Air Lift 57397 User manual

MN-773 • (021111) • ECR 7203
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.
INSTALLATION GUIDE
Kit 57397
Ford F-250/F-350
(Single and Dual Rear Wheel)
2-Wheel Drive

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 3/4 and 1 ton pickups and SUVs with leaf springs and
provide up to 5,000 lbs. of oad leveling support with air adjustability from 5-100 PSI. The
kits are also used in motor home rear kits and some motor home fronts where leaf spring
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 guidelines and operating
tips.
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 truck
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
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
LoadLifter 5000

Installation Diagram
g. 1
J
S
L
M
F
P
P
I
VW
E
W
VW
V
V
WU
N
W
P
H
G
P
C
W
V
S
T
W
U
N
Z
W
V
A
B
NOTE: Single rear wheel
mounting location shown.
3/4” Nyloc Nut* or (X)
3/4” Flat Washer* or (R)
3/4” Flat Washer* or (R) Y or R
Q**
D
3/4” Bolt* or (O) or (HH)
NOTE: Single rear wheel
mounting location shown. Q**
NOTE: Use hole that is
closest to the leaf spring! K
* 3/4” hardware is supplied by the
5th wheel hitch manufacturer. Use
the 1/2” hardware supplied with this
kit if no hardware is supplied by the
manufacturer.
** On some models with sway bars
under the axle, it may be necessary
to invert the long carriage bolt.
Driver side shown
5th Wheel
Bracket (Plate)
LoadLifter 5000

TOOLS LIST
Description......................................................................Qty
7/16” and 9/16” Open-end or box wrenches.......................2
Crescent wrench.................................................................1
Ratchet with 3/8”, 9/16”, & 1/2” deep well sockets.....................1
5/16” drill bits (very sharp)..................................................1
DIR grinder .........................................................................1
Hacksaw.............................................................................1
Heavy duty drill...................................................................1
Torque wrench....................................................................1
Standard, metric and SAE sockets and wrenches .............1
Hose cutter, razor blade, or sharp knife .............................1
Hoist or oor jacks..............................................................1
Safety stands......................................................................1
Safety glasses ....................................................................1
Air compressor or compressed air source..........................1
Spray bottle with dish soap/water solution .........................1
Item Part # Description ............................... Qty
A 03991 Lower Bracket.....................................2
B 07996 Upper Brace........................................1
C 07997 Upper Bracket.....................................1
D 01531 Clamp Bar...........................................2
E 10861 Spring Clamp Bar................................2
F 13966 Spacer.................................................2
G 11951 Roll Plate.............................................4
H 58437 Bellows................................................2
I 10880 Four Hole Locating Bracket ................4
J 10886 “L” Bracket ..........................................1
K 17110 3/8-16 x 5.5 Hex Head Cap Screw .....4
L 17135 1/4”-20 x 1” Hex Cap Screw................1
M 17141 3/8-16 x 2.5” Carriage Bolt..................2
N 17203 3/8-24 x 7/8” Hex Head Cap Screw ....8
O 17271 1/2”-13 x 3” Hex Cap Screw................2
P 17361 3/8-16 x 1.25” Carriage Bolt................8
Q 17387 3/8-16 x 10” Carriage Bolt...................4
Item Part # Description ............................... Qty
R 18207 1/2” Thick Flat Washer........................6
S 18419 Flat Washer #12..................................2
T 18425 1/4”-20 Nyloc Nut................................1
U 18427 3/8” Lock Washer................................8
V 18435 3/8”-16 Nyloc Nut...............................18
W 18444 3/8” Flat Washer ................................34
X 18460 1/2-13” Nyloc Nut................................2
Y 18556 3/4” Flat Washer .................................2
Z 21837 90 ˚ Swivel Air Fitting ..........................2
AA 10466 Zip Ties ...............................................6
BB 18411 5/16” Lock Washer..............................2
CC 21230 Valve Caps..........................................2
DD 21233 5/16” Hex Nut......................................2
EE 21234 Rubber Washer...................................2
FF 20086 Air Line Assembly ...............................1
GG 34924 Heat Shield Kit ....................................1
HH 17208 1/2-13 x 2” Hex Head Cap Screw .......2
HARDWARE LIST
Hardware and Tools Lists
LoadLifter 5000

g. 2
NOTE
NOTE
LoadLifter 5000
GETTING STARTED
1. Raise the vehicle and support the axle with jack stands, setting the jack stands as wide
as possible on the axle (g. 2).
2. Remove the jounce bumpers from under the frame, over the axle.
3. If necessary, disconnect the wiring harness from the driver side frame rail to gain clearance
for the upper bracket.
4. For all dual rear wheel vehicles (DRW) it will be necessary to remove the sway bar strap
and bolts holding the sway bar to the axle. Retain for later reinstallation.
5. If you have a fth wheel hitch already installed, it will be necessary to remove the ¾”
hardware that bolts the side bracket to the outside of the frame above the axle (g. 1).
Some hitch models have a spacer between the bracket and the frame rail. Be sure to reinstall
the spacer when attaching the upper bracket.
If your model truck has emission lines running along the inside of the frame rail (g. 3), it
will be necessary to relocate those lines as follows. Follow the directions in the section,
“Attaching the Assemblies to the Frame” for reattaching these lines.
l Carefully push the line holder out of the frame above the axle. Try to minimize
damage because it will be reused later. It may also be helpful to remove any holders
forward or rearward of the axle to aid in positioning the lines once the upper bracket
has been installed (g. 3) .
l Attach the L-bracket (J) to the back frame brace using the 1/4” bolt (L), at washers
(S) and nyloc nut (T) supplied (g. 1). This L-bracket will eventually be used to attach
the previously removed emissions line. Do not attach the line holder to it at this time.
Installing the LoadLifter 5000 System
g. 3
Line holder
Emissions lines
Electrical wiring loom
Jack Stands

NOTE
J
S
L
F
C
W
V
S
T
W
U
N
Z
W
V
B
P
3/4” Nyloc Nut* or (X)
3/4” Flat Washer* or (R)
3/4” Flat Washer* or (R) Y or R
3/4” Bolt* or (O) or (HH)
PM
Driver side shown
5th Wheel
Bracket (Plate)
LoadLifter 5000
SIDE BRACE INSTALLATION
1. Set the upper brace (B) into the driver and passenger side frame (g. 4).
If you have a fth wheel hitch that does not have a plate running alongside the full length
of the frame (these will have an “L” bracket forward and behind the axle leaving the
middle frame open) use the 1/2-13 x 2.00” Hex Cap Screw (HH) with a at washer (R)
through the slot in the side of the frame, then through another at washer (R) and nally
through the upper brace. Cap with a at washer (R) and a 1/2-13 nyloc nut (X) (g. 5).
Leave loose at this time.
OR
If you have an aftermarket fth wheel hitch that has a bracket (plate) running along side of
the frame and it used this slot to secure the bracket to the frame with existing hardware,
install the existing hardware previously removed in the “getting started section” from the
fth wheel installation for securing the brace (g. 4). Make sure to install the large 3/4”
at washer (Y) between the brace and frame (gs. 1 and 4). Do not tighten at this time.
OR
If you have an aftermarket fth wheel hitch that has a bracket (plate) running along side
of the frame and it does not have any attaching hardware on the side where the slot in
the frame is, it will be necessary to drill a ½” hole through the plate using the slot in the
frame as a template. Drill the hole as far back in the slot as you can.
It may be necessary to mark and remove the bracket (plate) from the side of the frame in
order to drill the hole correctly. Re-attach once the hole is drilled.
Insert a ½”-13 x 3.00” hex cap screw (O) with a at washer (R) through the fth wheel
plate previously drilled, the frame, then through another at washer (R)and nally the
upper frame brace. Cap with a at washer (R) and a ½”-13 Nyloc nut (X) (g. 4). Leave
loose at this time.
g. 4

NOTE
NOTE
g. 7
(F) - wide portion of spacer
points outboard
Left (Driver Side)
shown
(V), (U), (N)
g. 6
Driver Side
(M)
(P)
(C) Upper bracket
Passenger Side
(C)
Upper
bracket
(A) Lower bracket
(H) Bellows
LoadLifter 5000
BELLOWS AND BRACKET ASSEMBLY
1. Set a roll plate (G) over the top and bottom of the bellows (H) (g. 1).
The radiused (rounded) edge of the roll plate (G) will be towards the bellows so that the
bellows is seated inside both roll plates.
2. Install the swivel elbow tting (Z) into the top of the bellows nger tight. Tighten the swivel
tting one and a half turns.
3. The lower bracket (A) has two sets of bellows mounting holes. Using the corresponding
holes in the lower bracket designated (g. 5), attach the bellows to the brackets using
the 3/8” at washers (W), lock washers (U), and 3/8”-24 x 7/8” hex head cap screws (N).
Torque both mounting screws to 20 ft/lbs.
The tting on top of the bellows points inward (g. 7).
5. Insert two 3/8”-16 x 1.25” carriage bolts (P) up through the bottom of the upper bracket
s( g. 7), through the two square holes that are on the corresponding side. Also, insert
one 3/8”-16 x 2.5” carriage bolt (M) through the remaining hole. The head of this carriage
bolt will be hidden once mounted to the bellows.
6. Set the driver side (left) upper bracket onto the driver side bellows assembly previously
assembled, using the holes in the upper bracket designated (g. 6), and attach to the
bellows with two 3/8” at washers (W), lock washers (U), and 3/8”-24 x 7/8” hex head
cap screws (N). Torque both mounting screws to 20 ft/lbs.
7. Repeat the above process for the opposite side assembly (g. 7).
8. Set the spacer (F) over both long carriage bolts (g. 7).
The hole in the at spacer (F) is offset. Install the spacer so that the wide portion faces the
outside of the vehicle (g. 7).
NOTE
Left (driver)
side holes
Right (passenger)
side holes
Outside (wheel)
g. 5
(A) Lower bracket

CAUTION
NOTE
CAUTION
LoadLifter 5000
ATTACHING THE ASSEMBLIES TO THE FRAME
1. If not done so yet, drop the axle or raise the frame up to make room for the assemblies
to be put into position.
2. Set the left (driver side) assembly onto the axle (g. 1). Raise the axle just enough to
insert the long carriage bolt (M) (that is installed in the upper bracket) through the existing
jounce bumper hole in the bottom of the frame. At the same time, line up the upper brace
previously installed onto the remaining two carriage bolts (P) in the upper bracket. Do
this just enough for the carriage bolt to hold the assembly into position on the axle (g.
1).
3. Set the right (passenger side) assembly into position on the axle the same way the left
side was positioned (g. 1).
4. Raise the axle or lower the frame down so that the thick spacer (F) on the upper bracket
is parallel to, and contacts the frame (on both sides).
5. Install the 3/8” Flat Washer (W) and a 3/8’-16 Nyloc nut (V) on the carriage bolt (M) that
went through the existing jounce bumper hole and tighten securely on both sides (g. 1).
BE SURE NOT TO PINCH THE PREVIOUSLY MOVED WIRING OR LINES INSIDE THE
LEFT FRAME RAIL.
6. Cap the brace/upper bracket carriage bolts (P) with a 3/8” at washer (W) and 3/8” nyloc
nut (V) and tighten both securely on both sides.
7. With the spacers (F) on the upper brackets tight to the bottom of the frame and the braces
tight to the upper bracket, tighten the ½ or ¾” hardware previously installed, that hold
the braces to the frame. Tighten both sides securely.
8. If so equipped with the emissions line previously loosened from the frame, insert the
line holder post into the L-bracket (J) attached to the back leg of the upper left brace (B)
(g. 8). It may be necessary to move the line holder post forward or back on the lines to
line up correctly with the L-bracket hole. Reattach any line holders removed forward or
behind the axle, if possible, that were removed to aid in positioning the upper bracket.
LOWER BRACKET ATTACHMENT
ATTACHING THE LOWER BRACKET WILL DEPEND ON THE MODEL TRUCK YOU
HAVE. SEE FIGURE 10 TO DETERMINE WHICH HOLES TO USE FOR INSERTING THE
CARRIAGE BOLTS.
1. Insert a 3/8-16 x 5.5 hex head bolt bolt (K) and at washer (W) into one of the two bottom
holes of the locating bracket (I) (g. 9).
Use the hole that is closest to the leaf spring.
g. 8
Emissions line
holder (stock)
(J) L-bracket

NOTE
LoadLifter 5000
2a.If you are installing this kit on a single rear wheel (SRW) vehicle, use position 2 to insert
the long 3/8-16 x 10” carriage bolt (Q) through the top of the locating bracket and lower
bracket (g. 9).
2b.If you are installing this kit on a dual rear wheel (DRW) vehicle, use position 1 to insert
the long 3/8-16 x 10” carriage bolt (Q) through the top of the locating bracket and lower
bracket (g. 9).
3. Attach the locating bracket (I) to the lower bracket with a 3/8-16 x 1.25” carriage bolt
(P), at washer (W) and nyloc nut (V) using the remaining slot in the top of the locating
bracket. Leave loose at this time.
4. Push the front and back locating brackets against the u-bolts and tighten the short
carriage bolts at this time.
5. Using the 3/8-16 x 5.5 hex head bolts (K) and at washers (W) previously installed on the
locating brackets, insert them into the spring clamp bar (E) on the opposite side of the
leaf spring assembly (g. 9). Cap with 3/8” at washers (W) and nyloc nuts (V). Leave
loose at this time.
6. Set the axle clamp bar (D) onto the long 3/8-16 x 10” carriage bolts (Q) (g. 1) and cap
with 3/8” at washers (W) and nyloc nuts (V).
If you have a sway bar under the axle and the carriage bolt (Q) interferes, invert the carriage bolt.
7. Carefully draw the side hardware and axle hardware evenly. Torque the spring clamp
bar bolts to 10 ft/lbs and the axle clamp bar bolts to 16 ft/lbs. Repeat for opposite side.
Trim carriage bolts below nyloc nuts if necessary.
g. 10
P
I
VW
E
W
VW
V
V
WU
N
W
P
H
A
NOTE: Single rear wheel
mounting location shown.
Q**
D
NOTE: Single rear wheel
mounting location shown. Q**
NOTE: Use hole that is
closest to the leaf spring! K
* 3/4” hardware is supplied by the
5th wheel hitch manufacturer. Use
the 1/2” hardware supplied with this
kit if no hardware is supplied by the
manufacturer.
** On some models with sway bars
under the axle, it may be necessary
to invert the long carriage bolt.
Position 1 Position 1
Position 2 Position 2
g. 9
(A) Lower bracket
(I) Locating bracket

CAUTION
NOTE
g. 12
Secure emergency
brake cable using
this hole
(A) Lower bracket
LoadLifter 5000
For 2WD and 4WD DRW vehicles, in order to install the sway bar and sway bar retaining
straps back onto the axle, it will be necessary to slot the retaining straps (g. 11). Reattach
the sway bar once this is done.
FINAL STEPS
1. The emergency brake cable will have to be re-located away from the bellows.
FAILURE TO DO SO MAY CAUSE FAILURE TO THE BELLOWS AND VOID THE
WARRANTY.
2. Secure the emergency brake cable to the bottom bracket with supplied wire tie using
the hole in the corner of the lower bracket (g. 12).
g. 11
Grind slot larger Grind slot larger