TM Installation Guide S E R I E S Multiple Chevrolet, Dodge, Ford and GMC trucks Kits 57215 | 88215 | 89215 For maximum effectiveness and safety, please read these instructions completely before proceeding with installation. MN-1046 • (011704) • ERN 8631 Failure to read these instructions can result in an incorrect installation.
IDENTIFYING THE DIFFERENCES BETWEEN KITS Should you need to contact Air Lift customer service, you will need to know which kit you are inquiring about: standard LoadLifter 5000, LoadLifter 5000 Ultimate or LoadLifter 5000 Ultimate Plus. The kits are easily identifiable by looking at the roll plates and air lines. Standard LoadLifter 5000 — Zinc-plated steel roll plates and black nylon air lines. LoadLifter 5000 Ultimate — Black powder-coated roll plates and black nylon air lines.
TABLE TABLE OF OF CONTENTS CONTENTS Installation Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hardware and Tools Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Important Safety Notice . . . . . . . . . . . . . . . . . .
LoadLifter 5000 Series Installation Diagram O K I OR J A N E M OUTBOARD H D C FORWARD B H I F or G 2 I OR J K O fig.
LoadLifter 5000 Series Hardware and Tools Lists Common Parts Included in All 3 Kits Unique Parts in Each Kit TM Item Part# A 07475 B 03102 F 10594 G 10583 H 18435 L* 13377 M 18447 N 17159 P* 01525 Q* 17182 R* 20947 S* 18419 T* 18425 EE* 21234 Description......................................................... Qty Upper bracket.......................................................... 2 Lower bracket.................................................
LoadLifter 5000 Series Introduction The purpose of this publication is to assist with the installation, maintenance and troubleshooting of the standard LoadLifter 5000, LoadLifter 5000 Ultimate or LoadLifter 5000 Ultimate Plus air spring kits. All LoadLifter 5000 Series kits utilize sturdy, reinforced, commercial-grade single or double, depending on the kit, convolute bellows. LoadLifter 5000 Ultimate kits add an internal jounce bumper and black powder-coated roll plates.
LoadLifter 5000 Series Installing the LoadLifter 5000 Series System 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 & 3). fig. 2 2.
LoadLifter 5000 Series SPECIAL APPLICATION INSTRUCTIONS 1. 1994 and newer model Dodge 4WD pickups only: It will be necessary to remove the inner fender well 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 liner and provide clearance for the air spring (See page 13 for reinstallation instructions). fig. 4 2.
LoadLifter 5000 Series 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 toward the air spring so that the air spring is seated in both roll plates. 2. Install a 90-degree swivel air fitting. It should only be finger tight plus 1 1/2 turns. Do not overtighten. 3. Place the upper bracket onto the top of the air spring and roll plate with the legs facing down. 4.
LoadLifter 5000 Series POSITIONING THE BRACKETS 1. The air spring must be installed between 5” and 7” 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 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. 2.
LoadLifter 5000 Series 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.
LoadLifter 5000 Series 5. Remove the clamps and drill the remaining two holes. Install the appropriate hardware and torque the nuts to 44 lb.-ft. (60Nm). 6. Align the air spring uniformly between the upper and lower brackets and check the air spring alignment (fig. 13). 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. Frame fig. 13 Bag SECURING THE AIR SPRING TO THE BRACKETS 1.
Flat Vehicle body orXXX-XXX bumper MICHIGAN www.MICHIGAN.gov Hex nuts AN Schrader valve LoadLifter 5000 Series Installing the Air Lines Braided stainless s air line to air spring Air line he Star wash Rubber w 5/16” air hole Air lines are routed from the air springs to Schrader valves. LoadLifter 5000 Series lines come in two styles: nylon and braided stainless steel. Begin by choosing locations for the Schrader valves and drill a 5/16” hole, if necessary (fig. 15).
LoadLifter 5000 Series INSTALLING BRAIDED STAINLESS STEEL AIR LINES CAUTION KEEP THE AIR LINE AWAY FROM THE FUEL LINE, BRAKE LINES AND ELECTRICAL WIRES. 1. Use zip ties to secure the air line to fixed points along the chassis every 6” to 8”. Leave at least 2” of slack to allow for any movement that might pull on the air line. 2. Tighten the air line hex nut finger tight, then use 2 wrenches to turn 1 additional flat (1/6 of one full turn). Do not overtighten (figs. 18 or 19).
LoadLifter 5000 Series Reinstalling the Fender Well 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 fender well liner using the original fasteners and provided spacers to allow for air spring clearance (fig. 20). Before After fig. 20 2. Place the spacer between the fender well liner and the fender well at the center hole in the fender well liner (the hole nearest the air spring).
LoadLifter 5000 Series Before Operating 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.
LoadLifter 5000 Series INSTALLATION CHECKLIST Clearance test — Inflate the air springs to 75-90 PSI and make sure there is at least 1/2” clearance from anything that might rub against each sleeve. Be sure to check the tire, brakes, frame, shock absorbers and brake cables. Leak test before road test — Inflate the air springs to 75-90 PSI and check all connections for leaks. All leaks must be eliminated before the vehicle is road tested.
LoadLifter 5000 Series 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 air pressure weekly. 2. Always maintain normal ride height. Never inflate beyond 100 PSI. 3.
LoadLifter 5000 Series 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. 24). 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. 25).
LoadLifter 5000 Series Troubleshooting Guide PROBLEM CAUSE SOLUTION System won’t maintain pressure overnight. Improperly installed air line, air line has holes or cracks. Leak test the air line connections, the threaded connection into the air spring, and all fittings in the control system. Air spring or air line leak. Fitting seal or air line is compromised. Check to make sure air lines are seated in connectors. Inspect fittings with soapy water. Trim hose or re-seal fitting.
LoadLifter 5000 Series Notes MN-1046 19
LoadLifter 5000 Series Notes 20 MN-1046
LoadLifter 5000 Series Limited Warranty and Return Policy Air Lift Company provides a limited lifetime warranty to the original purchaser of its Load Support products, that the products will be free from defects in workmanship and materials when used on cars and trucks as specified by Air Lift Company and under normal operating conditions, subject to the requirements and exclusions set forth in the full Limited Warranty and Return Policy that is available online at www.airliftcompany.com/warranty.
Thank you for purchasing Air Lift Products — the professional Installer's choice! Need Help? Contact Air Lift customer service department by Contact AirCompany Lift Company customer service calling (800) 248-0892. department by the calling For calls from outside USA or (800) Canada,248-0892. dial (517) 322-2144. For calls from outside the USA or Canada, dial (517) 322-2144. Need Help? Need Help? Contact Air Lift Company customer service department by calling (800) 248-0892.
