The Air Lift LoadLifter 5000 Series is a system designed to enhance vehicle load-carrying capacity. Installation requires careful attention to safety precautions, particularly concerning compressed air and potential interference with existing vehicle systems. The system utilizes air springs, roll plates, and air lines, available in nylon or braided stainless steel configurations. Different kit variations—standard, Ultimate, and Ultimate Plus—are distinguished by components such as internal jounce bumpers and material choices for roll plates and air lines. Proper installation involves securing brackets, assembling air spring units, and routing air lines while avoiding contact with fuel, brake, and electrical lines.
System Components and Kit Variations
The LoadLifter 5000 Series comprises several key components. These include stainless steel star washers, rubber washers with 5/16” (8mm) dimensions, PTC to AN adapter fittings, and air line assemblies. The documentation identifies three primary kit variations: the standard LoadLifter 5000, the LoadLifter 5000 Ultimate, and the LoadLifter 5000 Ultimate Plus.
The LoadLifter 5000 Ultimate kits incorporate an internal jounce bumper and feature black powder-coated roll plates. The LoadLifter 5000 Ultimate Plus kits build upon the Ultimate features by adding stainless steel roll plates, air lines, and air spring mounting hardware. Identifying the specific kit is crucial when contacting Air Lift customer service, as components vary between versions.
Safety Precautions
Installation of the LoadLifter 5000 Series requires strict adherence to safety guidelines. Compressed air presents a potential hazard, and the documentation explicitly warns that improper handling can cause injury and damage to the vehicle. Users are instructed not to attempt inflating the air springs until they have been securely fastened to the vehicle.
Additionally, caution is advised during the drilling process. Before drilling, it is essential to inspect the backside of the vehicle frame for potential clearance issues with brake lines, gas lines, and electrical lines. Any obstructions must be temporarily relocated to prevent damage. When working with air lines, it is critical to avoid cutting them completely, as nicking the barb can render the fitting unusable.
Assembling the Air Spring Unit
The assembly of the air spring unit involves the use of roll plates. The documentation specifies that a roll plate should be positioned on both ends of the air spring, with the radiused (rounded) edge facing the air spring to ensure proper seating. This configuration ensures the air spring is securely held within both roll plates.
Bracket Positioning and Attachment
Proper positioning of the brackets is critical for optimal performance. The documentation recommends installing the air spring between 5” and 7” from both the upper and lower brackets. Positioning the upper bracket as high as possible is considered best practice.
Attaching the upper bracket requires drilling holes in the vehicle frame. Prior to drilling, a thorough inspection of the frame’s backside is necessary to identify and address any potential clearance issues with existing vehicle components. After drilling, appropriate hardware should be installed and tightened to a torque of 44 lb.-ft. (60Nm). The air spring should then be aligned uniformly between the upper and lower brackets, and its alignment should be verified.
Air Line Installation
Air lines route compressed air from the air springs to Schrader valves. The LoadLifter 5000 Series offers two air line styles: nylon and braided stainless steel. Installation begins with selecting appropriate locations for the Schrader valves and drilling a 5/16” hole if necessary.
When installing braided stainless steel air lines, it is crucial to keep the lines away from fuel lines, brake lines, and electrical wires. Securing the air lines with zip ties to fixed points is recommended to prevent movement and potential damage.
Specific Vehicle Considerations: Late Model 4WD Dodge
The documentation highlights a specific installation requirement for 1994 and newer model Dodge 4WD pickups. These vehicles require the removal of the inner fender well liner. This is accomplished by carefully driving a center punch through the fasteners. After installing the air spring system, the fender well liner must be reinstalled using the original fasteners and provided spacers to ensure adequate clearance for the air springs.
Troubleshooting and Customer Support
The documentation provides limited troubleshooting guidance. If issues arise during air line connection, users are advised not to cut the air line completely to avoid damaging the barb. If problems persist, contacting Air Lift customer service at (800) 248-0892 is recommended. Additionally, if a heat shield is required but not included in the kit, contacting customer service is advised. A final fastener test—rechecking all bolts for proper torque—is recommended upon completion of the installation.
Conclusion
The Air Lift LoadLifter 5000 Series offers a means of augmenting a vehicle’s load-carrying capabilities. Successful installation hinges on careful adherence to the provided instructions, with particular attention to safety precautions and vehicle-specific considerations. The system’s components and kit variations necessitate accurate identification for proper installation and customer support. Proper bracket positioning, air spring assembly, and air line routing are essential for optimal performance and longevity.