Air Lift loadlifter 5000 User manual

For maximum effectiveness and safety,
pleasereadtheseinstructionscompletely
before proceeding with installation.
Failure to read these instructions can result in an
incorrect installation.
MN-387 • (31210) • ECR 7433
INSTALLATION GUIDE
No. 57215
& 57207

1
MN-387
LoadLifter 5000
Introduction ...................................2
Important Safety Notice .............................................2
Notation Explanation ................................................2
Installation Diagram ............................ 3
Hardware List .....................................................4
Tools List.........................................................4
Installing the LoadLifter 5000 System.............. 4
5th Wheel Hitch....................................................4
Getting Started ....................................................4
Special Application Instructions........................................5
Assembling the Air Spring Unit ........................................6
Positioning the Brackets .............................................7
Attaching the Lower Bracket ..........................................7
Attaching the Upper Bracket ..........................................8
Securing the Air Spring to the Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installing the Air Lines ...............................................9
Reinstalling the Fenderwell Liner (Late Model 4WD Dodge Only) .............10
Checking For Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Maintenance and Servicing ...................... 11
Maintenance Guidelines .............................................12
Warranty and Return Policy ...................... 12
Product Use ................................... 13
Frequently Asked Questions ..........................................13
Tuning the Air Pressure..............................................13
Guidelines for Adding Air.............................................14
Replacement Information ........................ 14
Contact Information ............................ 14
TABLE OF CONTENTS
1

2MN-387
LoadLifter 5000
Introduction
The purpose of this publication is to assist with the installation, maintenance and
troubleshooting of the LoadLifter 5000 air spring kit. LoadLifter 5000 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. LoadLifter
5000 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.
Itisimportant toreadandunderstand theentireinstallationguide beforebeginninginstallation
orperforminganymaintenance,serviceorrepair.Theinformation here includes 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
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 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 injury
orpossibleimproperinstallationwhichmay render the vehicleunsafe.Notesareusedtohelp
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-387
LoadLifter 5000
Installation Diagram
A
M
IJ
N
B
LH
F or G
I
H
C
I
J
N
D
E
OUTBOARD
FORWARD
g. 1
Z
V
Y
X
WZ
T

4MN-387
LoadLifter 5000
Installing the LoadLifter 5000 System
5TH WHEEL HITCH
NOTE FOR FORD TRUCKS ONLY: If you have a Reese-style 5th wheel hitch kit installed and
you have purchased kit #57215, you need to order kit #57342 or contact Air Lift customer
service for the correct brackets at [phone]. Ask for bracket kit #26275.
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.
DANGER
GETTING STARTED
1. Support the axle with jack stands, remove the wheels, and raise or lower to obtain normal
ride height (gs. 2 and 3).
8”
g. 3
No Load in Truck
Remove wheels
g. 2
Item Part # Description................................Qty
A1 58437 Bellows (57215) ..................................2
A2 58491 Bellows (57207) ..................................2
B 07475 Upper bracket .....................................2
C 03102 Lower bracket .....................................2
D 11951 Roll plate.............................................4
E 33606 Elbow tting.........................................2
F 10594 2” U-bolt ..............................................4
G 10583 4.5” U-bolt ...........................................4
H 18435 Nyloc nut............................................16
I 18444 3/8” Flat washer .................................16
J 18427 3/8” Lock washer.................................8
K 13377 Upper bracket spacer* ........................8
L 18447 3/8” Large at washer .........................8
M 17159 3/8” x 1.5” Washer head frame bolt ....8
N 17203 3/8” x 7/8” Hex head cap screw ..........8
O 01525 Spacer bar*.........................................4
Dodge Fenderwell Spacer Parts
P 17182 ½” x 2” HHCS* ....................................2
Q 20947 Fenderwell liner spacer* .....................2
R 18419 10/32” Flat washer*.............................6
S 18425 ¼” Nyloc nut* ......................................2
Air Line Assembly
T 20086 Air line assembly* ...............................1
U 10466 Tie strap*.............................................6
V 21230 Valve caps*.........................................2
W 18405 5/16” Flat washer*...............................2
X 21234 Rubber washer* ..................................2
Y 18411 Small star washer*..............................2
X 21233 5/16” Hex nut*.....................................4
*Not shown in g. 1.
HARDWARE LIST
Missing or damaged parts? Call Air Lift customer
service at [phone] for a replacement part.
STOP!

5
MN-387
LoadLifter 5000
SPECIAL APPLICATION INSTRUCTIONS
1. 1994 model and newer Dodge 4WD pickups only:
It will be necessary to remove the inner fenderwell liner on late model 4WD Dodge trucks.
This is done by carefully driving the pin through the fasteners with a center punch (g.
4). These fasteners will be reused along with a special spacer to reattach the line and
provide clearance for the air spring. (See page 10 for reinstallation instructions.)
g. 4
2. Ford trucks only:
When installing the upper bracket on an F-250 or F-350, the mounting bolt holes can
line up directly over the indent in the frame. This is an acceptable situation and is an
approved method of installation for the product (g. 5). Torque the mounting hardware
to specications, as noted. Do not over torque.
g. 5
Frame
3. For 1999 and later SuperDuty F-250 and F-350 trucks:
Remove the bolt which holds the emergency brake cable to the outside of the frame
rail. Reinstall the bolt in the reverse order, with the nut on the inside of the frame rail,
to prevent rubbing against the air spring (g. 6).
FAILURE TO SWITCH THIS BOLT WILL CAUSE AIR SPRING TO RUPTURE.
g. 6
Emergency Brake Line
Clip
After
Before
Inboard
Inboard
CAUTION

6MN-387
LoadLifter 5000
ASSEMBLING THE AIR SPRING UNIT
See g. 7 below for assembly.
1. Set a roll plate on both ends of the air spring. 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.
2. Install a 90° swivel air tting. It should only be nger tight plus 11/2 turns. Do not
overtighten.
3. Place the upper bracket onto the top of the air spring and roll plate with the legs facing
down.
4. Set the air spring on the lower bracket aligning the two holes in the base of the air spring
with the two outer slots in the top of the lower bracket.
5. Loosely attach the upper bracket to the assembly using at washers, lock washers, and
hex head bolts. Remember that the bracket legs face down.
6. Loosely attach the lower bracket to the assembly using at washers, lock washers, and
hex head bolts.
The ange on the bracket must face the outside (tire-side) of the vehicle.
NOTE
g. 7
Upper Bracket
90° Swivel Air Fitting
Lower Bracket
Roll Plates Air Spring
Hex Head Bolt
Lock Washer
Flat Washer
Bracket Leg
Flange

7
MN-387
LoadLifter 5000
POSITIONING THE BRACKETS
1. The air spring must be installed between 5” and 8” from both the upper bracket to the
lower bracket (g. 8). It is best to position the upper bracket as high as possible.
Failure to mount the air spring at the recommended height can result in the air spring
bottoming out.
The top rear mounting hole may be above the frame rail. If this condition exists, use the
two lower mounting holes to mount the bracket (g. 8).
2. Set the air spring assembly on the leaf spring over the axle (g. 8).
3. Position the upper bracket so that at least four bolt holes (two on each side) will be on
the at section of the frame rail. Keep the edge of drilled holes no closer than 3/4” from
the top or bottom radius of the frame rail.
4. In some cases, it may be necessary to use the optional spacers to achieve the 5”- 8”
space (g. 8). For example, if only the top two holes contact above the lower radius edge
of the frame rail, it may be necessary to move up the spacers under the lower bracket
to achieve mounting height.
If you nd that the lower bracket needs to set at onto the leaf spring in order to achieve
the correct height and the stock u-bolts are too high to allow this, it will be necessary to trim
the stock u-bolts.
ATTACHING THE LOWER BRACKET
1. If the spacer is not used, attach the lower bracket securely using the provided U-bolts,
at washers, and lock nuts. Torque nuts to 16 ft/lbs. See gures 1 and 9.
Use shorter U-Bolts when attaching to frame contact overload springs.
2. If the spacer is used, place the spacers legs down on the leaf spring and attach the lower
bracket securely using the provided U-bolts, at washers, and lock nuts. Torque nuts to
16 ft/lbs (g. 9).
NOTE
NOTE
NOTE
g. 9
Shorter U-bolt
Trim stock u-bolts
if necessary.
g. 8
Lock Nut
Spacer (optional
to achieve proper
mounting height)
Flat Washer
U-bolt
Distance must be 5”- 8”
and equal on both
sides Upper and lower
bracket must be
parallel
Lower Mounting Holes
Trim stock u-bolts
if necessary.

8MN-387
LoadLifter 5000
ATTACHING THE UPPER BRACKET
BEFORE DRILLING, CHECK THE BACK-SIDE OF THE FRAME FOR CLEARANCE ISSUES
WITH THE BRAKE LINES, GAS LINES, AND ELECTRICAL LINES. ANY OBSTACLES
WILL NEED TO BE TEMPORARILY RELOCATED TO CLEAR THE AREA.
1. Position the upper bracket so that it is parallel with the lower bracket and align the
assembly vertically and horizontally.
2. Using the upper bracket as a template, center punch and drill one 3/8” locatorholethrough
the frame at one of the top bolt holes (g. 10).
After achieving the proper alignment, repeat for the opposite side of the bracket.
NOTE
CAUTION
3. Except for Dodge vehicles, loosely install a washer head frame bolt, oversized at
washer), and lock nut (g. 11).
For Dodge trucks only: The top two, or the bottom two, holes (depending on the model
of the truck) will fall into a horizontal indentation. Spacers are provided to compensate
for the indentation. Loosely install a washer head frame bolt, two upper bracket spacers,
an oversized at washer, and a lock nut for such instances (g. 12).
4. Install a washer head frame bolt, oversized at washer, and lock nut.
For Dodge trucks only: It may be necessary to add two of the provided spacers
(g. 12).
g. 11 g. 12
Upper Bracket
Washer Head
Frame Bolt Lock Nut
Oversized Flat
Washer
Frame
Upper Bracket
Washer Head
Frame Bolt
Lock Nut
Oversized Flat
Washer
Frame
Spacer
All models, except some
late model Dodge trucks Dodge trucks with ditch
(ditchcanbeontoporbottomportionofthe
frame, depending on vehicle model)
3/8”
g. 10

9
MN-387
LoadLifter 5000
SECURING THE AIR SPRING TO THE BRACKETS
1. Secure the air spring to the upper and lower brackets using an open ended 9/16” wrench
by tightening the two bolts on the top and the two bolts on the bottom of the spring
assembly.
DUE TO THE THICKNESS OF THE LEAF SPRING STACK, TRIM ALL FOUR U-BOLTS
ON EACH SIDE OF THE VEHICLE TO PREVENT BOTTOMING OUT ON THE UPPER
BRACKET (FIG. 14).
2. Check bolts and connectors to ensure that all hardware is secure and repeat the process
for the other side of the vehicle.
5. Remove the clamps and drill the remaining two holes. Install the appropriate hardware
and torque the nuts to 44 ft/lbs.
6. Align the air spring uniformly between the upper and lower brackets and check the air
spring alignment (g. 13).
INSTALLING THE AIR LINES
WHEN INSTALLING THE AIR LINES, THERE MUST BE AT LEAST SIX INCHES OF
CLEARANCE BETWEEN THE AIR LINES AND ANY HEAT SOURCES.
1. Choose a convenient location for mounting the ination valves. Popular locations for the
ination valves are: The wheel well anges; The license plate recess in bumper; Under
the gas cap access door; or through the license plate (g. 15).
2. Secure air lines with provided tie straps.
Whatever the chosen location for the line is, make sure there is enough clearance around
the ination valves for an air chuck.
NOTE
CAUTION
CAUTION
Option 1
Option 2
g. 15
U-Bolts
g. 14
Move the air spring in
the slots of the upper
and lower brackets to
align. Make sure there
is at least a thumbs
width of clearance
between the uninated
bag and the frame.
Frame
Bag g. 13