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-860 • (011301) • ECR 7518
INSTALLATION GUIDE
ADJUSTABLE AIR HELPER SPRINGS
TOW AND HAUL WITH SAFETY AND COMFORTTM
Kit Number
88101
safety, please read these instructions
completely before proceeding with
Failure to read these instructions can result in an
Kit Number

1
MN-860
LoadLifter 5000 Ultimate
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
Assembling the Air Spring Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Attaching the Lower Bracket .............................................5
Attaching the Upper Bracket .............................................5
Installing the Other Air Spring ............................................6
Installing the Air Lines ..................................................6
Checking For Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fixing Leaks .........................................................7
Before Operating ........................................ 8
Installation Checklist ...................................................8
Post-Installation Checklist ...............................................8
Product Use, Maintenance and Servicing ................... 9
Minimum and Maximum Pressure......................................... 9
Maintenance Guidelines ................................................9
Troubleshooting Guide ................................................. 9
Frequently Asked Questions .............................................10
Tuning the Air Pressure.................................................10
Guidelines for Adding Air................................................11
Choosing the Right On-Board Air Compressor System .......12
Warranty and Returns Policy ..............................13
Replacement Information .................................14
Contact Information ......................................14
TABLE OF CONTENTS

2MN-860
LoadLifter 5000 Ultimate
Introduction
The purpose of this publication is to assist with the installation, maintenance and
troubleshooting of the LoadLifter 5000 Ultimate air spring kit.LoadLifter 5000 Ultimate
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. An internal jounce bumper inside the spring absorbs shock and eliminates
harsh jarring 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 ¾ and 1 ton pickups and SUVs with leaf springs and provide
up to 5,000 lbs. 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.
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 tips, safety information and
a troubleshooting guide.
IMPORTANT SAFETY NOTICE
The installation of this kit does not alter the Gross Vehicle Weight Rating (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 inflation pressure data — is shown on the vehicle’s Safety
Compliance Certification 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
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
NOTE
WARNING
CAUTION

3
MN-860
LoadLifter 5000 Ultimate
Installation Diagram
g. 1

4MN-860
LoadLifter 5000 Ultimate
Installing the LoadLifter 5000 Ultimate System
DANGER
Item P/N Description................................ Qty
A58740 Bellow ................................................. 2
B07705 Upper Bracket..................................... 2
C03006 Lower Bracket..................................... 2
D21848 Elbow Fitting ....................................... 2
E17203 3/8”-24 x 7/8” Bolt.......................................8
F18427 3/8” Lock Washer................................... 8
G18444 3/8” Flat Washer ................................... 12
H18435 3/8” Nylock Nut ...................................... 4
I17142 3/8”-16 x 3.5” Carriage Bolt ......................4
J 17146 1/2”-13 x 1.5” Bolt .................................. 2
K18414 1/2” Flat Washer .................................... 2
L18429 1/2” Lock Washer................................... 2
M18431 1/2” Hex Nut .......................................... 2
Item P/N Description................................ Qty
N09484 Thermal Sleeve.................................... 2
O01665 Clamp Bar........................................... 2
Air Line Assembly Parts
AA 20086 Air Line Assembly............................... 1
BB 10466 Tie Strap*............................................ 6
CC 21230 Valve Caps*........................................ 2
DD 18405 5/16” Flat Washer*.............................. 2
EE 21234 Rubber Washer* ................................. 2
FF 18411 5/16 Small Star Washer* .................... 2
GG 21233 5/16” Hex Nut* .................................... 4
(* not shown in Figure 1)
Description...........................................................Qty
7/16”, 9/16” open-end or box wrenches........................... 1
7/16” and 9/16” open-end or box wrenches..................... 1
Crescent 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 .................................................................. 1
Safety Glasses ................................................................ 1
Air Compressor, or Compressed Air Source ................... 1
Spray Bottle with Dish Soap/Water Solution ................... 1
HARDWARE LIST
TOOL LIST
NOTE IMPORTANT: Your vehicle may be equipped with a rear brake proportioning valve.Any
type of load assist product could affect brake performance.It is recommended 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 .
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.
ASSEMBLING THE AIR SPRING ASSEMBLY
Refer to Figure 1.
1. Consult your User’s Manual to determine the normal ride height of your vehicle.

5
MN-860
LoadLifter 5000 Ultimate
NOTE
CAUTION
2. Loosely attach the 90∞ elbow tting (D) to the top of the air spring. Tighten nger
tight plus 1 and 1/2 turns.Be careful to tighten on the metal hex nut only.DO NOT
OVERTIGHTEN.
3. Loosely attach the upper bracket (B) to the air spring (A) with two 3/8” bolts (E), two 3/8”
lock washers (F), and two 3/8” at washers (G).
4. Attach the air spring to the lower bracket (C) with two 3/8” bolts (E), two 3/8” lock washers
(F), and two 3/8” at washers (G). Leave loose at this time.
ATTACHING THE LOWER BRACKET
Refer to Figure 1.
1. Insert two 3/8” carriage bolts (I) through the lower bracket.Attach the lower bracket
to the leaf spring forward of the axle by securing the carriage bolts to a clamp bar (O)
underneath the leaf spring.
2. Secure the carriage bolts with two 3/8” at washers (G) and 3/8” nyloc nuts (H). Tighten
all nuts to 20 ft.lbs.
ATTACHING THE UPPER BRACKET
Refer to Figure 1.
1. Position the upper bracket (B) on the frame rail so that it is aligned front-to-rear and
inboard-to-outboard. Upper and lower brackets are slotted for adjustment.
The short end of the upper bracket must be positioned so that it is touching the underside
of the frame rail (Figure 2).
2. Put the upper bracket into position on the frame rail and drill one 1/2” hole in the side of
the frame rail (Figure 3).
DO NOT DRILL HOLES IN THE FRAME BEFORE CHECKING FOR HYDRAULIC LINES,
GAS LINES AND/OR ELECTRICAL WIRES THAT MAY HAVE TO BE MOVED OUT OF
THE WAY TO EITHER SIDE OF THE FRAME.
g. 3
g. 2
Frame
Upper
Brac
ket
Short end of upper
bracket must touch
underside of frame
rail.
Frame Rail
Center
punch
and drill
one 1/2"
hole.
Upper
Bracket

6MN-860
LoadLifter 5000 Ultimate
g. 4
3. Recheck the alignment.Using the slots in the lower bracket, align the air spring so that
it is square, vertically and horizontally, to the upper bracket.
4. Tighten the air spring mounting bolts to 20 ft.lbs. Attach the upper bracket using one
1/2”-13 x 1.5î bolt (J), one 1/2” at washer (K), one 1/2” lock washer (L), and one 1/2”
hex nut (M). Only one bolt is required to secure the bracket to the frame.
INSTALLING OTHER AIR SPRING
1. Installation for one air spring is now complete.Continue by repeating the steps in
Assembling the Air Assembly, Attaching the Lower Bracket and Attaching the
Upper Bracket for the other side.
2. Proceed to Installing the Air Lines when the second air spring is installed.
INSTALLING THE AIR LINES
1. Choose a convenient location for mounting the ination valves. Popular locations for
the ination valve are in the wheel well anges, in the stowage area, or under the body
ange.
What ever the chosen location is, make sure there is enough clearance around the ination
valves for an air chuck.
2. Drill a 5/16” hole to install the ination valves.
3. Cut the air line assembly (AA) in two equal lengths.
WHEN CUTTING OR TRIMMING THE AIR LINE, USE A HOSE CUTTER, 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, WHICH CAUSES LEAKAGE AROUND THE O-RING
SEAL INSIDE THE ELBOW FITTING.
4. Place a 5/16” nut (GG) and a star washer (FF) on the air valve.Leave enough of the
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” nut (GG) and cap (CC). There should be approximately
1/2” of the valve exposed after installation to easily apply a pressure gauge or an air
chuck (Figure 4).
5. Push the ination valve through the hole and use the rubber washer (EE), at washer
(DD), and another 5/16” nut (GG) to secure it in place.Tighten the nuts to secure the
assembly in place (Figure 4).
NOTE
CAUTION
6. Route the air line along the frame to the air tting on the air spring (Figure 5). Keep at
least 6” of clearance between the air 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

7
MN-860
LoadLifter 5000 Ultimate
g. 5
NOTE
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.
CAUTION
7. On the exhaust side only, place the provided thermal sleeve (P) on the air line near the
exhaust.
8. Cut off air line, leaving approximately 12” of extra air line.A clean square cut will ensure
against leaks. Insert the air line into the push-to-connect air 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).
CHECKING FOR LEAKS
1. Inate the air spring to 60 p.s.i. 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.Leaks will be spotted
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, but not less than 20 p.s.i.
IMPORTANT: Check the air pressure again after 24 hours. A 2 to 4 p.s.i. 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, then:
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.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.
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 VISE-GRIPS TO PULL/TWIST THE AIR
LINE OFF THE FITTING.

8MN-860
LoadLifter 5000 Ultimate
Overnight leak down test — Recheck air pressure after the vehicle has been used for
24 hours.If the pressure has dropped more than 5 PSI, then there is a leak that must
be xed. Either x the leak yourself or return to the installer for service.
Air pressure requirements — Regardless of load, the air pressure should always be
adjusted to maintain ride height at all times.
Thirty day or 500 mile test —Recheck the air spring system after 30 days or 500 miles,
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.
POST-INSTALLATION CHECKLIST
Clearance test — Inflate the air springs to 60 PSI and ensure there is at least ½” clearance
around each bellow, away from anything that might rub against them. Be sure to check
the tire, brake drum, frame, shock absorbers and brake cables.
Leak test before road test — Inflate the air springs to 60 PSI, check all connections for
leaks with a soapy water solution. See page 12 for tips on how to spot leaks. All leaks
must be eliminated before the vehicle is road tested.
Fastener test — Recheck all bolts for proper torque. Axle clamp bar carriage bolt lock
nuts should be torqued to 16 ft/lbs. Re-torque after 100 miles.
Road test — The vehicle should be road tested after the preceding tests. Inflate the air
springs to 25 PSI (50 PSI if the vehicle is loaded). Drive the vehicle 10 miles and recheck
for clearance, loose fasteners and air leaks.
Operating instructions — If professionally installed, the installer should review the Product
Use, Maintenance and Servicing section on page 14 with the owner. Be sure to provide
the owner with all of the paperwork which came with the kit.
Technician’s Signature ________________________
Date______________
Before Operating
INSTALLATION CHECKLIST (To be completed by installer)

9
MN-860
LoadLifter 5000 Ultimate
Product Use, Maintenance and Servicing
MAINTENANCE GUIDELINES
By following the steps below, 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 inate beyond 100 PSI.
3. If you develop an air leak in the system, use a soapy water solution (1/5 liquid dish
soap and 4/5 water) to check all air line connections and the ination valve core before
deating and removing the air spring.
FOR YOUR SAFETY AND TO PREVENT POSSIBLE DAMAGE TO YOUR VEHICLE, DO
NOT EXCEED MAXIMUM GROSS VEHICLE WEIGHT RATING (GVWR), AS INDICATED
BY THE VEHICLE MANUFACTURER.ALTHOUGH YOUR AIR SPRINGS ARE RATED AT
A MAXIMUM INFLATION PRESSURE OF 100 P.S.I., THE AIR PRESSURE ACTUALLY
NEEDED IS DEPENDANT ON YOUR LOAD AND GVWR.
4. Loaded vehicles require at least 25 PSI or more.A “loaded vehicle” refers to a vehicle
with a heavy bed load, a trailer, or both.As discussed above, never exceed GVWR,
regardless of air spring, air pressure, or other load assist.The springs in this kit will support
approximately 40 lbs.of load (combined on both springs) for each 1 PSI of pressure.
The required air pressure will vary depending on the state of the original suspension.
Operating the vehicle below the minimum air spring pressure will void the Air Lift warranty.
5. 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.
6. Always add air to springs in small quantities, checking the pressure frequently.
7. Should it become necessary to raise the vehicle by the frame, make sure the system is at
minimum pressure (40 PSI) to reduce the tension on the suspension/brake components.
Use of on board leveling systems do not require deation or disconnection.
8. Periodically check the air spring system fasteners for tightness.Also, check the air springs
for any signs of rubbing. Realign if necessary.
9. On occasion, give the air springs a hard spray with a garden hose in order to remove
mud, sand, gravel or other abrasive debris.
TROUBLESHOOTING GUIDE
1. Leak test the air line connections, the threaded connection into the air spring, and all
ttings in the control system.
2.Inspect the air lines to be sure none are pinched.Tie straps may be too tight.Loosen or
replace the strap and replace leaking components.
3.Inspect the air line for holes and cracks.Replace as needed.
4.Look for a kink or fold in the air line.Reroute as needed.
NOTE
CAUTION
40 PSI 100 PSI
Maximum Air Pressure
Minimum Recommended Pressure