installation guide
Contents
1. 1 Drill 5 16 Drill Bil as ee 1 D 07994 Upper Brace left 1 Torque WCNC u 1 E 07995 Upper Bracket left 1 Hose Cutter Razor Blade or Sharp Knife 1 F 01531 Clamp Bar 2 Hoist or Floor Jack 1 G 10861 Spring Clamp Bar 2 Safety Ee GC 2 H 13966 AC ON A 2 Safety Glasses cccccccccococcncccncnnncnnoconononnnnnnnnnnononos 1 11967 Roll PANS See 4 Air Compressor or Compressed Air Source 1 J 58496 DBellows 2 Spray Bottle with Dish Soap Water Solution 1 K 10880 Four Hole Locating Bracket 4 L 10886 L Bracket AA 1 M 17135 1 4 20 X 1 Hex Cap crew 1 N 17271 1 2 13 X 3 Hex Cap Screw 2 O 17412 1 2 13 X 1 25 Hex Cap Screw 1 P 17161 1 2 13 X 1 5 Hex Cap Screw 1 Q 18419 Flat Washer A2 KEREN 2 R 18207 1 2 Thick Flat Waeber 2 S 18422 3 8 16 Serrated Flange Lock Nut 2 T 18425 1 4 20 Nyloc Nut 22222222222222220000020 1 U 18435 3 8 16 Nyloc NUl 5 044 500 4040240 20 V 18444 3 8 Flat Washer oooooccccccccccccccnnnccnnono 32 W 18485 1 2 Flat Washer ae 3 X 18501 M8 Flat Washber een 2 Y 21837 90 Swivel Air Fitting 2 Z 17203 3 8 24 X 7 8 Hex Cap Screw 8 AA 18556 3 4 Flat Washer oooooococccccccccccccccancnonos 1 BB 17177 8mm 1 25 X 25mm Hex Cap Screw 1 CC 17184 3 82. anaana eee eens 17 Product Use Maintenance and Servicing 18 Minimum Recommended Pressure and Maximum Pressure 18 Maintenance Guidelines 18 Troubleshooting Guide 18 Frequently Asked Questions ein wl 32 Se NEEN AE seen boot derer ade 19 Tuning the Air Pressure 0 0 cc eee eens 19 Guidelines for Adding Ar 20 Choosing the Right On Board Air Compressor System 21 Warranty and Returns Policy sasananananannnnn 22 Replacement Information eee eee 23 Contact Information nun nn nn eee nn nn nn 23 KS LoadLifter 5000 Ultimate Introduction WARNING NOTE 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 and 1 ton pickups and SUVs with leaf springs and provide up to 5 000 Ibs of load leveling support with air adjustability from 5 100 PSI The kits are also used in moto
3. 24 x 7 8 hex head cap screws 2 Tighten both mounting screws securely NOTE The fitting on top of the bellows points inward refer to figs 11 and 12 Left Driver Side Mounting holes Right Passenger Side Mounting holes 5 Insert two 3 8 16 x 1 25 carriage bolts DD up through the bottom of the driver side E and passenger side C upper bracket fig 10 through the two square holes that are on the corresponding side Also insert one 3 8 16 x 2 0 carriage bolt GG 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 fig 10 and attach to the bellows with two 3 8 flat washers V lock washers Il and 3 8 24 x 7 8 hex head cap screws Z Tighten both mounting screws securely fig 11 7 Repeat the above process with the passenger side assembly fig 12 10 MN 824 LoadLifter 5000 Ultimate R 8 Set the spacer H over both long carriage bolts figs 11 and 12 NOTE The hole in the flat spacer H is offset Install the spacer so that the wide portion faces the outside of the vehicle figs 11 and 12 DD Driver Side Passenger Side H wide portion of spacer points outboard jig 11 Left Driver Side Right Passenger Side ATTACHING THE ASSEMBLIES TO
4. 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 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 18 MN 824 LoadLifter 5000 Ultimate LF lf 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 Is it necessary to keep air in the air springs at all times and how much pressure will they need For LoadLifter 5000 Ultimate the recommended minimum air pressure is 5 PSI but it can safely be run at zero air pressure Is it necessary to add a compressor system to the air springs No Air pressure can be adjus
5. 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 fig 13a 13b Make sure the long carriage bolt on the bottom bracket goes in between the hard brake line and the axle this should be on the back side of the axle Raise the axle just enough to insert the long carriage bolt that is installed in the upper bracket through the existing jounce bumper hole in the bottom of the frame Atthe same time line up the upper brace previously installed onto the remaining two carriage bolts in the upper bracket Do this just enough for the carriage bolt to hold the assembly into position on the jounce bumper strike plate figs 1a and 5 MN 824 11 LoadLifter 5000 Ultimate R Jounce bumper strike plate located above axle fig 13a 3 Set the right passenger side assembly into position on the jounce bumper strike plate the same way the left side was positioned fig 1b and 7 4 Raise the axle or lower the frame down so that the thick spacer H on the upper bracket is parallel to and contacts the frame on both sides 5 Install the 3 8 16 serrated flange nut S on the carriage bolt that went through the existing jounce bumper hole and tighten securely on both sides fig 1a and 1b CAUTION BE SURE NOT TO PINCH THE PREVIOUSLY MOVED WIRING OR LINES INSIDE THE LEFT
6. than 5 PSI then there is a leak that must be fixed Either fix the leak yourself or return to the installer for service Q Air pressure requirements Regardless of load the air pressure should always be adjusted to maintain ride height at all times A 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 17 SF LoadLifter 5000 Ultimate Product Use Maintenance and Servicing Minimum Recommended Pressure Maximum Air Pressure 5 PSI 100 PSI 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 MANUFACTUR
7. 16 X 5 Hex Tap Bolt 4 DD 17361 3 8 16 X 1 25 Carriage Bolt 12 EE 17887 3 8 16 X 10 Carriage Bolt 4 FF 18505 1 2 13 Serrated Flange Lock Nut 2 GG 17140 3 8 16 X 2 Carriage Bolt 2 HH 18522 M8 X 1 25 Nyloc Nut 1 Il 18427 3 8 Lock Waeher 8 JJ 20086 Air Line Assembly oooococccccccccccccccncnnnos 1 KK 10466 ZID WE 6 LL 18411 5 16 Lock Waeher 2 MM 21230 Valve ee EN 2 NN 21233 5 16 Hex Nike 2 OO 21234 Rubber Wacher 2 PP 34924 Heat Shield Kit 1 Missing or damaged parts Call Air Lift customer service at 800 248 0892 for a replacement part MN 824 5 SF LoadLifter 5000 Ultimate Installing the LoadLifter 5000 Ultimate System GETTING STARTED 1 Raise the vehicle and support the axle with jack stands setting the jack stands as wide as possible on the axle And or support the vehicle in a way safely that will allow the axle to be dropped if using a hoist of some kind fig 2 J ack Stands ioe 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 brace Also push the harness connector out that holds the electrical lines going to the gas urea tank in or out of the tank bracket This will improve the socket bolt access that will be required for
8. 4 LoadLifter 5000 Ultimate SF NOTE NOTE ATTACHING THE LOWER BRACKET TO THE AXLE 1 Insert a long 3 8 bolt CC and flat washer V through the top round hole of the four hole locating bracket K fig 15 Use the hole that is closest to the leaf spring ee ing T Tecn Fe E E 0 Sy _ TE D Si CH a LI H L HD AN yA A Y I EI NA 7 GR Cu NOTE Lower Bracket sits on A Oo ia jounce bumper strike plate Attach the four hole locating bracket K on the top of the lower bracket and through the slots with two 3 8 16 x 1 25 carriage bolts DD flat washers V and nyloc nuts U One goes forward and one goes behind the axle on the leaf spring side Leave loose at this time See fig 13a amp 13b on page 12 Push the front and back four hole locating bracket against the stock u bolts and tighten the short carriage bolts at this time Using the long 3 8 bolt CC and flat washer V previously installed on the four hole locating bracket insert them into the spring clamp bar G on the opposite side of the leaf spring assembly fig 15 Cap with 3 8 flat washer V and nyloc nut U Leave loose at this time Insert a long carriage bolt EE through the remaining square hole in the lower bracket forward of the axle opposite of the one previously installed in the bellows as
9. E NOTE 1 Set the right upper brace B into the passenger side frame rail fig 7 SEO SSS Ee AoT K MAREA 050 SCHE 3 eu We See footnote in fig 1b See footnote in fig 1b If you have no fifth wheel hitch or if you have the standard equipment Reese fifth wheel hitch that was purchased on the truck from Ford insert the Y2 13 x 1 50 hex cap screw P and large flat washer R through the brace between the brace and the frame add the large flat washer R then through the frame from the inside out Cap with a flat washer W and a 12 serrated flanged lock nut FF figs 6 and 7 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 used this slot to secure the bracket to the frame with existing hardware install the existing hardware previously removed in the Getting Started section However add the thick washer R or AA depending on whether the exiting hardware is Y2 or 34 in between the brace and the frame fig 7 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 12 hole through the plate using the slot in the frame as a template It may be necessary to mark and remove
10. ER 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 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
11. FRAME RAIL 6 Cap the brace upper bracket carriage bolts with a 3 8 flat washer V and 3 8 nyloc nut U and tighten both securely on both sides 7 With the spacers H on the upper brackets tight to the bottom of the frame and the braces tight to the upper bracket tighten the 8mm driver side only and Y or 9 hardware previously installed that hold the braces to the frame Tighten both sides securely NOTE If possible use a thin 34 socket and it helps to pull back the driver side 72 mounting hardware O or N as far back in the slot as you can while tightening 8 Once the left driver side 1 2 or 9 hardware has been tightened push the wiring harness connector which was removed in the getting started section back into the gas urea tank mounting hole If this broke during disassembly wire tie it to the bracket fig 3 9 If so equipped with the emissions line previously loosened from the frame insert the line holder post into the L bracket L attached to the back leg of the upper left brace D fig 14 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 a AA re Y O we Emissions line holder stock u ee N SSE fig 14 ug To L bracket 12 MN 82
12. IDE BRACE INSTALLATION le Set the left upper brace D into the driver side frame rail The brace has a small hole that will line up with an existing hole in the frame insert the 8mm hex cap screw BB with a flat washer X through the brace and frame fig 5 and cap with flat washer X and M8 Nyloc nut HH Leave loose at this time If there is a fifth wheel plate on the outside of the frame it may be necessary to drill the side plate using the existing hole in the frame as a template It may also be necessary to use a longer M8 bolt not supplied BE SURE NOT TO PINCH THE PREVIOUSLY MOVED WIRING OR LINES INSIDE THE LEFT FRAME RAIL fig gt See footnote in fig 1a MN 824 KS LoadLifter 5000 Ultimate NOTE 2 If you have no fifth wheel hitch or if you have the standard equipment Reese fifth wheel hitch that was purchased on the truck from Ford in the frame there is a slot that is forward of the M8 bolt just installed insert the 12 13 x 1 25 hex cap screw O and flat washer W through the brace and frame from the inside out Cap with a flat washer W and a serrated flanged lock nut FF fig 5 and 6 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 used this slot to secure the bracket to the frame with existing hardware install the existing hardware prev
13. Load 5000 ADJUSTABLE AIR HELPER SPRINGS Kit Number 38396 Internal INSTALLATION GUIDE pe jounce bumper 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 824 e 031309 e ECR 7786 TABLE OF CONTENTS Introduction Lo 2 Important Safety Notice 2 N tation eidel NEEN 2 Installation Diagram Driver Side 3 Installation Diagram Passenger Side 4 Hardware and Tools Liste 0c eee eee 5 Installing the LoadLifter 5000 Ultimate System 6 Elie kel e sc ae sn GSE bodies od eeu one ee FSG Ebates oe eee gees beeen ee eee 6 Installing the Braces a m coe baw ae ot Ob he ad rn Shoe a A eda a ewe Oe hs ade 7 Driver Side Brace Installation T Passenger Side Brace Installation n n annann 0c cc ee ees 8 Bellows and Bracket Assembly 0 0 00 ccc eee eee ee nenn 9 Attaching the Assemblies to the Frame 0 0 0 0c ees 11 Attaching the Lower Bracket to the Axle 13 Installing the Air mes 14 Installing the Feeler 60 ge iaa He nes weiner ede denen nina 15 Checking For Leaks 04 u 0 04 0 0 55008608 oo en nase eher 16 Fixing Leaks nn a God ee nr a aa ee 16 Before Operating 00 cece ee eee eee 17 Installalon CMCCKISE ee anes en Goa e eed oad a Goce os ae hee ee eee 17 Post Installation Checklist
14. ally requires an increase in pressure Bad headlight aim fig 2 1 Rough ride fg 2 2 Sway and Ag 2 3 body roll MN 824 19 R LoadLifter 5000 Ultimate 20 GUIDELINES FOR ADDING AIR 1 Start with the vehicle level or slightly above N When in doubt always add air 3 Ifthe front of the vehicle dives while braking increase the pressure in the front air bags if equipped If it is ever suspected that the air bags have bottomed out increase the pressure fig 2 4 Adjust the pressure up and down to find the best ride If the vehicle rocks and rolls adjust the air pressure to reduce movement e K A lt 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 2 5 AS much as a 50 PSI difference is not uncommon es ap Y Caa SY Bottoming out Jig 2 4 Unlevel Level WED MN 824 LoadLifter 5000 Ultimate LF Choosing the Right On Board Air Compressor System Add an on board air compressor sytem to inflate and deflate your air springs with the touch of a button from inside or outside of the vehicle D NO QUESTIONS ASKED MONEY DAY Hey Ni COMPRESSOR SYSTEM WARRANTY For conv
15. 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 Q 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 Q 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 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 LJ 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 Technician s Signature Date POST INSTALLATION CHECKLIST LI Overnight leak down test Recheck air pressure after the vehicle has been used for 24 hours If the pressure has dropped more
16. dLifter 5000 Ultimate 000000 EEES KEE EE DDD eee e m 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 12 dead air space between exhaust pipe and heat shield fig 19a 2 Attach the heat shield to the exhaust pipe using the clamps Bend the heat shield for maximum clearance to the air spring fig 19a NOTE Some vehicles have large resonators in this area it will be necessary to double up on the clamps to fit these models fig 19b L Dead alr space Bend tabs fig 19a Exhaust resonator Double up supplied hose clamps provided MN 824 15 R LoadLifter 5000 Ultimate 16 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
17. enient on the go control of your air springs add an Air Lift on board air compressor system Air Lift on board air compressor systems eliminate the search for gas stations that have a working compressor saving you time energy and money All systems include a compressor controller and all parts needed for easy installation al 1 Choose single or dual path inflation see E illustrations at right 2 Choose wireless or analog control Fe A BETT l l 15 PSI SPRING INFLATION e Wireless Control your air springs from inside or outside the vehicle Easiest installation no wires to the cab SHEL Ello Olas SR ei l controlled separately to allow for different e Analog In cab control of your air springs air pressure from side to side Perfect for Economically priced uneven or top heavy loads 3 Choose heavy or standard duty compressor e Standard duty A standard duty compressor will work well for most customers who use their system on an intermittent basis Bif y pa H i TAIR LIFT IR AIR LIFT e Heavy duty For daily use consider an IK the heavy duty compressor it inflates i han th ndar faster and more quietly than the standard E E EE compressor inflate at the same time Good for loads Visit www airliftcompany com for more detailed that are evenly distributed from left to info on compressor systems WirelessAIR right or front to back LoadCONTROLLER Dual Compact economically pr
18. ge 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 no warranties that extend beyond the description on the face hereof Seller disclaims the implied warranty of merchantability Dated proof of purchase required Air Lift 1000 00 Lifetime Limited LoadContr
19. iced control Easy installation Includes heavy duty compressor DEFLATE INFLATE DEFLATE P N Standard Duty Compressor I BOIH RIGHT P N 72000 25850 P N Heavy Duty mpressor 25854 WirelessONE Single e Easy installation Compact e Includes standard economically priced duty compressor control P N 25870 Load CONTROLLER DEFLATE INFLATE P N Standard Duty Compressor BOH BOTH 25852 P N Heavy Duty Compressor 25856 MN 824 21 SF LoadLifter 5000 Ultimate Warranty and Returns Policy 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 transportation 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 char
20. if the loss is more than 5 Ibs 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 16 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 Reinstall by hand tightening as much as possible and then use a wrench for an additional two turns 2 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 3 If the preceding steps have not resolved the problem call Air Lift customer service at 800 248 0892 MN 824 LoadLifter 5000 Ultimate R Before Operating MN 824 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
21. installing and tightening the frame brace fig 3 4 If you have a fifth wheel hitch already installed other than the standard factory Reese hitch purchased with the truck it will be necessary to remove the 2 or 9 hardware that bolts the side bracket plates to the outside of the frame above the axle Push this electrical harness connector out of the gas urea tank bracket for better access to mounting hole slot in frame O Set left side brace inside the frame D fig 3 MN 824 LoadLifter 5000 Ultimate LF NOTE INSTALLING THE BRACES Gas engine models have emission lines on the inside of the frame If your model truck has emission lines running along the inside of the frame rail fig 4 it will be necessary to relocate those lines as follows 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 brace has been installed fig 4 The same holds true with the electrical wire loom holders Emissions lines jig 4 Electrical wiring loom e Attach the L bracket L to the back frame brace using the 1 4 bolt M flat washers Q and nyloc nut T supplied fig 5 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 DRIVER S
22. iously removed in the getting started section from the fifth wheel installation for securing the brace fig 5 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 12 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 CLEAR ANY ELECTRICAL OR HARD LINES FROM THE AREA SO AS NOT TO DAMAGE THEM IN ANY WAY WHEN DRILLING THE HOLE 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 00 hex cap screw N with a flat washer W through the brace frame and fifth wheel plate previously drilled Cap with a flat washer W and a 13 serrated flange lock nut FF fig 5 Leave loose at this time PASSENGER SIDE BRACE INSTALLATION Ford standard Reese equipped fifth wheel hitch bracket along the outside of the frame NOTE Also use if there is NO fifth wheel hitch on the vehicle Driver side shown K E ER 1 2 flat washer W EN 1 2 13 serrated flange locknut FF A y SE Ss A Existing jounce gt y bumper hole e fig 6 8 MN 824 LoadLifter 5000 Ultimate R NOT
23. l MN 824 3 SF LoadLifter 5000 Ultimate Installation Diagram Passenger Side NOTE Use 3 4 flat washer AA if using 3 4 fifth wheel hitch hardware removed D or AA O lt ae a LF ee P or N Ze Cl ele LA 3 un a E NONE O ER ES Te A ST a DA NOTE If you have a fifth wheel hitch installed that has E side plates along the frame WA o i O use the existing hardware A removed If not use the gt TE 1 2 hardware supplied and recommended in this kit and in the directions in this manual DD EA AS WN A WE OA W D a GE Ga Bien i lt a SN A S Alf zz i ES EA e SE N gt ESS PR A h A m fi A Di VA gt gt WN Y Sg nE E N A y J NOTE Lower Bracket sits on jounce bumper strike plate See fig 13a amp 13b on page 12 4 MN 824 LoadLifter 5000 Ultimate R Hardware and Tools Lists HARDWARE LIST TOOLS LIST Item Part Description ccceeseeeseeees Qty Description nn ee Qty A 03990 Lower Bracket 2 Metric amp STD Open Box End Wrenches set B 07996 Upper Brace right 1 Ratchet with Metric and STD Sockets set C 07997 Upper Bracket right
24. 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 NO MN 824 R LoadLifter 5000 Ultimate Installation Diagram Driver Side VW Sy 7 tT IF XI Soe f y A el 8 i se SCH S Zeil E f 1 SENA AAA A E N ES EA SAS u h die Hei D NW Y IN IS 3 I Mi NOTE Lower Bracket sits on a a ed jounce bumper strike plate CU See fig 13a amp 13b on page 12 v y lt q EE lt E NOTE If you have a fifth wheel hitch installed that has side plates along the frame use the existing hardware removed If not use the 1 2 hardware supplied and recommended in this kit and in the directions in this manua
25. oller Dual 2 Year Limited RideControl 222200 Lifetime Limited Load Controller I 2 Year Limited LoadLifter 5000 Lifetime Limited Load Controller Il 2 Year Limited LoadLifter 5000 Ultimate Lifetime Limited SmartAir cccceccseeee 2 Year Limited SlamAir 0ecceeceeceeceeeeeeeees Lifetime Limited Wireless AIR om mooom 2 Year Limited AirCel ansann Lifetime Limited WirelesSONE ccse 2 Year Limited Air Lift Performance 1 Year Limited Other AccessSories 2 Year Limited LoadController Single 2 Year Limited formerly SuperDuty formerly LifeSTYLE amp Performance EasyStreet 29 MN 824 LoadLifter 5000 Ultimate LF 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 Parts are missing from the kit e Need technical assistance on installation or operation e Broken or defective parts in the kit e Wrong parts in the kit e Have a warranty claim or question Contact the retailer where the kit was purchased e If it is necessary to return or exchange the kit for any reason e If there is a problem with shipping if shipped from the retailer e If there i
26. oor Cut CAUTION 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 CAUSING IT TO LEAK AROUND THE O RING SEAL INSIDE THE ELBOW FITTING FIG 16 Air line 5 16 Flat washer Valve cap 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 and have room for the rubber washer flat washer and 5 16 nut and cap There should be enough valve exposed after installation approximately 12 to easily apply a pressure gauge or an air chuck fig 17 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 18 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 14 MN 824 R Loa
27. rhome 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 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 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 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
28. s a problem with the price Contact Information MN 824 If you have any questions comments or need technical assistance contact our customer service department by calling 800 248 0892 Monday through Friday For calls from outside the USA or Canada our 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 airlifttcompany com 23 KS Notes 24 LoadLifter 5000 Ultimate MN 824 LoadLifter 5000 Ultimate Notes MN 824 R 25 Contact our customer service department by calling 800 248 0892 Monday through Friday For calls from outside the USA or Canada our local number is 517 322 2144 Register your warranty online at www airlificompany com warranty Since 77 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
29. sembly Set the clamp bar F over the two carriage bolts and cap with two 3 8 flat washers V and two nyloc nuts U Carefully draw the side hardware and axle hardware evenly Torque the spring clamp bar bolts to 10fl lbs and the axle clamp bar bolts to 16ft lbs Repeat for the opposite side Trim the long carriage bolts below the nyloc nuts if necessary DO NOT PINCH THE HARD BRAKE LINE ON THE PASSENGER SIDE WHILE TIGHTENING It may be necessary on some models to not tighten the axle clamp bar evenly on the right side passenger side so that the clamp bar will clear the hard brake line Once tight the upper and lower bracket will not be parallel and may look like they are out of alignment This condition will be OK because of the way the lower bracket and upper bracket mounts also there may be some variance in models and this is considered a normal condition MN 824 13 LoadLifter 5000 Ultimate R 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 fig 16 Good Cut P
30. ted 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 How long should air springs last If the air springs are properly installed and maintained they can last indefinitely 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 2 1 Raise the air pressure to correct either of these problems and level the vehicle Ride comfort If the vehicle has a rough or harsh ride it may be due to either too much pressure or not enough fig 2 2 Try different pressures to determine the best ride comfort 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 3 Tuning out these problems usu
31. 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 13 x 3 00 hex cap screw N with a large flat washer R through the brace between the brace and the frame add the large flat washer R then through the frame and fifth wheel plate previously drilled Cap with a flat washer W and a 13 serrated flange lock nut FF fig 7 Leave loose at this time BELLOWS AND BRACKET ASSEMBLY 1 Seta roll plate 1 over the top and bottom of the bellows J fig 1a and 1b The radiused rounded edge of the roll plate 1 will be towards the bellows so that the bellows is seated inside both roll plates Install the swivel elbow fitting Y into the top of the bellows finger tight Tighten the swivel fitting one and a half turns MN 824 R LoadLifter 5000 Ultimate 3 Insert one long carriage bolt EE into the lower bracket A fig 8 NOTE The long carriage bolt will be behind the axle once the assembly is installed on the axle Insert long carriage bolt EE in these square holes in the lower bracket before assembling to bellows as noted Passenger Side Use this hole Driver Side Use this hole 4 The lower bracket A has two sets of bellows mounting holes Using the corresponding holes in the lower bracket designated fig 9 attach the bellows to the brackets using the 3 8 flat washers V lock washers Il and 3 8
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