For Ford Transit van owners seeking enhanced suspension performance and versatility, the Air Lift LoadLifter 5000 Ultimate and WirelessAir Suspension system represents a robust solution. Designed to improve handling, reduce sag, and provide on-demand leveling and ground clearance, the system is ideal for both on-road comfort and off-road capability. This guide details the installation process, drawing exclusively from the manufacturer-provided information and user experiences documented in the source material.
The installation involves both mechanical and electrical components, including the air spring kit, compressor, air tank, and control system. The process is detailed in multiple stages, each with precise instructions on hardware preparation, routing, and integration into the van’s existing framework. This article will walk through each step, emphasizing safety, compatibility, and performance considerations.
Installation Overview and Key Components
The Air Lift system comprises two primary kits: the LoadLifter 5000 Ultimate air spring kit and the WirelessAir compressor and tank system. The air spring kit replaces the factory jounce bumpers and provides adjustable suspension stiffness, while the compressor system enables real-time pressure adjustments for leveling and ground clearance. The tank allows for additional air storage, which is useful for inflating tires or setting up tubeless systems.
Installation of the system is modular but requires careful planning to ensure compatibility with the Ford Transit’s undercarriage layout. The source material outlines multiple potential mounting locations for the compressor and tank, emphasizing the importance of accessibility and space constraints.
Step-by-Step Installation Guide
1. Vehicle Preparation and Safety
Before beginning the installation, it is critical to ensure the vehicle is secure and accessible. The process involves working under the van, which necessitates proper lifting and stabilization.
- Optionally Raise the Van: To create additional working space, the van can be raised using RhinoGear Ramps MAX or a jack and jack stands. This is not mandatory but recommended for easier access to undercarriage components.
- Stabilize the Vehicle: Engage the parking brake and apply wheel chocks to both front wheels to prevent movement. This is essential for safety during undercarriage work.
- Lift the Rear of the Van: Using a jack, lift the rear of the van slightly to unload the suspension. This provides clearance between the axle and body, facilitating access to the factory jounce bumpers.
The source material emphasizes that while the jack is only supporting a few hundred pounds (not the full weight of the van), it is crucial to use a sturdy jack and jack stands as a secondary safety measure.
2. Removing the Factory Jounce Bumpers
The LoadLifter 5000 Ultimate replaces the factory jounce bumpers. These bumpers are typically mounted between the suspension arm and the body.
- Remove the Factory Jounce Bumpers: With the suspension unloaded, the factory jounce bumpers can be removed. The source material notes that this is performed on both the driver and passenger sides.
Once removed, the air bags will be installed in the same location, providing a more durable and adjustable suspension solution.
3. Installing the Inflation Valves and Air Lines
The inflation valves are essential for maintaining and adjusting air pressure in the air bags.
- Position the Inflation Valves: The inflation valves are installed under the plastic trim, approximately 6 inches behind the rear wheels. A 5/16-inch hole must be drilled for the valve.
- Secure the Valve: A 5/16-inch hex nut and star washer are installed on the valve, followed by a rubber washer, flat washer, and another hex nut.
- Route the Air Line: The air line is routed from the inflation valve to the air bag. To accommodate future trimming, the source material suggests leaving extra length during this step.
- Secure the Line to the P Clamp: The air line is secured through a P clamp and pushed into a swivel fitting to ensure a secure and leak-free connection.
This step is critical for maintaining proper air pressure and system functionality.
4. Compressor and Tank Installation
The WirelessAir compressor system includes a heavy-duty compressor, air tank, and manifold.
- Mount the Compressor: The compressor is installed in the bay just behind the driver-side front wheel. The source material provides detailed instructions for securing the compressor through the floor:
- Use a 1/4-inch drill bit to mark the hole locations.
- Pilot the holes with a 1/8-inch bit and then enlarge them to 1/4-inch.
- Apply rust prevention treatments (smooth, clean, prime, paint) to the hole edges.
- Insert M6 bolts and stainless steel washers to secure the compressor.
- Remote Air Filter Installation: The air filter is installed remotely in the cabin to reduce dust exposure. It is connected to the compressor using a 1/4-inch air line.
The air tank is also prepared for installation, with fittings such as the water drain valve attached to the lowest port to allow for periodic drainage.
5. Electrical and Control System Integration
The WirelessAir system includes a control unit that allows for remote pressure adjustments.
- Wiring Connections: The control system requires three electrical connections:
- Black (Ground): Connected to a 12V negative (ground) source.
- Red (Positive): Connected to a 12V positive source. This can be connected to the auxiliary house battery or the CCP (central control panel).
- Pink (Ignition Signal): Connected to an upfitter switch or ignition signal. The source material recommends using Auxiliary Upfitter Switch #2, which is fused at 40A (Switches #1 and #4 are fused at 20A and are not suitable).
- Routing the Wiring Harness: The wiring harness is routed behind the driver seat and into the passenger seat pedestal. The source material provides detailed routing instructions, including using split loom tubing for protection and organizing the harness in the glove box compartment.
This step ensures the system is powered and controllable via the WirelessAir remote or mobile app.
6. Final Assembly and Testing
Once all components are installed, the system must be tested for functionality and leaks.
- Inflation and Leak Check: Air is added to the air bags up to the maximum pressure of 100 PSI. A leak test is performed to ensure all connections are secure.
- System Calibration: The control unit is configured to pair with the compressor. The user is instructed to hold the center button until the pairing menu appears. Settings such as compressor duty cycle (Tank or Air Bags) and air bag type (LoadLifter 5000) are selected.
- Preset Configuration: The user can save custom pressure settings using the “Preset” button. A sample preset of “Left: 5, Right: 100” is suggested to account for road inclinations.
- Mobile App Integration: The WirelessAir App (available for Android and iOS) allows for additional control and monitoring of the system.
These final steps ensure the system is fully operational and tailored to the user’s needs.
Compatibility and Model Selection
The Air Lift system is available in multiple configurations, each with different features and capabilities.
- LoadLifter 5000 Regular: Offers a 5,000 lbs capacity and full adjustability. However, it does not include an internal jounce bumper to prevent bottom-out.
- LoadLifter 5000 Ultimate: Includes an internal jounce bumper, making it more suitable for off-road use.
- WirelessAir Systems: Available in single-path (same left/right pressure) and dual-path (independent left/right pressure) configurations. The source material outlines several models, including:
- WirelessAir: Heavy-duty compressor.
- WirelessAir with EZ Mount: Pre-mounted compressor.
- WirelessAir App Only with EZ Mount: No physical remote (cheaper option).
- WirelessAir Tank with EZ Mount: Includes a 2-gallon air tank.
Users should select the model that best fits their budget and intended use. The source material notes that the system is not compatible with E-Transit 350, 350HD, or dual rear wheel (DRW) models.
Alternative Ride Improvement Solutions
While the Air Lift system is highly versatile, there are other alternatives available in the market.
- Sumo Springs: A low-cost option that replaces the factory jounce bumper but offers no adjustability.
- More Leaf Spring: Adds stiffness to the rear suspension but does not provide adjustability.
- Sway Bar: Reduces body sway on highways but may negatively impact off-road performance.
- RAS (Ride Adjustment System): Increases suspension stiffness to reduce squat and improve stability, similar to air bags.
These alternatives are briefly mentioned in the source material but are not as comprehensive as the Air Lift solution.
Conclusion
The Air Lift LoadLifter 5000 Ultimate and WirelessAir Suspension system offers a powerful and customizable solution for improving the performance of the Ford Transit van. The installation process, while detailed, is well-documented and follows a logical sequence of steps that emphasize safety, compatibility, and functionality.
By following the outlined procedures, users can achieve a suspension system that provides on-demand leveling, improved ground clearance, and enhanced handling—both on and off the road. The system’s modular design allows for flexibility in component selection, and its integration with a mobile app adds a layer of convenience for modern users.
For those who require additional air storage, the tank option is a valuable addition, especially for off-road enthusiasts or those who need to inflate tires without relying on external sources.
Ultimately, the Air Lift system represents a high-value investment for Ford Transit owners seeking a versatile and durable suspension upgrade.