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1. 1 E 21230 Valve rr 2 Spray bottle with dish soap water solution 1 F 21233 SAG Flex NUT sacs 4 G 21234 Rubber washer 2 H 18411 Star Washel asc tnc dina 2 l 18405 5 16 Flat washer 2 J 21236 MCC aa i aa A 1 K 21455 MENTITUM 2 Missing or damaged parts Call Air Lift customer service at 800 248 0892 for a replacement part Installing the Air Lift 1000 System GETTING STARTED 1 Jack up the rear of the vehicle or raise on a hoist Support the frame with safety stands fig 1 2 Mark the spring upper spring mount with a marker so that the spring can be reinstalled and indexed properly 3 Remove the shock absorbers from the lower shock mounts on the axle Lower the axle or raise the body of the vehicle until the springs can be removed CAUTION OBSERVE TENSION ON BRAKE AIR LINE DO NOT STRAIN IF NECESSARY REMOVE MN 704 ANY MOUNTINGS TO CREATE MORE SLACK a Air Lift 1000 INSTALLING THE AIR SPRING 1 Insert the air spring into the removed coil spring with the stem at the top fig 2 lt _ 0 Insert air spring into coil spring with stem at top fig 2 2 Push the air spring to the bottom of the coil and insert the protector at the top fig 3 NOTE The protector can be inserted into the coil facing either direction 3 Reinstall the springs back into the vehicle spring mounts Use the marks
2. 02905 ECR 6701 MN 704 Air Lifbiojuu Kit 60818 m Dodge 1500 Pickup 2 amp AWD Toft lt 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 ssc cs ieee asa s RERWea RA EE EE ERE 2 Important Safety Notice 2 Notation Explanation 2 Installing the Air Lift 1000 System 3 Hardware LIST 2x cede up ua kt e eec RUBRO S RR ae eet RAD RO Baies 3 Tools List ss e ee RR ms k kis ede RR dry Rc ORE pue RR Re x 3 Getting Started c kd ks pask REFER ile ER dns eme 3 Installing the Air Spring 4 Installing the Air Line 5 Tee Air Line Routing so gt saiae eraa mana Ea ae eee 5 Dual Air Line Routirig 4 2 24 ak ki epe k Rb ERA e EERE d eee ee 7 Completing the Installation 7 Maintenance and Servicing 8 Maintenance Guidelines 8 Operating Tips ness pede nas a E xp bed adis esse 8 Prod ct USB iis ik RR RR Rena as Rr CAE ACORN Ec d 9 Frequently Asked Questions 9 Tuning the Air P
3. Slide a clamp onto the air line and push the air line over the fitting covering all the barbs With pliers slide the air line clamp forward until it fully covers the barbed section see fig 8 Raise the axle or lower body until the air springs lightly touch the upper spring seat and lower spacers DO NOT INFLATE AIR SPRINGS BEFORE READING THE MAINTENANCE AND OPERATION SECTION COMPLETING THE INSTALLATION Tighten the lower shock mounts Inflate the air springs to 35 PSI Test for air leaks by applying a liquid solution of 5 dish soap to 5 water to all valve cores fittings and connections Lower the vehicle to the ground Read Maintenance and Servicing for proper care of your air springs Recheck air pressure after 24 hours A 2 4 PSI loss after initial installation is normal If pressure has dropped more than 5 Ibs retest for leaks P Air Lift 1000 Maintenance and Servicing Minimum Air Pressure Maximum Air Pressure FAILURE TO MAINTAIN CORRECT MINIMUM PRESSURE OR PRESSURE PROPORTIONAL TO LOAD BOTTOMING OUT OVER EXTENSION OR RUBBING AGAINST ANOTHER COMPONENT WILL VOID THE WARRANTY MAINTENANCE GUIDELINES By following these steps vehicle owners will obtain the longest life and best results from their air springs 1 2 Check the air pressure weekly Always maintain at least the recommended minimum air pressure to prevent the air spring from being pinched Never inflate beyond the maximum air pr
4. 11 LF Air Lift 1000 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 comments or need technical assistance contact our customer service department by calling 800 248 0892 Monday through Friday 8 a m to 8 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 12 MN 704 Air Lift 1000 Notes MN 704 R Need Help Contact our customer service department by calling 800 248 0892 Monday through Friday 8 a m to 8 p m Eastern Time For calls
5. vehicle s Safety Compliance Certification Label Payload The combined maximum allowable weight of cargo and pasengers 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 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 704 Air Lift 1000 P HARDWARE LIST TOOLS LIST Item Part Description Gty D SCriPUOM asi isininusssikisuin si ss aiss oria ruin an sss Qty A 46159 Air Spring 2 Hoist or floor jacks R 2 B 09105 Protectors sss 2 Safety Stands ueneno eam eie espe en 1 C 20937 Air line assembly 1 Safety glasses eee 1 D 10466 Tie strap 6 Air compressor or compressed air source
6. you made in the Getting Started section to properly index the spring Raise the suspension up far enough to install the lower shocks in the mounts Do not tighten at this time Install the protector on the top fig 3 MN 704 Air Lift 1000 gi INSTALLING THE AIR LINE A tee air line installation is recommended If the weight in the vehicle varies from one side to the other and unequal pressures are needed to level the load or compensate for axle torque transfer in racing applications use dual air lines see page 7 TEE AIR LINE ROUTING CAUTION TO PREVENT THE AIR LINE FROM MELTING MAINTAIN AT LEAST 8 FROM THE EXHAUST SYSTEM TO THE AIR LINE 1 Locate the desired tee location on the frame rail or cross member Determine and cut an adequate length of air line to reach from the tee to the left and right side air springs CAUTION LEAVE SUFFICIENT AIR LINE SLACK TO PREVENT ANY STRAIN ON THE FITTING DURING AXLE MOTIONS 2 Slide an air line clamp onto the air line 3 Push the air line over one side of the tee until all the barbs are covered With a pair of pliers slide the air line clamp forward until it fully covers the barbed section Repeat the entire procedure for the other leg of the tee fig 4 4 Route the air line along the cross member and either the lower control arm or the upper spring seat to the air spring J a Use this procedure for all air A line connections a Slide the air line clamp onto the air
7. e 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 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 9 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 10 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
8. essure If you develop an air leak in the system use a soapy water solution of 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 Always add air to springs in small quantities checking the pressure frequently Sleeves require less air volume than a tire and inflate quickly OPERATING TIPS 1 Inflate your air springs to 35 PSI before adding the payload This will allow the air cylinder to properly mesh with the coil spring After the vehicle is loaded adjust your air pressure down to level the vehicle and for ride comfort When carrying a payload it will be helpful to increase the tire inflation pressure in proportion to any overload condition We recommend a 2 PSI increase above normal for each 100 Ibs additional load on the axle DO NOT EXCEED THE VEHICLE MANUFACTURERS MAXIMUM GROSS VECHICLE WEIGHT RATING MN 704 Air Lift 1000 Product Use MN 704 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 GWVR 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 shap
9. from outside the USA or Canada our local number is 517 322 2144 Register your warranty online at www airliftcompany com warranty 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 airlifttompany com Printed in the USA
10. her X Q Hex nut 6 Be sure to fully cover y the barbed section Rubber washer g um 13 Raise the axle or lower the vehicle body until the air springs lightly touch the upper spring seat and lower spacers DO NOT INFLATE AIR SPRINGS BEFORE READING THE MAINTENANCE AND SERVICING SECTION Hex nut fig 8 14 Continue to Completing the Installation MN 704 Air Lift 1000 MN 704 LF DUAL AIR LINE ROUTING TO PREVENT AIR LINE FROM MELTING KEEP IT AT LEAST 8 FROM EXHAUST SYSTEM 1 Select a location for the inflation valves in the rocker panel flange or rear bumper assuring that each valve will be protected and accessible with an air hose Determine and cut an adequate length of air line to reach from the valve location to the left side air spring LEAVE SUFFICIENT AIR LINE SLACK TO PREVENT ANY STRAIN ON FITTING DURING AXLE MOTIONS 3 4 5 10 Insert the air line through the spring seat and spacer Slide the air clamp onto the cut air line Push the air line onto the stem covering all the barbed section see fig 5 With pliers slide the air line clamp forward until it fully covers the barbed section Repeat process for the right side Drill a 5 16 hole for the inflating valves and mount as illustrated The rubber washer is for an outside weather seal see fig 7 Route the air line along the control arm and frame to the inflation valve location and cut off the excess
11. line b Push the air line over the barbed stem Compress the ears on the air line clamp with pliers and slide it forward to fully cover the barbed section 5 Insert the air line through the spring seat and spacers 6 Push the air line onto the stem covering all the barbs fig 5 With the pliers slide the air line clamp upward until it fully covers the barbed section EB Stem Air line fig 5 J MN 704 5 a Air Lift 1000 7 Push the remaining air line over the last fitting on the tee and route it along the frame to the desired inflation valve location Attach the air line with plastic straps or wire 8 Select a location for the inflation valve in the gas cap well the trunk rear bumper fender flange or behind the license plate insuring that the valve will be protected and accessible with an air hose fig 6 1 x1 2 t ar panna at ai 1 MITTIT Hn Sees Emm m mme Eme E ER 5 i option Option 2 EPT 5 pocrspreqeei 9 Drill a 5 16 hole for the inflation valve and mount as shown fig 7 The rubber washer Serves as an outside weather seal 10 Slide the air line clamp over the air line Push the air line onto the fitting covering all barbs Using pliers slide the air line clamp forward until it fully covers the barbed section fig 8 Air line Inflation Air line Lock valve clamp Vehicle body washer or bumper fT Flat was
12. oduct 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 Lifetime Limited Load Controller I 2 Year Limited LoadLifter 5000 Lifetime Limited Load Controller Il 2 Year Limited SlamAir 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 formerly SuperDuty formerly LifeSTYLE amp Performance AND EasyStreet
13. ressure 9 Guidelines for Adding Air 10 Warranty and Return Policy 11 Replacement Information 12 Contact Information 12 P Air Lift 1000 Introduction NOTE The purpose of this publication is to assist with the installation maintenance and troubleshooting of the Air Lift 1000 air spring kit 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 tools 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 Contact Air Lift Company at 800 248 0892 or go online to www airliftcompany com for the latest version of this manual 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
14. sacrifice a perfectly level and comfortable ride Stability issues include roll control bounce dive during braking and sponginess fig 11 Tuning out these problems usually requires an increase in pressure B Bad headlight aim 9 fig 11 Sway and body roll a 10 Air Lift 1000 GUIDELINES FOR ADDING AIR 1 Oo NO Start with the vehicle level or slightly above When in doubt always add air For motorhomes start with 50 100 PSI in the rear because it can be safely assumed that it is heavily loaded 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 12 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 13 As much as a 50 PSI difference is not uncommon LN L p d D BS undi Bottoming out fa 12 Unlevel Level fig 13 MN 704 Air Lift 1000 gi Warranty and Returns Policy MN 704 Air Lift Company warrants its products for the time periods listed below to the original retail purchaser against manufacturing defects when
15. 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 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 pr

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