Installation Manual
Contents
1. install it If there is no heat shield but one is required call 800 248 0892 Q 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 Q 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 Q 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 POST INSTALLATION CHECKLIST QO 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 fixed Either fix the leak yourself or return to the installer for service QO Air pressure requirements understand the air pressure requirements of my air spring system Regardless of load the air pressure should always be adjusted to maintain ride height at all times Q Thirty day or 500 mile test understand that must 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 i2. regardless of air spring air pressure or other load assist The springs in this kit will support approximately 40 Ibs 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 5 PSI to reduce the tension on the suspension brake components Use of on board leveling systems do not require deflation 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 fittings in
3. claim or question Contact the retailer where the kit was purchased e If itis necessary to return or exchange the kit for any reason If there is a problem with shipping if shipped from the retailer If there is a problem with the price Contact Information If you have any questions comments or need technical assistance contact our customer service department by calling 800 248 0892 For calls from outside the USA or Canada our MN 776 local number is 517 322 2144 For inquiries by mail our address is PO Box 80167 Lansing MI 48908 0167 Our shipping address for returns is 2727 Snow Road Lansing MI 48917 You may also contact us anytime by e mail at sales airliftcompany com or on the web at www airliftcompany com 17 Need Help Contact our customer service department by calling 800 248 0892 For calls from outside the USA or Canada our local number is 517 322 2144 Register your warranty online at www airliftcompany com warranty KET Thank you for purchasing Air Lift products the professional installer s choice Air Lift Company 2727 Snow Road Lansing MI 48917 or PO Box 80167 Lansing MI 48908 0167 Toll Free 800 248 0892 Local 517 322 2144 Fax 517 322 0240 www airliftcompany com Printed in the USA
4. frame then through another flat washer Q and finally through the upper brace Cap with a flat washer Q and a 1 2 13 nyloc nut V fig 4 Leave loose at this time OR If you have an aftermarket fifth 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 fifth wheel installation for securing the brace fig 4 Make sure to install the large 3 4 flat washer W between the brace and frame figs 1 and 4 Do not tighten at this time OR If you have an aftermarket fifth 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 Y2 hole through the plate using the slot in the frame as a template 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 2 13 x 3 hex head cap screw N with a 1 2 thick flat washer Q through the fifth wheel plate previously drilled the frame then through another 1 2 thick flat washer Q and finally the upper frame brace Cap with a 1 2 thick flat washer Q and a 13 Nyloc nut V fig 4 Leave loose at this time BELLOWS AND BRACKET ASSEMBLY 1 Seta
5. 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 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 18 Raise the air pressure to correct either of these problems and level the vehicle 2 Ride comfort If the vehicle has a rough or harsh ride it may be due to either too much pressure or not enough fig 19 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 20 Tuning out these problems usually requires an increase in pressure Sway and fig 20 body roll MN 776 15 LP LoadLifter 5000 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 PSI in
6. no warranties that extend beyond the description on the face hereof Seller disclaims the implied warranty of merchantability Dated proof of purchase required MN 776 LoadLifter 5000 LP Warranty amp Returns Policy continued Air Lift 1000 Lifetime Limited LoadController Dual 2 Year Limited RideControl assassines Lifetime Limited Load Controller I 2 Year Limited LoadLifter 5000 Lifetime Limited Load Controller II 2 Year Limited LoadLifter 5000 ULTIMATE Lifetime Limited SmartAir cccccccsssee 2 Year Limited SlamAir 0 00008 Lifetime Limited Wireless AIR 2 Year Limited AirCell ooo csccessesseseseee Lifetime Limited WirelessONE 0 2 Year Limited Air Lift Performance 1 Year Limited Other Accessories 2 Year Limited LoadController Single 2 Year Limited formerly SuperDuty formerly LifeSTYLE amp Performance and EasyStreet Replacement Information If you need replacement parts contact the local dealer or call Air Lift customer service at 800 248 0892 Most parts are immediately available and can be shipped the same day Contact Air Lift Company customer service at 800 248 0892 first if e Parts are missing from the kit e Need technical assistance on installation or operation e Broken or defective parts in the kit Wrong parts in the kit Have a warranty
7. roll plate F over the top and bottom of the bellows G fig 1 The radiused rounded edge of the roll plate F will be towards the bellows so that the bellows is seated inside both roll plates MN 776 LoadLifter 5000 NOTE NOTE MN 776 2 SP Install the swivel elbow fitting AA into the top of the bellows finger tight Tighten the swivel fitting one and a half turns The lower bracket A has two sets of bellows mounting holes Using the corresponding holes in the lower bracket designated fig 5 attach the bellows to the brackets using the 3 8 flat washers U lock washers CC and 3 8 24 x 7 8 hex head cap screws BB Tighten both mounting screws securely The fitting on top of the bellows points inward fig 7 Left driver side holes Outside wheel eee A Lower bracket Fi Right passenger side holes Insert two 3 8 16 x 1 25 carriage bolts O up through the bottom of the upper brackets fig 6 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 Set the driver side left upper bracket onto the driver side bellows assembly previously assembled using the holes in the upper bracket designated fig 6 and attach to the bellows with two 3 8 flat washers U lock washers CC and 3 8 24
8. vehicle and support the axle with jack stands setting the jack stands as wide as possible on the axle fig 2 fig 2 Jack Stands ee y 2 Remove the jounce bumpers from under the frame over the axle 3 Ifnecessary 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 fifth wheel hitch already installed it will be necessary to remove the 34 hardware that bolts the side bracket to the outside of the frame above the axle fig 1 NOTE Some hitch models have a spacer between the bracket and the frame rail Be sure to reinstall the spacer when attaching the upper bracket 6 In order to obtain clearance between the upper bracket and the emergency brake cable bolt on the inside of the frame it will be necessary to remove the bolt and re insert through the emergency brake cable bracket from the outside of the frame in Install the 7 16 spacer Y on the bolt and cap with the new M10 1 5 nyloc nut Z fig 1 Tighten hardware securely NOTE If your model truck has emission lines running along the inside of the frame rail fig 3 it will be necessary to relocate those lines as follows Follow the directions in the section Attaching the Assembli
9. x 7 8 hex head cap screws BB Tighten both mounting screws securely Repeat the above process for the opposite side assembly fig 7 Depending on the model of the truck there are two spacer X1 or X2 lengths that are supplied to properly fit between the frame jounce bumper bracket and frame Use the spacer that can be inserted where the stock jounce bumper was removed which when butted against the frame will be flush or close to the bottom of the jounce bumper bracket that is riveted to the frame The upper bracket when in position should rest on the spacer and the stock jounce bumper bracket C Upper bracket X1 or X2 B T CC BB fig 6 Passenger Side G Bellows G Upper bracket A Lower bracket Ed D Driver Side Lf Left Driver Side 0 fe shown 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 Set the left driver side assembly onto the jounce bumper strike plate figs 8a amp 8b Raise the axle just enough to insert the 3 8 16 x 2 5 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 3 8 16 x 1 25 carriage bolts O in the upper brack
10. 4 Minimum and Maximum Pressure 000000 cece eee eee 14 Maintenance Guidelines 0 0 0c cee eens 14 Troubleshooting Guide 0 00 14 Frequently Asked Questions 000 cece cette 15 Tuning the Air Pressure 0 2 eee 15 Guidelines for Adding Air 0 2 0 0 0000s 16 Warranty and Returns Policy 222005 16 Replacement Information 0000000eeeeeeeee 17 Contact Information 0000e cence eee eeees 17 LP LoadLifter 5000 Introduction NOTE N 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 Ibs 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 Air Li
11. EATH 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 MN 776 LoadLifter 5000 Installation Diagram R 3 4 Flat Washer or Q 5th Wheel Bracket Plate f Y 3 4 Flat Washer W or Q Driver side shown Cro e 3 4 Flat Washer or Q 3 4 Nyloc Nut or V Emergency Brake Cable Clamp Driver Side Only NOTE Single rear wheel mounting location shown NOTE Single rear wheel mounting location shown NOTE Lower Bracket sits on jounce bumper strike plate See fig 8a amp 8b on page 8 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 NOTE Use hole that is closest to the leaf spring On some models with sway bars under the axle it may be necessary to invert the long carriage bolt MN 776 3 LP Hardware and Tools Lists HARDWARE LIST Item Part Description eee Qty Item Part A 03990 Lower Bracket cccccccceeeeeesseseeeees 2 U 18444 B 07996 Up
12. MN 776 041406 ECR 7913 Load 7 NERS by AIR LIFT Kit 57390 Ford F 250 F 350 Single and Dual Rear Wheel 4 Wheel Drive 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 TABLE OF CONTENTS INGFOGUCHION ss esaii a Mean a a 2 Important Safety Notice 0 0 cee a 2 Notation Explanation 0 0 0 eee 2 Installation Diagram ccoscduwcdetiese hues wccuns dak aa 3 Hardware and Tools Lists 2022202e2e200es 4 Installing the LoadLifter 5000 System 5 Getting Started 2 0 eee 5 Side Brace Installation 0 0 0 00 ccc cette 6 Bellows and Bracket Assembly 0 000 e eee ee eae 6 Attaching the Assemblies to the Frame 000 cece eee 8 Lower Bracket Attachment 00 000 cece eee 9 Installing the Air LINES 2 42 4 02s644 084 h0p8de00 edad iieri t iwr ituipdk 11 Installing the Heat Shield 0 0 0 0 cece ee 12 Checking for LeakS 0 ccc ee eee 12 Fixing Leaks sser Beck Agta hh ete nE e estates ep eS ese De tees in noe 12 Before Operating 2020e cece eee eee eee 13 Installation Checklist ss dtccs ee tale Mieaw A Rad Sites sist aan atda wee me Rew alee 13 Post Installation Checklist 0 0 0 0 cc cee eens 13 Product Use Maintenance and Servicing 1
13. and have room for the rubber washer flat washer and 5 16 nut and cap There should be enough valve exposed after installation approximately 2 to easily apply a pressure gauge or an air chuck fig 14 5 Push the inflation valve through the hole and use the rubber washer flat washer and another 5 16 nut to secure it in place Tighten the nuts to secure the assembly 6 Route the air line along the frame to the air fitting on the air spring fig 15 Keep AT LEAST 6 of clearance between the air line and heat sources such as the exhaust pipes muffler or catalytic converter Avoid sharp bends and edges Use the plastic tie straps to secure the air line to fixed non moving points along the chassis Be sure that 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 MN 776 11 R NOTE 12 LoadLifter 5000 ii Option 1 a Option 2 fine fig 13 7 Cut off the air line leaving approximately 12 of extra air line A clean square cut will ensure against leaks Insert the air line into the air fitting This is a push to connect fitting Simply push the air line into the 90 swivel fitting until it bottoms out 9 16 of air line should be in the fitting INSTALLING THE HEAT SHIELD 1 Bend tabs to provide a dead air space between exhaust pipe and heat shield fig 16 2 Attach the heat
14. es to the Frame for reattaching these lines e 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 fig 3 e Attach the L bracket J to the back or front leg of the frame brace using the 1 4 20 x 1 hex head bolt L flat washers R and 1 4 20 nyloc nut S supplied fig 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 Emissions lines fig 3 Electrical wiring loom MN 776 5 NOTE NOTE LoadLifter 5000 SIDE BRACE INSTALLATION 3 4 Flat Washer or Q 3 4 Flat Washer W or Q Driver side shown 5th Wheel Bracket Plate 3 4 Flat Washer or a 3 4 Nyloc Nut or v Emergency Brake Cable Clamp Driver Side Only 1 Set the upper brace B into the driver and passenger side frame fig 4 If you have no fifth wheel hitch or a 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 LL with a flat washer Q through the slot in the side of the
15. eseeeeseneeeeeeeeeeeeeeeeneneeeeeeees 1 Standard metric and SAE sockets and wrenches 1 Hose cutter razor blade or sharp knife n c 1 Hoist of TOOK JACKS riisiin 1 Safety StANS rinite anaa aa ER Eira il Safety GlASSES sce cocitke Soca eden evescnvee eS antes iaaiiai daia 1 Air compressor or compressed air SOUICE eeeeeeeeeeeeee 1 Spray bottle with dish soap water solution 0006 1 LoadLifter 5000 Description cceeecseeeeeeeees Qty 3 8 Flat Washer ceceeeeeeeeee 25 1 2 13 Nyloc NUfoto inssin 2 3 4 Flat Washer ccccceeeeeeeeees 2 SPACO eari enane 2 SPACE is iaca eiiiai 2 TING SPACER iirrainn onsa 1 M10 1 5 Nyloc Nut sisisi isesi 1 90 Swivel Elbow Fitting 06 2 3 8 24 x 7 8 Hex Head Cap Screw 8 3 8 Lock WaSNE ecseeeeeseeeeeees 8 ZIP TIOS eaid Seasetesecedepevenicdesvetadecdatests 6 5 16 Lock WaSher sccencc 2 V le Caps 2 i iscieeseiacsedeestensestheeceseess 2 5 160 HeX NUtii2si siete ected seens isis ok 4 Rubber Washe esceeseeeeseeeees 2 Flat Washet cccccceeeeeeeeteeeeeeeees 2 Air Line Assembly ssassn 1 Heat Shield Kit sssini 1 1 2 13 x 2 0 Hex Head Cap Screw 2 service at 800 248 0892 for a replacement part sto Missing or damaged parts Call Air Lift customer MN 776 R LoadLifter 5000 Installing the LoadLifter 5000 System GETTING STARTED 1 Raise the
16. et Do this just enough for the carriage bolt to hold the assembly into position on the jounce bumper strike plate figs 1 amp 8b NOTE Driver sidesshowWn A Lower bracket Jounce bumper strike plate fig 8a located above axle Set the right passenger side assembly into position on the axle the same way the left side was positioned fig 1 Raise the axle or lower the frame down so that the round spacer X1 or X2 on the upper bracket inserts into the stock jounce bumper bracket hole on both sides Install the 3 8 Flat Washer U and a 3 8 16 Nyloc nut T on the 3 8 16 x 2 5 carriage bolt M that went through the existing jounce bumper hole and tighten securely on both sides fig 1 BE SURE NOT TO PINCH THE PREVIOUSLY MOVED WIRING OR LINES INSIDE THE LEFT FRAME RAIL 6 Install the emergency brake cable clamp I over the emergency brake cable and attach to the forward brace upper bracket bolt O fig 1 Cap with a 3 8 nyloc nut T Both sides Cap the remaining brace upper bracket carriage bolts O with a 3 8 flat washer U and 3 8 16 nyloc nut T and tighten all hardware securely With the spacers X1 or X2 on the upper brackets tight in the frame and the braces tight to the upper bracket tighten the or 34 hardware previously installed that hold the braces to the frame Tighten both sides securely If so equipped with the emissions line previous
17. ft 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 800 248 0892 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 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 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 definitions explain the use of these notations as they appear throughout this guide INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR D
18. ion costs prepaid to the dealer from which it was purchased or to Air Lift Company for verification Air Lift will repair or replace at its option defective products or components A minimum 10 00 shipping and handling charge will apply to all warranty claims Before returning any defective product you must call Air Lift at 800 248 0892 in the U S and Canada elsewhere 517 322 2144 for a Returned Materials Authorization RMA number Returns to Air Lift can be sent to Air Lift Company 2727 Snow Road Lansing MI 48917 Product failures resulting from abnormal use or misuse are excluded from this warranty The loss of use of the product loss of time inconvenience commercial loss or consequential damages is not covered The consumer is responsible for installation reinstallation labor charges of the product Air Lift Company reserves the right to change the design of any product without assuming any obligation to modify any product previously manufactured This warranty gives you specific legal rights and you may also have other rights that vary from state to state Some states do not allow limitations on how long an implied warranty lasts or allow the exclusion or limitation of incidental or consequential damages The above limitation or exclusion may not apply to you There are no warranties expressed or implied including any implied warranties of merchantability and fitness which extend beyond this warranty period There are
19. it on a dual rear wheel DRW vehicle use position 1 to insert the long 3 8 16 x 10 carriage bolt P through the top of the locating bracket and lower bracket fig 11 3 Attach the locating bracket H to the lower bracket with a 3 8 16 x 1 25 carriage bolt O 3 8 flat washer U and 3 8 16 nyloc nut T 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 stock 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 3 8 flat washers U previously installed on the locating brackets insert them into the spring clamp bar E on the opposite side of the leaf spring assembly fig 11 Cap with 3 8 flat washers U and 3 8 16 nyloc nuts T Leave loose at this time Position 1 Position 1 Position 2 Position 2 A Lower bracket H Locating bracket NOTE NOTE 10 LoadLifter 5000 6 Set the axle clamp bar D onto the long 3 8 16 x 10 carriage bolts Q fig 1 and cap with 3 8 flat washers U and 3 8 16 nyloc nuts T If you have a sway bar under the axle and the 3 8 16 x 10 long carriage bolt P 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 necessa
20. ll by hand tightening as much as possible and then use a wrench for an additional two turns MN 776 LoadLifter 5000 SLP If there is a problem with the inflation valve a Check the valve core by tightening it with a valve core tool b Check the air line by removing the air line from the barbed type fitting Cut the air line off a few inches in front of the fitting and use a pair of pliers or vice grips to pull twist the air line off of the fitting DO NOT CUT OFF THE AIR LINE COMPLETELY AS THIS WILL USUALLY NICK THE BARB AND RENDER THE FITTING USELESS If the preceding steps have not resolved the problem call Air Lift customer service at 800 248 0892 Before Operating MN 776 Technician s Signature Date INSTALLATION CHECKLIST To be completed by installer Q Clearance test Inflate the air springs to 60 PSI and ensure there is at least 1 2 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 QO 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 O Heat test Be sure there is sufficient clearance from any heat sources at least 6 for air springs and air lines If a heat shield was included in the kit
21. ly loosened from the frame insert the line holder post into the L bracket J attached to the back or front leg of the upper left brace B fig 9 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 Emissions line holder stock Option J L bracket J L bracket TM MN 776 LoadLifter 5000 NOTE MN 776 SP LOWER BRACKET ATTACHMENT ATTACHING THE LOWER BRACKET WILL DEPEND ON THE MODEL TRUCK YOU HAVE SEE FIGURES 10 AND 11 TO DETERMINE WHICH HOLES TO USE FOR INSERTING THE CARRIAGE BOLTS p NOTE Single rear wheel mounting location shown NOTE Use hole that is closest to the leaf spring On some models with sway bars under the axle it may be necessary to invert the long carriage bolt 1 Insert a 3 8 16 x 5 5 hex head bolt bolt K and 3 8 flat washer U into one of the two bottom holes of the locating bracket H fig 11 Use the hole that is closest to the leaf spring 2a lf 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 P through the top of the locating bracket and lower bracket fig 11 2b If you are installing this k
22. per Brace iccciecccceeccceeessetensscsteeses 2 V 18460 C 07997 Upper Bracket ecccscseseeseeeees 2 W 18556 D 01531 Axle Clamp Bat cecceeseeseeeteeeeees 2 x1 13964 E 10861 Spring Clamp Baf sisissssiiiisssirores 2 X2 13978 F 11951 Roll Plate si cin isien 4 Y 18443 G 58437 BellOWS cesceeeseeseeeeeeeeeseeeeeeenaeeeaes 2 Z 18495 H 10880 Four Hole Locating Bracket 4 AA 21837 l 10181 Emergency Brake Cable Clamp 1 BB 17203 J 10886 FIL Bracket co nn irea aaia 1 CC 18427 K 17110 3 8 16 x 5 5 Hex Head Cap Screw 4 DD 10466 L 17135 1 4 20 x 1 Hex Head Cap Screw 1 EE 18411 M 17141 3 8 16 x 2 5 Carriage Bolt 2 FF 21230 N 17271 1 2 13 x 3 Hex Head Cap Screw 2 GG 21233 O 17361 3 8 16 x 1 25 Carriage Bolt 8 HH 21234 P 17387 3 8 16 x 10 Carriage Bolt 4 Il 18501 Q 18207 1 2 Thick Flat Washer 6 JJ 20086 R 18419 Flat Washer 1200000 eee 2 KK 34924 S 18425 1 4 20 Nyloc Nut ceseececeeseeeeeees 1 LL 17208 T 18435 3 8 16 Nyloc Nut eeeeeeeeeeeeees 18 Notshown TOOLS LIST Description eee ee Qty 7 16 and 9 16 Open end or box wrenches 2 Crescent wrenchiis seiersen ante dane non iari 1 Ratchet with 3 8 9 16 amp 1 2 deep well sockets 1 5 16 drill bits very sharp DIR Orde ieres anani HACKSAW eso veclertecs Ho tse e ete are aes Heavy duty drill reos anessan ara aa 1 TOrQUG WICIICN ccecccneceecceeeseeee
23. ry 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 fig 12 Reattach the sway bar once this is done Grind slot larger Grind slot larger g Oe MN 776 LoadLifter 5000 fF INSTALLING THE AIR LINES 1 Choose a convenient location for mounting the inflation valves Popular locations for the inflation valve are a The wheel well flanges b The license plate recess in bumper c Under the gas cap access door d Through the license plate NOTE Whatever the chosen location make sure there is enough clearance around the inflation valves for an air chuck 2 Drill two 5 16 holes to install the inflation valves 3 Cut the air line assembly in two equal lengths oe Good Cut Poor Cut CAUTION WHEN CUTTING OR TRIMMING THE AIR LINE USE AHOSE 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 CAUSING IT TO LEAK AROUND THE O RING SEAL INSIDE THE ELBOW FITTING FIG 13 JJ Air line a Vehicle body or 7 bumper II 5 16 Flat washer FF Valve cap LL EPH HH Rubber washer fig 14 GG 5 16 Hex nut 4 Place a 5 16 nut and star washer on the air valve Leave enough of the inflation valve in front of the nut to extend through the hole
24. shield to the exhaust pipe using the clamps Bend the heat shield for maximum clearance to the air spring fig 16 Some vehicles have large resonators in this area it will be necessary to double up on the clamps to fit these models fig 17 Ya Dead air space Exhaust resonator Double up supplied hose Bend tabs clamps provided fig 16 fig 17 CHECKING FOR LEAKS 1 Inflate the air spring to 30 PSI 2 Spray all connections and the inflation valves with a solution of 1 5 liquid dish soap and 4 5 water Spot leaks easily by looking for bubbles in the soapy water 3 After the test deflate the springs to the minimum pressure required to restore the system to normal ride height Do not deflate to lower than 5 PSI 4 Check the air pressure again after 24 hours A 2 4 PSI 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 fitting a Check the air line connection by deflating the spring and removing the line by pulling the collar against the fitting and pulling firmly on the air line Trim 1 off the end of the air line Be sure the cut is clean and square see fig 13 Reinsert the air line into the push to connect fitting b Check the threaded connection by tightening the swivel fitting another turn If it still leaks deflate the air spring remove the fitting and re coat the threads with thread sealant Reinsta
25. t 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 13 LF LoadLifter 5000 Product Use Maintenance and Servicing Minimum Pressure Maximum Air Pressure 5 PSI 100 PSI FAILURE TO MAINTAIN CORRECT MINIMUM PRESSURE OR PRESSURE PROPORTIONAL TO LOAD BOTTOMING OUT OVER EXTENSION OR RUBBING AGAINST ANOTHER COMPONENT WILL VOID THE WARRANTY MAINTENANCE GUIDELINES NOTE 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 inflate 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 inflation valve core before deflating and removing the air spring CAUTION 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
26. 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 14 MN 776 LoadLifter 5000 fF 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 If the preceding steps do not solve the problem it is possibly caused by a failed air spring either a factory defect or an operating problem Please call Air Lift at 800 248 0892 for assistance 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 times 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
27. 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 If itis ever suspected that the air bags have bottomed out increase the pressure fig 21 Adjust the pressure up and down to find the best ride If the vehicle rocks and rolls adjust the air pressure to reduce movement oN ODO 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 22 As much as a 50 PSI difference is not uncommon Bottoming out fig 21 Unlevel Level fig 22 Warranty and Returns Policy 16 Air Lift Company warrants its products for the time periods listed below to the original retail purchaser against manufacturing defects when used on catalog listed applications on cars vans light trucks and motorhomes under normal operating conditions for as long as Air Lift manufactures the product The warranty does not apply to products that have been improperly applied improperly installed used in racing or off road applications used for commercial purposes or which have not been maintained in accordance with installation instructions furnished with all products The consumer will be responsible for removing labor charges the defective product from the vehicle and returning it transportat
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