No. 57215 & 57207
Contents
1. vr 1 Level fig 26 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 Need technical assistance on installation or operation Broken or defective parts in the kit Wrong parts in the kit Have a warranty claim or question Contact the retailer where the kit was purchased If it is 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 14 If you have any questions comments or need technical assistance contact our customer service department by calling 800 248 0892 Monday through Friday 8 a m to 5 p m Eastern Time 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 airliftcompany com MN 387 Need Help Contact our customer service department by calling 800 248 0892 Monday through Friday 8 a m to 5 p m East2. 2 18444 3 8 Flat 16 18405 5 16 Flat 2 J 18427 3 8 Lock 8 X 21234 Rubber 2 13377 Upper bracket spacer 8 Y 18411 Small star 2 L 18447 3 8 Large flat washer 8 X 21233 5 16 4 M 17159 3 8 x 1 5 Washer head frame bolt 8 N 17203 3 8 x 7 8 Hex head cap screw 8 Notshownin fig 1 01525 Spacer bar ica nee 4 Missing or damaged parts Call Air Lift customer service at 800 248 0892 for a replacement part Installing the LoadLifter 5000 System 5TH WHEEL HITCH NOTE FOR FORD TRUCKS ONLY If you have a Reese style 5th wheel hitch kit installed and you have purchased kit 57215 you need to order kit 57342 or contact Air Lift customer service for the correct brackets at 800 248 0892 Ask for bracket kit 426275 DANGER COMPRESSED AIR CAN CAUSE INJURY AND DAMAGE TO THE VEHICLE AND PARTS IF IT IS NOT HANDLED PROPERLY FOR YOUR SAFETY DO NOT TRY TO INFLATE THE AIR SPRINGS UNTIL THEY HAVE BEEN PROPERLY SECURED TO THE VEHICLE GETTING STARTED 1 Support the axle with jack stands remove the wheels and raise or lower to obtain normal ride height figs 2 and
3. 7433 MN 387 31210 amp 57207 Load iF uay No 57215 by AIR LIFT 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 Introduccion chc aae a 2 Important Safety Notice 0 ccc heh 2 Notation III 2 Installation Diagram 3 Hardware List ee eee ee 4 TOOS aes A Seman Re Sea ames 4 Installing the LoadLifter 5000 System 4 5th Wheel p a eee ee 4 Getting Started 225 secures I am bE RAG ORE De eae ane Bee RACE eRe 4 Special Application 1 5 5 5 Assembling the Air Spring 6 Positioning the Brackets 7 Attaching the Lower 7 Attaching the Upper 0 0 8 Securing the Air Spring to the 9 Installing the Air 9 Reinstalling the Fenderwell Liner Late Model 4WD Dodge Only 10 Checking For
4. 1 and 9 NOTE Use shorter U Bolts when attaching to frame contact overload springs 2 Ifthe spacer is used place the spacers legs down on the leaf spring and attach the lower bracket securely using the provided U bolts flat washers and lock nuts Torque nuts to 16 ft lbs fig 9 stock u bolts if necessary Shorter U bolt fig 9 MN 387 7 LF LoadLifter 5000 ATTACHING THE UPPER BRACKET CAUTION BEFORE DRILLING CHECK THE BACK SIDE OF THE FRAME FOR CLEARANCE ISSUES WITH THE BRAKE LINES GAS LINES AND ELECTRICAL LINES ANY OBSTACLES WILL NEED TO BE TEMPORARILY RELOCATED TO CLEAR THE AREA 1 Position the upper bracket so that it is parallel with the lower bracket and align the assembly vertically and horizontally 2 Using the upper bracket as a template center punch and drill one 3 locator hole through the frame at one of the top bolt holes fig 10 NOTE After achieving the proper alignment repeat for the opposite side of the bracket 3 Except for Dodge vehicles loosely install a washer head frame bolt oversized flat washer and lock nut fig 11 For Dodge trucks only The top two or the bottom two holes depending on the model of the truck will fall into a horizontal indentation Spacers are provided to compensate for the indentation Loosely install a washer head frame bolt two upper bracket spacers an oversized flat washe
5. 3 L No Load in Truck Remove wheels 5 E mL b e 2 fig 3 fe 2 4 MN 387 LoadLifter 5000 LF SPECIAL APPLICATION INSTRUCTIONS 1 1994 model and newer Dodge 4WD pickups only It will be necessary to remove the inner fenderwell liner on late model 4WD Dodge trucks This is done by carefully driving the pin through the fasteners with a center punch fig 4 These fasteners will be reused along with a special spacer to reattach the line and provide clearance for the air spring See page 10 for reinstallation instructions fig 4 2 Ford trucks only When installing the upper bracket on an F 250 or F 350 the mounting bolt holes can line up directly over the indent in the frame This is an acceptable situation and is an approved method of installation for the product fig 5 Torque the mounting hardware to specifications as noted Do not over torque 3 For 1999 and later SuperDuty F 250 and F 350 trucks Remove the bolt which holds the emergency brake cable to the outside of the frame rail Reinstall the bolt in the reverse order with the nut on the inside of the frame rail to prevent rubbing against the air spring fig 6 TCH THIS BOLT WILL CAUSE AIR SPRING TO RUPTURE AX CAUTION FAILURE TO SWITC S BO CAUS S G TO RUPTU Im Inboard H Emergency Brake Fine Clip fig 6 Before
6. Nut 1 2 Small Star Washer Valve Cap 5 16 Hex Bolt Rubber Washer 6 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 Leave at least 2 of slack when securing the air lines to allow for any movement that might pull on the air line fig 18 7 Cut off air line leaving approximately 12 of extra air line Insert the air line into the air fitting Simply push the air line into the 90 swivel fitting until it bottoms out 16 of air line should be in the fitting REINSTALLING THE FENDERWELL LINER LATE MODEL 4WD DODGE ONLY 1 If this installation was on a late model 4WD Dodge truck it is now necessary to reinstall the inner fenderwell liner using the original fasteners and provided spacers to allow for air spring clearance fig 18 M 18 Before After 10 MN 387 LoadLifter 5000 LF 2 Place the spacer between the fenderwell liner and the fenderwell at the center hole in the fenderwell liner the hole nearest the air spring Attach using the 1 4 Hex Head Cap Screw HHCS the 9 32 flat washers 1 4 nyloc nut provided fig 19 NOTE Fasten the HHCS with the washer and nut behind the fenderwell fig 19 Tighten securely Fenderwell Liner 1 4 HHCS Fenderwell 10 32 Flat Washer fig 19 Fenderwell Liner Space
7. bottoming out The top rear mounting hole may be above the frame rail If this condition exists use the two lower mounting holes to mount the bracket fig 8 2 Set the air spring assembly on the leaf spring over the axle fig 8 3 Position the upper bracket so that at least four bolt holes two on each side will be on the flat section of the frame rail Keep the edge of drilled holes no closer than 9 7 from the top or bottom radius of the frame rail 4 n some cases it may be necessary to use the optional spacers to achieve the 5 8 space fig 8 For example if only the top two holes contact above the lower radius edge of the frame rail it may be necessary to move up the spacers under the lower bracket to achieve mounting height NOTE If you find that the lower bracket needs to set flat onto the leaf spring in order to achieve the correct height and the stock u bolts are too high to allow this it will be necessary to trim the stock u bolts Lower Mounting Holes Distance must be 5 8 and equal on both sides Upper and lower bracket must be parallel Lock Nut Flat Washer O Trim stock u bolts if necessary Spacer optional to achieve proper Ed mounting height ATTACHING THE LOWER BRACKET 1 If the spacer is not used attach the lower bracket securely using the provided U bolts flat washers and lock nuts Torque nuts to 16 ft lbs See figures
8. 10 32 Flat Washer e 4 Nyloc Nut 3 Replace the remaining fenderwell liner rivets carefully Push the rivets through the fenderwell liner by hand They should push through completely fig 20 4 From the opposite side use a rubber mallet and carefully tap the rivet posts back into the rivets in order to secure them properly fig 21 Repeatthis process for all remaining rivets Rivet Locations e TON fig 21 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 s water to check for leaks You should be able to spot leaks easily by looking for bubbles in the soapy water 3 Afterthe test deflate the springs to the minimum pressure required to restore the normal ride height but not less than 10 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 Ibs Maintenance and Servicing Minimum Pressure Maximum 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 MN 387 11 R NOTE LoadLifter 5000 MAINTENANCE GUIDELINES By following the steps below vehicle owners will obtain the longest life and best results from their air springs 1
9. After MN 387 5 R NOTE LoadLifter 5000 ASSEMBLING THE AIR SPRING UNIT See fig 7 below for assembly 1 Set a roll plate on both ends of the air spring The radiused rounded edge of the roll plate will be towards the air spring so that the air spring is seated in both roll plates Install 90 swivel air fitting It should only be finger tight plus 11 2 turns Do not overtighten Place the upper bracket onto the top of the air spring and roll plate with the legs facing down Set the air spring on the lower bracket aligning the two holes in the base of the air spring with the two outer slots in the top of the lower bracket Loosely attach the upper bracket to the assembly using flat washers lock washers and hex head bolts Remember that the bracket legs face down Loosely attach the lower bracket to the assembly using flat washers lock washers and hex head bolts The flange on the bracket must face the outside tire side of the vehicle Hex Head Bolt C Flat Washer Upper Bracket T T Lock Washer 90 Swivel Air Fitting Roll Plates Air Spring p Lower Bracket MN 387 LoadLifter 5000 LF POSITIONING THE BRACKETS 1 The air spring must be installed between 5 and 8 from both the upper bracket to the lower bracket fig 8 It is best to position the upper bracket as high as possible NOTE Failure to mount the air spring at the recommended height can result in the air spring
10. BRACKET FIG 14 2 Check bolts and connectors to ensure that all hardware is secure and repeat the process for the other side of the vehicle U Bolts fig 14 INSTALLING THE AIR LINES WHEN INSTALLING THE AIR LINES THERE MUST BE AT LEAST SIX INCHES OF CLEARANCE BETWEEN THE AIR LINES AND ANY HEAT SOURCES 1 Choose a convenient location for mounting the inflation valves Popular locations for the inflation valves are The wheel well flanges The license plate recess in bumper Under the gas cap access door or through the license plate fig 15 2 Secure air lines with provided tie straps Whatever the chosen location for the line is make sure there is enough clearance around the inflation valves for an air chuck Option 1 Option 2 u LF LoadLifter 5000 3 Drill a 5 16 hole to install the inflation valves 4 Cutthe air line assembly AA in two equal lengths CAUTION WHEN CUTTING OR TRIMMING THE AIR LINE USE A HOSE CUTTER AIR LIFT P N 10530 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 fig 16 Good Cut Bad Cut 5 Install the inflation valves as shown in fig 17 Vehicle Body or to Bumper ellows 5 16 Flat Washer 5 16 Hex
11. Check the air pressure weekly 2 Always maintain normal ride height Never inflate beyond 100 PSI If you develop an air leak in the system use a soapy water solution 1 part dish soap 4 parts water to check all air line connections and the inflation valve core before deflating and removing the air spring 4 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 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 5 Always add air to springs in small quantities checking the pressure frequently Sleeves require less air volume than a tire and inflate quickly 6 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 onboard leveling systems do not require deflation or disconnection Warranty and Returns Policy 12 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 l
12. Leaks bade Poe kb uera 11 Maintenance and Servicing 11 Maintenance Guidelines 12 Warranty and Return 12 PrOGUCL 056 iesus See E REA 13 Frequently Asked 5 13 Tuning the Air ee 13 Guidelines for Adding 14 Replacement Information 14 Contact Information 14 a 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 34 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 motorhome rear kits and some motorhome fronts where leaf springs are used Itis important to read and understand the entire installation guide before beginning installation or performing any maintenance service or repair The information here i
13. R 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 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 22 Raise the air pressure to correct either of these problems and level the vehicle 2 Ride comfort If the ve
14. ern Time For calls from outside the USA or Canada our local number is 517 322 2144 Register your warranty online at www airliftcompany com warrantyreg htm R 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
15. hicle has a rough and harsh ride it may be due to either too much pressure or not enough fig 23 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 24 Tuning out these problems usually requires an increase in pressure p f ay Bad headlight aim fig 22 fig 24 Sway and body roll MN 387 13 R 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 the rear because it can be safely assumed that it is heavily loaded 4 Ifthe 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 25 Adjust the pressure up and down to find the best ride If the vehicle rocks and rolls adjust the air pressure to reduce movement 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 26 As much as a 50 PSI difference is not uncommon OC
16. ight 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 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 pr
17. n 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 MN 387 R LoadLifter 5000 Installation Diagram OUTBOARD fig 1 MN 387 3 LF LoadLifter 5000 HARDWARE LIST Part Qty Dodge Fenderwell Spacer Parts A 58437 Bellows 57215 2 17182 Ya x 2 2 A 58491 Bellows 57207 2 Q 20947 Fenderwell liner spacer 2 B 07475 Upper 2 18419 10 32 Flat 6 03102 Lower 2 S 18425 2 11951 ROll Plate 4 33606 Elbow fitting iieri enne 2 AirLine Assembly F 10594 PAO ofa nii tiene 4 T 20086 Air line assembly 1 G 10583 4 5 4 10466 6 H 18435 Nyloc n t eec 16 V 21230 Valve
18. ncludes 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 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 explai
19. oduct 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 Lifetime Limited Load Controller 2 Year Limited RideControl Lifetime Limited Load Controller Il 2 Year Limited SlamAir Lifetime Limited SmartAir 2 Year Limited LoadLifter 5000 Lifetime Limited Wireless AIR 2 Year Limited EasyStreet Systems 1 Year Limited Other Accessories 2 Year Limited formerly SuperDuty MN 387 R LoadLifter 5000 Product Use 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 GWV
20. r and a lock nut for such instances fig 12 4 Install a washer head frame bolt oversized flat washer and lock nut For Dodge trucks only It may be necessary to add two of the provided spacers fig 12 All models except some Dodge trucks with ditch late model Dodge trucks ditch can be on top or bottom portion of the frame depending on vehicle model SS 9 Washer Head Lock Nut Oversized Flat Washer uS Lock Nut Upper Bracket Washer Head Spacer Frame Frame Bolt Frame MN 387 LoadLifter 5000 NOTE MN 387 SP 5 Remove the clamps and drill the remaining two holes Install the appropriate hardware and torque the nuts to 44 ft Ibs 6 Align the air spring uniformly between the upper and lower brackets and check the air spring alignment fig 13 Frame Move the air spring in the slots of the upper and lower brackets to align Make sure there is at least a thumbs width of clearance between the uninflated bag and the frame fiz 13 Bag e SECURING THE AIR SPRING TO THE BRACKETS 1 Secure the air spring to the upper and lower brackets using an open ended 3 16 wrench by tightening the two bolts on the top and the two bolts on the bottom of the spring assembly DUE TO THE THICKNESS OF THE LEAF SPRING STACK TRIM ALL FOUR U BOLTS ON EACH SIDE OF THE VEHICLE TO PREVENT BOTTOMING OUT ON THE UPPER
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