Installation Manual
Contents
1. 2 V 18438 B 07996 Upper Brace eee 2 W 18444 C 07997 Upper Bracket eese 2 X 18460 D 01531 Axle Clamp 2 Y 18556 E 11951 Roll 4 71 13964 58437 BellOWS occccccccoccooconcncccnnnoncnononononononos 2 Z2 13978 G 10181 Emergency Brake Cable Clamp 2 AA 18443 H 10886 ML Bracket entes 1 BB 18495 11400 Adapter 2 CC 21837 J 17103 5 16 18 x 1 Hex Head Cap Screw 4 DD 17203 K 17135 1 4 20 x 1 Hex Head Cap Screw 1 EE 18427 L 17141 3 8 16 x 2 5 Carriage Bolt 2 FF 20086 M 17163 3 8 16 x 7 Carriage Bolt 4 GG 10466 N 17268 M10 1 5 x 35 Hex Flange Bolt 1 HH 18411 17271 1 2 13 x 3 Hex Head Cap Screw 2 I 21230 P 17361 3 8 16 x 1 25 Carriage Bolt 4 JJ 21233 Q 18207 1 2 Large Flat Thick Washer 6 KK 21234 R 18419 Flat Washer 12 2 18401 S 18425 1 4 20 Nyloc Nut MM 34924 T 18433 5 16 a NN 17208 U 18435 3 8 16 Nyloc 10 Not shown TOOLS LIST DOSCMPUOM PPEFERERPPELFEPFERERRPREREEFERFEREREREFEFERFEREFEEFEFERFEREFEEREERRAH Qty 7 16 and 9 16 Open end or box wrenches2. 2 Star 2 Heat Shield Kit 1 1 2 13 x 2 00 Hex Head Cap Screw 2 Missing or damaged parts Call Air Lift customer service at 800 248 0892 for a replacement part MN 777 a LoadLifter 5000 Installing the LoadLifter 5000 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 fig 2 fig 2 Jack Stands 2 Remove the jounce bumpers from under the frame over the axle 3 Ifnecessary disconnect the wiring harness from the driver side frame rail to gain clearance for the upper bracket 4 If you have a fifth wheel hitch already installed it will be necessary to remove the 34 hardware that bolts the side bracket to the outside of the frame above the axle fig 1 NOTE Some hitch models have a spacer between the bracket and the frame rail Be sure to reinstall the spacer when attaching the upper bracket 5 In order to obtain clearance between the upper bracket and the emergency brake cable bolt on the inside of the frame it will be necessary to remove the bolt and re insert through the emergency brake cable bracket from the outside of the frame in Install the 7 16 spacer AA on the bolt and cap with the new M10 1 5 nyloc nut BB fig 1 Tighten h
3. 2 Crescent wrench esssssssssseeeeeeeeeneenenn 1 Ratchet with 3 8 9 16 amp 1 2 deep well sockets 1 5 16 drill bits very sharp 1 DIR grindern a ER 1 Lect CES 1 Heavy duty drill eter 1 Torque Wrench cci een nn 1 Standard metric and SAE sockets and wrenches 1 Hose cutter razor blade or sharp knife 1 Hoist or floor jacks esem nnnnn 1 Safety ud er de Rer Ie edere nn 1 Safety glasses reine etd ates rep 1 Air compressor or compressed air 1 Spray bottle with dish soap water solution 1 LoadLifter 5000 Description Qty 5 16 18 Nyloc 4 3 8 Flat 9 1 2 13 Nyloc 2 3 4 Flat 2 SPACC MN assi enata paste esit titu oes ti ates 2 SpaAG E 2 AA 1 M10 1 5 Nyloc 1 90 Swivel Elbow Fitting 2 3 8 24 x 7 8 Hex Head Cap Screw 8 3 8 Split Lock Washer 8 Air Line 1 AMS 6 5 16 Flat Washer 2 Valve Caps teet en 2 5 16 Hex eee 2 Rubber
4. wg 95477777 QM 1 i 1 1 i 1 eteeett 1 RYE Vie e n pom Inn arm rs ca MT zer INN i i 1 PVavesary ty s I ww 11 NN PGA www PO po er 1 D NASSSNSA l s Ne 15555555 zerrr00H 1 a a AE zerro 000 I SSS 1 1 1 I SS ss 1 Ceren eril Option 1 Earn ptio 1 2 1 1 t 2 DI Option j 1 fi o N Issue 1 A_L______ I lessz t 0 8 SS aS etn mmm a a m C M a ee 7 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 11 R 12 LoadLifter 5000 INSTALLING THE HEAT SHIELD 1 Bend tabs to provide a Y dead air space between exhaust pipe and heat shield fig 15 2 Attach the heat shield to the exhaust pipe using the clamps Bend the heat shield for maximum clearance to the air spring fig 15 Some vehicles have large resonators in this area it will be necessary to double up on the clamps to fit these models fig 16 Yo Dead air space Exhaust resonator Double up supplied hose Bend tabs clamps provi
5. 20 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 21 AS much as a 50 PSI difference is not uncommon li B PAN Bottoming out fig 20 Unlevel Level fig 21 MN 777 LoadLifter 5000 Warranty and Returns Policy MN 777 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 sh
6. Flat washer JJ 5 16 Hex nut 11 Valve cap E LIZZZZ KK Rubber washer fig 13 JJ 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 7 to easily apply a pressure gauge or an air chuck fig 13 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 Route the air line along the frame to the air fitting on the air spring fig 14 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 aLL S 2 CEF EEE MEn ba Qs mio I s t i 1 SS 1 1 i 1 LESEN ERA log Pur 1 T RSS See ta Q9 NL PSA 000010004 X A mi 14010004 16666666 i Dae te 2 Ma Ai werd amp 1 FOSS SSSA Be Seal py
7. home rear kits and some motor home fronts where leaf spring 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 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 minimize risk
8. supplied by the manufacturer 1 Set the upper brace B into the driver and passenger side frame fig 4 If you have a fifth wheel hitch that does not have a plate running alongside the full length of the frame these will have an L bracket forward and behind the axle leaving the middle frame open use the 1 2 13 x 2 00 Hex Cap Screw NN with a flat washer Q through the slot in the side of the frame then through another flat washer Q and finally through the upper brace Cap with a flat washer Q and a 1 2 13 nyloc nut X fig 4 Leave loose at this time OR If you have an aftermarket fifth wheel hitch that has a bracket plate running along side of the frame and it used this slot to secure the bracket to the frame with existing hardware install the existing hardware previously removed in the getting started section from the fifth wheel installation for securing the brace fig 4 Make sure to install the large 3 4 flat washer Y between the brace and frame figs 1 and 4 Do not tighten at this time OR If you have an aftermarket fifth wheel hitch that has a bracket plate running along side of the frame and it does not have any attaching hardware on the side where the slot in the frame is it will be necessary to drill a 7 hole through the plate using the slot in the frame as a template It may be necessary to mark and remove the bracket plate from the side of the frame in order to drill the hol
9. D BOTTOMING OUT OVER EXTENSION OR RUBBING FAILURE TO MAINTAIN CORRECT MINIMUM PRESSURE OR PRESSURE AGAINST ANOTHER COMPONENT WILL VOID THE WARRANTY MAINTENANCE GUIDELINES By following the steps below vehicle owners will obtain the longest life and best results from their air springs 1 2 3 Check the air pressure weekly 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 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 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 Ibs of load combined on both springs for each 1 PSI of pressure The required air pressure will vary depending on the state of the original suspension Operating the vehicle below the minimum air spring pressure will void the Ai
10. Installation Checklist teens 13 Post Installation 13 Product Use Maintenance and Servicing 14 Minimum and Maximum lt 5 14 Maintenance Guidelines 14 Troubleshooting Guide tte ee 15 Frequently Asked 15 Tuning the Air 16 Guidelines for Adding 16 Warranty and Returns 17 Replacement 18 Contact Information 18 LoadLifter 5000 Introduction NOTE N The purpose of this publication is to assist with the installation maintenance and troubleshooting of the LoadLifter 5000 air spring kit LoadLifter 5000 utilizes sturdy reinforced commercial grade single or double depending on the kit convolute bellows The bellows are manufactured like a tire with layers of rubber and cords that control growth LoadLifter 5000 kits are recommended for most 3 4 and 1 ton pickups and SUVs with leaf springs and provide up to 5 000 Ibs of oad leveling support with air adjustability from 5 100 PSI The kits are also used in motor
11. MN 777 021112 ECR 7217 Ford F 250 F 350 parum Single and Dual Rear Wheel 2 Wheel Drive Load a Kit 57393 28 8 Pis SU 1 3 5 rt Lin Ge gt DOE Y 4 e w e 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 saec RE Aus HH nee 2 Important Safety Notice 22 cette 2 Notation Explanation ssis seriernas uia NNE rennen 2 Installation Diagram 3 Hardware and Tools 615 4 Installing the LoadLifter 5000 System 5 Getting Started ss su sr eR RE REGRESO Re 5 Side Brace Installation eh 6 Bellows and Bracket 5 6 Securing Emergency Brake Cable on the 8 Attaching the Assemblies to the 8 Installing the Air LineS llle BI 10 Installing the Heat Shield s 1 12 Checking for 5 12 FIXING LOOKS tuse AA ee 12 Before 13
12. ardware securely NOTE If your model truck has emission lines running along the inside of the frame rail fig 3 it will be necessary to relocate those lines as follows Follow the directions in the section Attaching the Assemblies to the Frame for reattaching these lines e Carefully push the line holder out of the frame above the axle Try to minimize damage because it will be reused later It may also be helpful to remove any holders forward or rearward of the axle to aid in positioning the lines once the upper bracket has been installed fig 3 e Attach the L bracket H to the back or front leg of the frame brace using the 1 4 20 x 1 hex head bolt K flat washers R and 1 4 20 nyloc nut S supplied fig 1 This L bracket will eventually be used to attach the previously removed emissions line Do not attach the line holder to it at this time Emissions lines fig 3 Electrical wiring loom MN 777 5 R NOTE NOTE LoadLifter 5000 SIDE BRACE INSTALLATION 314 Flat Washer or Q 314 Flat Washer Y or Driver site show 5th Wheel Plate 3 4 Bolt or or NN 3 4 Flat Washer or B G Emergency Brake Cable Clamp Driver Side Only fig 4 3 4 hardware is supplied by the 5th wheel hitch manufacturer Use the 1 2 hardware supplied with this kit if no hard ware is
13. c nuts U Torque both nuts evenly to 16ftlbs 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 R NOTE 10 LoadLifter 5000 0 Driver side shown Mm a CECI 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 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 ce Good Cut Poor Cut 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 12 MN 777 LoadLifter 5000 MN 777 a Vehicle body or FF Air line bumper HH 5 16
14. ded fig 15 fig 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 if the loss is more than 5 lbs FIXING LEAKS 1 Ifthere is a problem with the swivel fitting a Checkthe 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 12 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 u
15. e 3 8 16 x 2 5 carriage bolt L through the remaining hole The head of this carriage bolt will be hidden once mounted to the bellows 5 Set the driver side left upper bracket onto the driver side bellows assembly previously assembled using the holes in the upper bracket designated fig 6 and attach to the bellows with two 3 8 flat washers W lock washers EE and 3 8 24 x 7 8 hex head cap screws DD Tighten both mounting screws securely 6 Repeat the above process for the opposite side assembly fig 7 7 Depending on the model of the truck there are two spacer Z1 or Z2 lengths that are supplied to properly fit between the frame jounce bumper bracket and frame Use the spacer that can be inserted where the stock jounce bumper was removed which when butted against the frame will be flush or close to the bottom of the jounce bumper bracket that is riveted to the frame NOTE The upper bracket when in position should rest on the spacer and the stock jounce bumper bracket C Upper bracket Z1 or Z2 W EE DD A Outboard Wheel Side X B Driver Side F Bellows F A Lower bracket bracket D Passenger Side 7 n _ Passenger Side MN 777 7 a NOTE LoadLifter 5000 SECURING EMERGENCY BRAKE CABLE ON THE AXLE The emergency brake cable that goes to the right side of the vehicle will have to be modified in order fo
16. e correctly Re attach once the hole is drilled Insert a 13 x hex head cap screw O with a 1 2 thick flat washer through the fifth wheel plate previously drilled the frame then through another 1 2 thick flat washer Q and finally the upper frame brace Cap with a 1 2 thick flat washer and a 13 Nyloc nut X fig 4 Leave loose at this time BELLOWS AND BRACKET ASSEMBLY 1 Seta roll plate E over the top and bottom of the bellows F fig 1 The radiused rounded edge of the roll plate E will be towards the bellows so that the bellows is seated inside both roll plates 2 Install the swivel elbow fitting CC into the top of the bellows finger tight Tighten the swivel fitting one and a half turns MN 777 LoadLifter 5000 aS 3 The lower bracket A has two sets of bellows mounting holes Using the corresponding holes in the lower bracket designated fig 5 attach the bellows to the brackets using the 3 8 flat washers W lock washers EE and 3 8 24 x 7 8 hex head cap screws DD Tighten both mounting screws securely NOTE The fitting on top of the bellows points inward fig 7 Outside wheel 5 Left driver side holes Right passenger side holes 4 Insert two 3 8 16 x 1 25 carriage bolts P up through the bottom of the upper brackets fig 6 through the two square holes that are on the corresponding side Also insert on
17. e tension off of the air springs 15 aS LoadLifter 5000 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 17 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 18 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 19 Tuning out these problems usually requires an increase in pressure Bad headlight aim fig 17 Sway and jig 19 body roll 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 0 16 that it is heavily If the 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
18. e vehicle is loaded Drive the vehicle 10 miles and recheck for clearance loose fasteners and air leaks Operating instructions If professionally installed the installer should review the Product Use Maintenance and Servicing section on page 14 with the owner Be sure to provide the owner with all of the paperwork which came with the kit POST INSTALLATION CHECKLIST 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 Air pressure requirements understand the air pressure requirements of my air spring system Regardless of load the air pressure should always be adjusted to maintain ride height at all times LJ Thirty day or 500 mile test understand that must recheck the air spring system after 30 days or 500 miles whichever comes first If any part shows signs of rubbing or abrasion the source should be identified and moved if possible If 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 13 LoadLifter 5000 Product Use Maintenance and Servicing NOTE 14 Maximum Air Pressure Minimum Pressure 5 PSI 100 PSI PROPORTIONAL TO LOA
19. ents or need technical assistance contact our customer service department by calling 800 248 0892 Monday through Friday 8 a m to 7 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 18 MN 777 Need Help Contact our customer service department by calling 800 248 0892 Monday through Friday 8 a m to 7 p m Eastern Time For calls from outside the USA or Canada our local number is 517 322 2144 Register your warranty online at www airliftcompany com warranty KFT 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
20. ime Limited LoadController Dual 2 Year Limited RideControl Lifetime Limited Load Controller I 2 Year Limited LoadLifter 5000 Lifetime Limited Load Controller Il 2 Year Limited SlamaAir Lifetime Limited SmartAir 2 Year Limited AirCell Lifetime Limited Wireless AIR 2 Year Limited Air Lift Performance 1 Year Limited WirelessONE 2 Year Limited LoadController Single 2 Year Limited Other Accessories 2 Year Limited EEE formerly SuperDuty formerly LifeSTYLE amp Performance 17 LF LoadLifter 5000 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 If you have any questions comm
21. ing two 5 16 bolts J four flat washers T and two nyloc nuts V fig 5 or 11 Tighten securely 2 If not done so yet drop the axle or raise the frame up to make room for the assemblies to be put into position MN 777 LoadLifter 5000 NOTE MN 777 3 Set the left driver side assembly onto the axle fig 1 Raise the axle just enough to insert the 3 8 16 x 2 5 long carriage bolt L that is installed in the upper bracket through the existing jounce bumper hole in the bottom of the frame At the same time line up the upper brace previously installed onto the remaining two 3 8 16 x 1 25 carriage bolts P in the upper bracket Do this just enough for the carriage bolt to hold the assembly into position on the axle fig 1 or 4 4 Set the right passenger side assembly into position on the axle the same way the left side was positioned fig 1 or 4 5 Raise the axle or lower the frame down so that the round spacer Z1 or Z2 on the upper bracket inserts into the stock jounce bumper bracket hole on both sides 6 Install the 3 8 Flat Washer W and a 3 8 16 Nyloc nut U on the 3 8 16 x 2 5 carriage bolt L that went through the existing jounce bumper hole and tighten securely on both sides fig 1 or 4 BE SURE NOT TO PINCH THE PREVIOUSLY MOVED WIRING OR LINES INSIDE THE LEFT FRAME RAIL 7 Install the emergency brake cable clamp G over the emergency brake cable and attach to the forward brace upper brac
22. ipping and handling charge will apply to all warranty claims Before returning any defective product you must call Air Lift at 800 248 0892 in the U S and Canada elsewhere 517 322 2144 for a Returned Materials Authorization RMA number Returns to Air Lift can be sent to Air Lift Company 2727 Snow Road Lansing MI 48917 Product failures resulting from abnormal use or misuse are excluded from this warranty The loss of use of the product loss of time inconvenience commercial loss or consequential damages is not covered The consumer is responsible for installation reinstallation labor charges of the product Air Lift Company reserves the right to change the design of any product without assuming any obligation to modify any product previously manufactured This warranty gives you specific legal rights and you may also have other rights that vary from state to state Some states do not allow limitations on how long an implied warranty lasts or allow the exclusion or limitation of incidental or consequential damages The above limitation or exclusion may not apply to you There are no warranties expressed or implied including any implied warranties of merchantability and fitness which extend beyond this warranty period There are 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 Lifet
23. ket bolt P fig 1 or 4 Cap with a 3 8 nyloc nut U Both sides Cap the remaining brace upper bracket carriage bolts P with a 3 8 flat washer W and 3 8 16 nyloc nut U and tighten all hardware securely 8 With the spacers Z1 or Z2 on the upper brackets tight in the frame and the braces tight to the upper bracket tighten the Y or 3 hardware previously installed that hold the braces to the frame Tighten both sides securely 9 If so equipped with the emissions line previously loosened from the frame insert the line holder post into the L bracket H attached to the back or front leg of the upper left brace B fig 10 It may be necessary to move the line holder post forward or back on the lines to line up correctly with the L bracket hole Reattach any line holders removed forward or behind the axle if possible that were removed to aid in positioning the upper bracket Emissions line holder stock H L bracket Option H L bracket Emergency Brake Line Holder G Location Driver Side Only C Upper Bracket 10 Repeat for the other side of the vehicle 11 Raise the axle or lower the body all the way now and push the lower bracket against the leaf spring fig 1 or 11 12 Insert two 3 8 carriage bolts M into the square holes the lower bracket and install the clamp bar D onto the carriage bolts fig 1 or 11 13 Cap with a 3 8 flat washer W and nylo
24. 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 777 LoadLifter 5000 Installation Diagram a 3 4 Flat Washer or Q 3 4 Flat Washer Y or Q Driver side shown 5th Wheel Bracket Plate ___ 3 4 Flat Washer or 0 Emergency Brake Cable 3 4 Bolt or O or nn ENS C Clamp Driver Sida Only 3 4 hardware is supplied by the 5th ee a o MA BE wheel hitch manufacturer Use the 1 2 E hardware supplied with this kit if no hard ware is supplied by the Ta fig 1 MN 777 3 Hardware and Tools Lists HARDWARE LIST Item Part Description Qty Item Part A 03115 Lower
25. r Lift warranty 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 Always add air to springs in small quantities checking the pressure frequently 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 Periodically check the air spring system fasteners for tightness Also check the air springs for any signs of rubbing Realign if necessary On occasion give the air springs a hard spray with a garden hose in order to remove mud sand gravel or other abrasive debris MN 777 LoadLifter 5000 PP Troubleshooting Guide 1 Leak test the air line connections the threaded connection into the air spring and all fittings in the control system 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 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 Ifthe preceding
26. r the lower bracket to sit on the axle properly e f you have an F 250 or your cable is secured like what is in fig 8 just bend the wire bracket forward and down at the same time This will move the cable forward and down clearing the bottom of the lower bracket e If you have an F 350 or your cable is secured like what is in fig 9 remove the wire cable holder off the side of the sway bar bracket that is attached to the axle and remove the top bolt if so equipped that holds the sway bar strap on discard the holder and both bolts Attach the emergency brake cable clamp G to the brake cable and attach the frame clamp to the top sway bar hole that the bolt was previously removed from using the M10 flange bolt supplied N fig 9 Tighten securely y id o Wire bracket on emergency brake cable F 250 Bend wire bracket forward and down to clear bracket EM Wire bracket on emergency brake cable F 350 Attach frame clamp using new flange bolt bend slightly ATTACHING THE ASSEMBLIES TO THE FRAME The F 250 models usually have a 3 50 diameter axle tube In order for the lower bracket to fit correctly no adapter will be needed for these vehicles The F 350 models usually have a 4 00 diameter axle tube and require the use of an adapter I that mounts to the lower bracket in order for it to nest into position between the stock u bolts fig 1 1 Attach the adapter I to the lower bracket A us
27. se 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 777 LoadLifter 5000 R Before Operating MN 777 Technician s Signature Date INSTALLATION CHECKLIST To be completed by installer Clearance test Inflate the air springs to 60 PSI and ensure there is at least 7 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 L 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 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 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 Road test The vehicle should be road tested after the preceding tests Inflate the air springs to 25 PSI 50 PSI if th
28. steps do not solve the problem itis possibly caused by a failed air spring either a factory defect or an operating problem Please call Air Lift at 300 248 0892 for assistance Frequently Asked Questions MN 777 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 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 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 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 th
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