Kit 57396 - Air Lift
Contents
1. E lt H 1 2 flat washer W a bk t i e 1 2 13 serrated J flange locknut FF Existing jounce bumper hole FRONT OF VEHICLE fe 15 MN 770 LoadLifter 5000 SF PASSENGER SIDE BRACE INSTALLATION 1 Set the right upper brace B into the passenger side frame rail figs 16 17 and 18 Inside View of Passenger Right side frame shown i UA H W fig 16 See footnote in fig 1b See footnote in fig 1b FRONT OF REAR OF ab Venice VEHICLE For the passenger side before inserting the upper brace hardware make sure that the 1 2 thick washer R or AA is installed in between the brace and frame see Step 2 Note The 1 2 thick washer R is nota half inch thick It has a 1 2 hole and is a thick washer 206 UE Passenger side upper brace shown with hardware supplied in place fig 18 MN 770 11 R NOTE 12 LoadLifter 5000 2 For trucks with No fifth wheel or the OEM purchased Reese fifth wheel hitch insert the 1 2 13 x 1 50 hex cap screw P and 1 2 thick flat washer R through the brace between the brace and the frame add the 1 2 thick flat washer R then through the frame from the inside out Note The 1 2 thick flat washer R is not a half inch thick It has a 1 2 hole and is a thick washer Cap with a 1 2 flat washer W and a 1 2 13 serrated flange lock nut FF figs 15 an2. 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 Lifetime Limited LoadController Dual 2 Year Limited RideControl eeseseeee Lifetime Limited Load Controller I 2 Year Limited LoadLifter 5000 Lifetime Limited Load Controller Il 2 Year Limited LoadLifter 5000 Ultimate Lifetime Limited GmartAlr N KKK KN N
3. 13 X 1 5 Hex Cap Screw 1 Flat Washer i 2 1 2 Thick Flat Waeber 2 3 8 16 Serrated Flange Lock Nut 2 1 4 20 Nyloc NUt cccccssesseeeres 1 3 8 16 Nyloc NUN EE 20 3 8 Flat Washer aaannnnannnnnnnnnnnnnannnn 32 1 2 Flat VWaeher 3 M8 Flat Wacher 2 90 Swivel Air Fitting ee 2 3 8 24 X 7 8 Hex Cap Screw 8 3 4 Flat Waeher 1 8mm 1 25 X 25mm Hex Cap Screw 1 3 8 16 X 5 Hex Tap Bolt 000000nn 4 3 8 16 X 1 25 Carriage Bolt 12 3 8 16 X 10 Carriage Bot 4 1 2 13 Serrated Flange Lock Nut 2 3 8 16 X 2 Carriage Boht 2 M8 X 1 25 Nyloc NUL E 1 3 8 Lock WASMEN saccsc2cesacsatetevictnadeeaueet 8 Air Line Assembly csecceeeeeeeeeeees 1 LIO Eege eree 6 5 16 Lock Wacher 2 Valve Cape 2 5 16 Hex TU sees ege ees sereeregee 2 Rubber Wacher 2 Heat hued 1 R TOOLS LIST DESCYIiPtiON ccccccesseeeeeeseeesseneeeseeeenees Qty Metric amp STD Open Box End Wrenches set Ratchet with Metric and STD Sockets set Diill and 5 16 Drill BIE sasccccsexesvstadveseesndthiededsenetiorce 1 Torque Wrench 1 Hose Cutter Razor Blade or Sharp Knife 1 Hoist or Floor Jack 1 Safety StandS cicccccscccccsscsessesveeencacccccestacesneeeseceees 2 Safety Glasses cccceceeceeceeeeeeeeeeeeeeeseeeeeeeeeeeaeaes 1 Air Compressor or Compressed
4. MN 770 LoadLifter 5000 SF DRIVER SIDE BRACE INSTALLATION 1 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 1 25 x 25mm hex cap screw BB with an M8 flat washer X through the brace and frame figs 12 and 13 and cap with M8 flat washer X and M8 x 1 25 Nyloc nut HH Leave loose at this time CAUTION BE SURE NOT TO PINCH THE PREVIOUSLY MOVED WIRING OR LINES INSIDE THE LEFT FRAME RAIL Q T OaE Ia Tad La NI Q FDA ug Q s Let VC Ca 7 e De X a mme Attach the bracket to the frame using the M8 hardware noted fig 13 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 1 2 13 x 1 25 hex cap screw O and 1 2 flat washer W through the brace and frame from the inside out Cap with a 1 2 flat washer W and a 1 2 13 serrated flange lock nut FF figs 12 14 and 15 Do not tighten at this time Driver side brace shown with supplied hardware in place Existing 5th wheel hardware which may have been removed may look different fe 14 MN 770 9 R NOTE 10 LoadLifter 5000 OR If you have an aftermarket fifth wheel hitch that has an outer bracket
5. the 3 8 16 x 10 carriage bolt goes in between the axle and the hard brake ABS line fig 36 17 R LoadLifter 5000 Raise the axle up while aligning the 3 8 16 x 2 00 carriage bolt through the frame and the two 3 8 16 X 1 25 carriage bolts in the upper bracket through the brace Ue OF 3 Set the right passenger side assembly into position on the jounce bumper strike plate the same way the left side was positioned figs 1b 12 and 38 Make sure when setting the right side in place passenger side that the 3 8 16 x 10 carriage bolt goes on the outside backside of the hard brake ABS line fig 38 4 Make sure the thick spacer H is parallel to the frame and bracket fig 39 and raise the axle or lower the frame until the spacer contacts the frame on both sides Make sure the spacer H is parallel to both the frame and upper bracket Raise axle or lower frame until the spacer touches the frame on both sides We De 5 Install the 3 8 16 serrated flange lock nut S on the 3 8 16 x 2 00 carriage bolt GG that went through the existing jounce bumper hole and tighten securely on both sides figs 1a 1b and 40 BE SURE NOT TO PINCH THE PREVIOUSLY MOVED WIRING OR LINES INSIDE THE LEFT FRAME RAIL CAUTION 18 MN 770 Load tier 5000 MN 770 R Install the 3 8 16 serrated flange lock nut S onto the 3 8 16 x 2 00 carriage bol
6. 031507 e ECR 8169 MN 770 Load iP yay by AIR LIFT Kit 57396 Ford F 250 F 350 F 450 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 Introduction cc ieee eh EELER ed ase eck eens 2 Important Safety Notice 2 Notation ExXplanaliO ss aah eww ies Cee eee Eneee ad deer eee tae se ws 2 Installation Diagrams 000 eee es 3 Installation Diagram Driver Gudde 3 Installation Diagram Passenger Side 0 0 00 ees 4 Hardware and Tools Liste 0c eee eee 5 Hardware List 22 222 ee E ude Sse red EEN 26 ew ieee nae dadense ds 5 TOOR EE 5 Installing the LoadLifter 5000 System 6 Geng Starled EE 6 Installing the Braces 1 0 0 cc eee ees 7 Retaining Clip L Bracket Installation on Brace 0 2 0 eee 8 Driver Side Brace Installation 9 Passenger Side Brace Installation 0 0 0 0 0 ccc ees 11 Bellows and Bracket Assembly 00 00 cc eee eee eee eee 13 Attaching the Assemblies to the Frame 0 00 eee 17 Attaching the Lower Bracket to the Axle 1 nananana naaa aaa 20 installing the Air LINGS ccna adie Caos et Baha Oe Oe ee alee a 23 Installing the Heat hued 24 Finished Installation PHOWS 3 oo i 22002040 806 2bhs4 deo ae r
7. 1 2 13 serrated flange lock nut FF fig 16 Leave loose at this time MN 770 LoadLifter 5000 SF BELLOWS AND BRACKET ASSEMBLY 1 Seta roll plate 1 over the top and bottom of the bellows J figs 1a 1b and 19 NOTE The radiused rounded edge of the roll plate I will be towards the bellows so that the bellows is seated inside both roll plates 2 Install the swivel elbow fitting Y into the top of the bellows finger tight Tighten the swivel fitting one and a half turns Set roll plate 1 over the bellows and install the fitting Y as stated Repeat for both bellows eat 3 Insert one of the 3 8 16 x 10 carriage bolts EE into the lower bracket A figs 20 21 and 22 NOTE The 3 8 16 x 10 carriage bolt will be behind the axle once the assembly is installed on the axle Insert 3 8 16 x 10 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 For the driver side lower bracket insert the 3 8 16 x 10 carriage bolt EE through the square hole as shown in the picture and in figure 20 jig 21 MN 770 13 R NOTE 14 LoadLifter 5000 For the passenger side lower bracket insert the 3 8 16 x 10 carriage bolt EE through the square hole as shown ra in the picture and in eee figure 20 a ZZ 4 The lower bracket A has two se
8. air fitting on the air spring fig 54 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 770 23 R 24 LoadLifter 5000 7 Before installing the right passenger side hose install the hose heat shield over the hose fig 55 Once the hose has been inserted into the fitting push the hose heat shield up to the fitting Hose heat shield shown in place on the right side passenger of the vehicle Make sure heat shield is pushed up against the fitting once the hose is installed fig 93 8 Cut off the air line leaving approximately 12 of extra air line A clean square cut will prevent 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 56 2 Attach the heat shield to the exhaust pipe using the clamps Bend the heat shield for maximum clearance to the air spring fig 56 3 Fi
9. 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 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 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 minimiz
10. needed for easy installation Choose single or dual path inflation see illustrations at right Choose wireless or analog control Wireless Control your air springs from inside or outside the vehicle Easiest installation no wires to the cab Analog In cab control of your air springs Economically priced 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 e Heavy duty For daily use consider the heavy duty compressor it inflates faster and more quietly than the standard compressor Visit www airlifttcompany com for more detailed info on compressor systems MN 770 WirelessAIR P N 72000 WirelessONE P N 25870 LoadCONTROLLER SEPARATE AIR e fas Psi SPRING INFLATION 45 PSI Dual path systems Air springs are controlled separately to allow for different air pressure from side to side Perfect for uneven or top heavy loads E EQUAL AIR 50 PSI SPRING INFLATION H Ff so psi Single path systems Two springs will inflate at the same time Good for loads that are evenly distributed from left to right or front to back Dual Easy installation Compact Includes heavy economically priced duty compressor control ey P N Standard Duty Compressor 25850 P N Heavy Duty mpressor 25854 LoadCONTROLLER Single Easy installation Compact Includes standard eco
11. Air Source 1 Spray Bottle with Dish Soap Water Solution 1 Missing or damaged parts Call Air Lift customer mei service at 800 248 0892 for a replacement part LF LoadLifter 5000 Installing the LoadLifter 5000 System GETTING STARTED 1 Raise the vehicle and support it in a way using jack stands or equivalent that the axle can be safely dropped away from the frame This will need to be done in order for the air spring assembly to be put into position between the axle and frame figs 1a 1b and 2 Figure 2 shows the frame being supported with the vehicle on a drive on hoist al VU db N ef r E d ei r i AZ AM ei d 1 d l d l Li K z 4 2 Remove the jounce bumpers from under the frame over the axle figs 3 and 4 Wett FE TECH TIP Wire brush the stud on the jounce bumper and use some penetrating oil to help in removal of the jounce bumper Usually the socket size for the nut is a 15mm 6 MN 770 R LoadLifter 5000 3 If necessary disconnect the wiring harness from the driver side frame rail to gain clearance for the upper brace fig 5 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 installing and tightening the frame brace fig 6 Remove the line holders from the gas urea tank bracket for P easier access to the upper bra
12. H is offset Install the spacer so that the wide portion faces the outside of the vehicle figs 29 30 and 32 Spacer H set on bracket and in position The wide portion will face the outside of the vehicle We DA 16 MN 770 Load tier 5000 MN 770 R 9 Figure 33 shows the assemblies complete and ready to install Driver side Passenger side assembly assembly fig 23 ATTACHING THE ASSEMBLIES TO THE FRAME 1 If not done so yet drop the axle or raise the frame up to make room for the assemblies to be put into position 2 Set the left driver side assembly onto the jounce bumper strike plate figs 34 and 35 Make sure the 3 8 16 x 10 carriage bolt EE 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 3 8 16 x 2 carriage bolt GG that is installed in the upper bracket through the existing jounce bumper hole in the bottom of the frame At the same time line up the upper brace previously installed onto the remaining two carriage bolts in the upper bracket figs 36 and 37 Do this just enough for the carriage bolt to hold the assembly into position on the jounce bumper strike plate figs 1a and 12 NOTE Passenger side shown Lower bracket Jounce bumper strike plate located above axle fig 34 Make sure when setting the left side in place driver side that
13. K KAN 2 Year Limited SlamAir ERKENNEN Lifetime Limited Wireless AIR c00 2 Year Limited AirCell oa csececeesescescanees Lifetime Limited WirelessONE 00 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 EasyStreet 32 MN 770 Load tier 5000 KS 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 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 is a problem with the price Contact Information MN 770 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 addres
14. 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 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 2 2 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 2 3 Tuning out these problems usually requires an increase in pressure Bad headlight aim fig 2 1 Rough ride fig 2 2 Sway and fig 2 3 body roll MN 770 29 R 30 LoadLifter 5000 GUIDELINES FOR ADDING AIR 1 Start with the vehicle level or slightly above When in do
15. ce D 19 R LoadLifter 5000 fig 43 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 GAN d Ces 7 me eke et 3 3 Saat Amen ee insert the line holder E AN ii ee previously removed AN x E into the L bracket WA KK pa A installed on the A upper brace as shown at fig 43 ATTACHING THE LOWER BRACKET TO THE AXLE 1 Insert a 3 8 16 x 5 hex tap bolt CC and 3 8 flat washer V through the top round hole of the four hole locating bracket K figs 44 and 45 NOTE Use the hole that is closest to the leaf spring MOTT Sena ST LNE n N n AEN E QA aAa NOTE Lower Bracket sits on A jounce bumper strike plate See figs 34 amp 35 on page 17 Insert the 3 8 16 x 5 hex tap bolt and 3 8 flat washer through the top round hole of the four hole locating bracket closest to the bend first fig 45 20 MN 770 LoadLifter 5000 MN 770 KS 2 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 3 8 flat washers V and 3 8 Nyloc nuts U fig 46 One goes forward and one goes behind the axle on the leaf s
16. ce hardware LE 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 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 Set left side brace slot in frame inside the frame D INSTALLING THE BRACES Gas engine models have emission lines on the inside of the frame If your truck has emission lines running along the inside of the frame rail fig 7 it will be necessary to relocate those lines as follows 1 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 emissions fuel line retaining clips forward or rearward of the axle to aid in positioning the lines once the upper brace has been installed figs 7 and 8 The same holds true with the electrical wire loom retaining clips If equipped this emissions fuel line retaining clip must be pulled away from the frame in order to install the upper frame brace D fig 7 MN 770 T R LoadLifter 5000 Image shows lines clear on the frame opening it up for the brace installation fig 8 RETAINING CLIP L BRACKET INSTALLATION ON BRACE 1 In order to re attach the previously removed emissions line it w
17. d 16 Do not tighten at this time OR If you have an aftermarket fifth wheel hitch that has an outer bracket plate running along side of the frame and it used this slot to secure the bracket to the frame with existing hardware re install the original hardware previously removed in the Getting Started section However add the 1 2 thick flat washer R or 3 4 flat washer AA depending on whether the existing hardware is in between the brace and the frame fig 16 Note The 1 2 thick flat washer R is not a half inch thick It has a 1 2 hole and is a thick washer 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 1 2 hole through the plate using the slot in the frame as a template lt 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 1 2 13 x 3 00 hex cap screw N with a 1 2 thick flat washer R through the brace between the brace and the frame add the 1 2 thick flat washer R then through the frame and fifth wheel plate previously drilled Note The 1 2 thick flat washer R is not a half inch thick It has a 1 2 hole and is a thick washer Cap with a 1 2 flat washer W and a
18. e 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 MN 770 R LoadLifter 5000 Installation Diagram Driver Side Ss TTo J Er _ Lac e Eeer TA ei SE ZEN SE e e NA Geert sl WEE pra LS RE a NOTE Lower Bracket sits on A WITT CU See figs 34 amp 35 on page 17 v 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 manual MN 770 3 LF LoadLifter 5000 Installation Diagram Passenger Side NOTE Use 3 4 flat washer AA if using 3 4 fifth wheel hitch hardware removed R or AA R C E Ze ER D or Nik NOTE If you have a fifth wheel hitch installed that has NN side plat
19. eeu deine hes 25 Checking for Leaks 26 Se MOONS sorer punen rnn Ve urs eee eae uwaes Lends yep ad pagan as 26 Before Operating 0 cece eee eee 27 Installation Checklist n escnvas de oebee Seema abe d Ra dh odds saa 27 Post Installation Checker 27 Product Use Maintenance and Servicing 28 Minimum and Maximum Pressure 000 0c ee eee 28 Maintenance Guidelines Auen At gege de ated ies ob644 e500 A e 28 Troubleshooting Guide 28 Frequently Asked Questions a gue Ee EE oes EEN A E 29 Tuning the Air Pressure 1 ee ee eee ees 29 Guidelines for Adding EE 30 Choosing the Right On board Air Compressor System 31 Warranty and Returns Policy 00000000ee 32 Replacement Information 0000 0c ee eee eee 33 Contact Information 00cc eee eee eee ees 33 KS LoadLifter 5000 Introduction WARNING NOTE 2 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
20. es along the frame tm ot d C1 use the existing hardware a eege LLL removed If not use the 1 2 hardware supplied and recommended in this kit and in the directions in this manual y NA ANU UZANA We rn 2 Y ip Wu T J MA i up pE Bee H Lez Lal l m _ as y KEEN a AN C l A 7 SS Se 1 AAi eri d dere SC CH E A A Ji p Se NOTE Lower Bracket sits on jounce bumper strike plate See figs 34 amp 35 on page 17 4 MN 770 Load tier 5000 Hardware and Tools Lists HARDWARE LIST Hem Part A 03990 B 07996 C 07997 D 07994 E 07995 F 01531 G 10861 H 13966 l 11951 J 58437 K 10880 L 10886 M 17135 N 17271 O 17412 P 17161 Q 18419 R 18207 S 18422 T 18425 U 18435 V 18444 W 18485 A 18501 Y 21837 Z 17203 AA 18556 BB 17177 CC 17184 DD 17361 EE 17387 FF 18505 GG 17140 HH 18522 JJ 18427 KK 20086 LL 10466 MM 18411 NN 21230 OO 21233 PP 21234 QQ 34924 MN 770 Description ccseeeeeeeeeenees Qty Lower Bracket 2 Upper Brace right ccccseseeeeeeeees 1 Upper Bracket robt 1 Upper Brace ent 1 Upper Bracket et 1 Clamp Bar 2 Spring Clamp Bar 2 Se Le E 2 Biel 4 Bellows 2 Four Hole Locating Bracket 4 Ree 1 1 4 20 X 1 Hex Cap crew 1 1 2 13 X 3 Hex Cap Screw 2 1 2 13 X 1 25 Hex Cap Screw 1 1 2
21. gainst 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 52 Reinsert the air line into the push to connect fitting b Check the threaded connection by tightening the swivel fitting another 1 2 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 lf 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 CAUTION 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 26 MN 770 Load tier 5000 Before Operating MN 770 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 LI Leak test before road test Inflate the a
22. hirty 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 27 KS LoadLifter 5000 Product Use Maintenance and Servicing NOTE 28 Minimum Recommended Pressure Maximum Air Pressure 5 PSI MAINTENANCE GUIDELINES By following the steps below vehicle owners will obtain the longest life and best results 100 PSI 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 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 PSI 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
23. hreaded 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 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 MN 770 LoadLifter 5000 SF 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 For LoadLifter 5000 Ultimate the recommended minimum air pressure is 5 PSI but it can safely be run at zero air pressure 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
24. ill be necessary to attach the provided L bracket L to the back frame brace using the 1 4 20 x 1 bolt M flat washers 12 Q and 1 4 20 Nyloc nut T supplied fig 6 Placing this L bracket depends on where the line holder is on the wiring or the emissions line that was previously pulled from the frame Set the driver side frame brace D up into the frame and insert the 8mm 1 25 x 25mm hex cap screw BB with an M8 flat washer X through the brace and into the hole in the side of the frame that the line holder was removed from fig 9 to hold it in place and note what side the line holder is in in respect to the back leg of the brace Is it forward or behind the back leg of the brace Where the line holder lines up is the side where the L bracket is to be installed figs 6 and 9 Brace being temporarily held in place by the 8mm bolt and washer L bracket is shown in FF location already Note yi the side the line holder _ is on depends on the location of the factory retaining clip fig 9 2 Pull the brace back out and attach the L bracket onto the brace with the hardware noted above in the proper location previously found figs 10 and 11 Make sure the L bracket faces up and tighten securely Attach the L bracket to the brace in No matter what side the L bracket is on the position previously found using the make sure it is installed so the flat side hardware specified points up when tightening
25. ir springs to 60 PSI check all connections for leaks with a soapy water solution See the Checking for Leaks section 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 LI Fastener test Recheck all bolts for proper torque 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 LI Operating instructions If professionally installed the installer should review the Product Use Maintenance and Servicing section 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 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 Q T
26. lat washer and 3 8 Nyloc nut Leave loose at this time fig 49 6 Carefully draw the side hardware evenly making sure the lower bracket is tight against the leaf spring fig 50 Tighten the axle clamp bar evenly until it touches the axle see note below Torque the axle clamp bar bolts to 16ftlbs figs 50 and 51 Repeat for the opposite side Trim the 3 8 16 x 10 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 Spring clamp bar E e Four hole ye locating bracket With the spring clamp bar tight so that the lower bracket is up against the stock U bolts the four hole locating bracket should be forward and behind the U bolts as shown Note the lower bracket being parallel with the leaf spring fig 50 Image shows the right driver side rear view of the lower bracket and hardware in position fig 1 MN 770 LoadLifter 5000 SF INSTALLING THE AIR LINES 1 Choose a convenient location fo
27. 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 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 t
28. maining hole The head of this carriage bolt will be hidden once mounted to the bellows DD Driver Side Passenger Side DD The Driver side bracket with The Passenger side bracket hardware in place with hardware in place Use the mounting holes noted for mounting to the bellows NOTE One of the 3 8 16 x 1 25 carriage bolts DD will not be covered by the roll plate and may fall out If so retain for use in the Attaching the Assemblies to the Frame section later in this manual MN 770 15 R LoadLifter 5000 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 27 and attach to the bellows with two 3 8 flat washers V 3 8 lock washers JJ and 3 8 24 x 7 8 hex head cap screws Z Tighten both mounting screws securely figs 29 and 31 H wide portion of spacer points outboard V JJ Z V JJ Z i CO A ca f V U VK Di UU WA Left Driver Side Right Passenger Side CACC Attach the upper bracket to the bellows assembly with two 3 8 flat washers V 3 8 lock washers Ju and 3 8 24 x 7 8 hex head cap screws Z fig 1 7 Repeat the above process with the passenger side assembly figs 30 and 31 8 Set the spacers H over both 3 8 16 x 2 carriage bolts GG figs 29 30 and 32 NOTE The hole in the flat spacer
29. nished heat shield installation fig 56 e The shield is shown in position with air gap between it and the exhaust pipe fige 56 MN 770 R LoadLifter 5000 FINISHED INSTALLATION PHOTOS 1 The following shows the finished installation of both sides figs 57 58 59 and 60 DT gaz Sc we Ze E ff 57 e AN ek Ta ae CH it k A pe E E a p P Te A ZS Wi D z A a H ee eg 2s l 8 e BT i cb Back left driver side E Back center left driver side rear view of the kit installed rear view of the kit installed Back right passenger side Back right passenger side rear view of the kit installed forward center view of the kit installed MN 770 25 KS LoadLifter 5000 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 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 a
30. nomically priced duty compressor control P N Standard Duty Compressor 25852 P N Heavy Duty Compressor 25856 d U TN DEFLATE INFLATE DEFLATE LEFT BOTH RIGHT DEFLATE INFLATE BOTH 31 LF LoadLifter 5000 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 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 can be sent to Air Lift Company 2727 Snow Road
31. plate running along side of the frame and it used this slot to secure the bracket with existing hardware install the original fifth wheel hardware previously removed in the getting started section from the fifth wheel installation for securing the brace fig 12 Do not tighten at this time OR If you have an aftermarket fifth wheel hitch that has an outer 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 1 2 hole through the plate using the slot in the frame as a template Drill the hole as far to the rear of 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 lt may be necessary to mark and remove the outer bracket plate from the side of the frame in order to drill the hole correctly Re attach once the hole is drilled Insert a 1 2 13 x 3 00 hex cap screw N with a 1 2 flat washer W through the brace frame and fifth wheel plate previously drilled Cap with a 1 2 flat washer W and a 1 2 13 serrated flange lock nut FF fig 12 Leave loose at this time Rear View of Driver Left side shown A REAR OF VEHICLE 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
32. pring side fig 47 Leave loose at this time Right driver side rear view shown jig 46 Right driver side front view shown jig 47 3 Rotate the lower bracket so that it is parallel to the leaf spring Note the upper and lower brackets will not be parallel to each other once the lower bracket is mounted in place This is anormal condition Push the front and back four hole locating bracket against the stock u bolts and tighten the short carriage bolts at this time Keep the four hole locating bracket as tight to the U bolts as possible Using the 3 8 16 x 5 hex tap bolt CC and 3 8 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 figs 44 and 48 Cap with 3 8 flat washer V and 3 8 Nyloc nut U Leave loose at this time Install the spring clamp bar and leave loose at this time fig 48 21 R NOTE 22 LoadLifter 5000 5 Insert the remaining 3 8 16 x 10 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 assembly Set the clamp bar F over the two 3 8 16 x 10 carriage bolts EE and cap with two 3 8 flat washers V and two 3 8 Nyloc nuts U fig 49 Set the axle clamp bar over the 3 8 16 x 10 carriage bolts and cap with 3 8 f
33. r 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 20 DP Good Cut Poor 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 52 Vehicle body or AI NG bumper 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 1 2 to easily apply a pressure gauge or an air chuck fig 53 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
34. s 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 33 Need Help 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 airliftcompany com warranty SF 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 e Lansing MI 48908 0167 Toll Free 800 248 0892 Local 517 322 2144 Fax 517 322 0240 e www airliftcompany com Printed in the USA
35. t that goes through the flange on the frame and tighten securely jig 40 6 Cap the 3 8 16 x 1 25 carriage bolts DD with a 3 8 flat washer V and 3 8 nyloc nut U on both sides and torque to 15 ft lbs fig 41 Cap the 3 8 16 x 1 25 carriage bolts with 3 8 flat washer and 3 8 Nyloc nut and torque to 15ftlos Repeat for both sides fig 41 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 1 2 or 3 4 hardware previously installed that hold the braces to the frame fig 42 Tighten both sides securely Tech Tip If possible use a thin socket and it helps to pull back the driver side mounting hardware O or N as far back in the slot as you can while tightening Tighten the 8mm hardware and the 1 2 or 3 4 if from the 5th wheel hitch hardware and tighten securely Repeat for the hardware on the opposite side fig 42 8 Once the left driver side 1 2 or 3 4 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 42 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 bra
36. ts of bellows mounting holes Using the corresponding holes in the lower bracket designated figs 23 24 and 25 attach the bellows to the brackets using the 3 8 flat washers V 3 8 lock washers JJ and 3 8 24 x 7 8 hex head cap screws Z Tighten both mounting screws securely The fitting on top of the bellows points inward refer to fig 26 Left Driver Side Mounting holes Right Passenger Side Mounting holes Driver side bellows mounting holes shown in location to the 3 8 16 x 10 carriage bolt previously installed When installing on the bellows make sure the bracket edge facing you is on the fitting side of the bellows This slot should be on the opposite side of the fitting on the bellows once mounted jig 24 Passenger side bellows mounting holes shown in location to the 3 8 16 x 10 carriage bolt previously installed When installing on the bellows make sure the bracket edge facing you is on the fitting side of the bellows MN 770 R LoadLifter 5000 The bellows fitting must be on this side of the assembly Driver side Passenger side shown shown fig 26 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 figs 27 and 28 through the two square holes that are on the corresponding side Also insert one 3 8 16 x 2 00 carriage bolt GG through the re
37. ubt 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 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 2 5 AS much as a 50 PSI difference is not uncommon NO NO om P Lal e Bottoming out jig E Unlevel Level fig EE MN 770 Load tier 5000 KS Choosing the Right On Board Air Compressor System 6 NO QUESTIONS ASKED MONEY DAY eG COMPRESSOR SYSTEM WARRANTY 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 For convenient 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
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