINTAIN MINIMUM PRESSURE WILL VOID THE WARRANTY
Top Shock Mount
1" Hole In Frame
Figure 7
Fig.4 MN 185
Hose
Clip
16. Inflate cylinder to 15 p.s.i., remove jack stands
and jack. Roll truck back and forth a couple of
times and tighten upper spacer assembly nut
lightly. Put other nut supplied in kit on as a
lock nut and tighten the two securely together
(Figure 3 & 5).
17. Adjust air pressure, for design height and ride.
Air pressure minimum is 10 p.s.i., maximum
60 p.s.i.

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. 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 an 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
If the vehicle’s headlights are shining into the trees or the vehicle is leaning to one side, then it is not level (fig. 1).
Raise the air pressure to correct either of these problems and level the vehicle.
2. Ride comfort
If the vehicle has a rough and harsh ride it may be due to either too much pressure or not enough. 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. 2). Tuning
out these problems usually requires an increase in pressure.
Continued on pg. 2
fi g . 2
fi g . 1
Bad headlight aim Level
Unlevel, bottoming out

Thank you for purchasing Air Lift products! For technical support, please call [phone].
Air Lift Company • P.O. Box 80167, MI 48908-0167 • [phone] • Fax: [phone] • www.airliftcompany.com
Guidelines for adding air:
1. Start with the vehicle level or slightly above.
2. When in doubt, always add air.
3. For motorhomes, start with 50-100 p.s.i. in the rear because it can be safely assumed that it is heavily loaded.
4. If the front of the vehicle dives while braking, increase the pressure in the front air bags, if equipped.
5. If it is ever suspected that the air bags have bottomed out, increase the pressure (fig. 3).
6. Adjust the pressure up and down to find the best ride.
7. If the vehicle rocks and rolls, adjust the air pressure up and down to reduce the rocking and rolling.
8. 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. 4). As much as a 50 p.s.i. difference is not
uncommon.
Rev. 4/5/07
Continued from pg. 1
LevelUnlevel
Poor stability
fi g . 4
fi g . 3