The Air Lift LoadLifter 5000 is a high-performance air spring kit designed to provide load-leveling support for a wide range of 3/4- and 1-ton pickups and SUVs with leaf springs. This kit offers up to 5,000 lbs. of support with air pressure adjustable from 5 to 100 PSI. It is also suitable for motor home rear kits and some front applications where leaf springs are used. Proper installation, maintenance, and understanding of the system are essential to ensure safe and effective operation.
This guide is based on the official installation manual and technical specifications provided by Air Lift. It outlines the tools, hardware, and step-by-step procedures required for a successful installation. It also includes troubleshooting tips, maintenance guidelines, and important safety precautions to follow before and after installation.
Key Installation Considerations
Before beginning the installation process, it is important to understand the intended use and limitations of the LoadLifter 5000 system. The air spring kit does not alter the vehicle’s Gross Vehicle Weight Rating (GVWR) or payload capacity. Therefore, users must always refer to the vehicle’s owner's manual and adhere to the maximum load limits specified by the manufacturer.
The installation involves replacing or supplementing the vehicle’s existing leaf spring suspension with the LoadLifter 5000’s air spring system. This system includes reinforced, commercial-grade bellows and a comprehensive set of hardware and fittings to ensure secure mounting and optimal performance.
Tools and Hardware Required
The following tools and hardware are necessary for the installation of the LoadLifter 5000 kit:
Hardware List
| Item | Part Number | Description | Quantity |
|---|---|---|---|
| A | 58407 | Bellow | 2 |
| B | 07705 | Upper Bracket | 2 |
| C | 03006 | Lower Bracket | 2 |
| D | 21848 | Elbow Fitting | 2 |
| E | 17203 | 3/8"-24 x 7/8" Bolt | 8 |
| F | 18427 | 3/8" Lock Washer | 8 |
| G | 18444 | 3/8" Flat Washer | 12 |
| H | 18435 | 3/8" Nylock Nut | 4 |
| I | 17142 | 3/8"-16 x 3.5" Carriage Bolt | 4 |
| J | 17146 | 1/2"-13 x 1.5" Bolt | 2 |
| K | 18414 | 1/2" Flat Washer | 2 |
| L | 18429 | 1/2" Lock Washer | 2 |
| M | 18431 | 1/2" Hex Nut | 2 |
| N | 09484 | Thermal Sleeve | 2 |
| O | 01665 | Clamp Bar | 2 |
| AA | 20086 | Air Line Assembly | 1 |
| BB | 10466 | Tie Strap | 6 |
| CC | 21230 | Valve Caps | 2 |
| DD | 18405 | 5/16" Flat Washer | 2 |
| EE | 21234 | Rubber Washer | 2 |
| FF | 18411 | 5/16 Small Star Washer | 2 |
| GG | 21233 | 5/16" Hex Nut | 4 |
Tool List
| Tool | Quantity |
|---|---|
| 7/16", 9/16" open-end or box wrenches | 1 |
| Crescent Wrench | 1 |
| Ratchet with 3/8", 9/16", and 1/2" deep well sockets | 1 |
| 3/8" and 5/16" drill bits (very sharp) | 1 |
| 3/8" Nut Driver | 1 |
| Heavy Duty Drill | 1 |
| Torque Wrench | 1 |
| Hose Cutter, Razor Blade, or Sharp Knife | 1 |
| Hoist or Floor Jacks | 1 |
| Safety Stands | 1 |
| Safety Glasses | 1 |
| Air Compressor, or Compressed Air Source | 1 |
| Spray Bottle with Dish Soap/Water Solution | 1 |
It is important to ensure that all tools are in good working condition and that the hardware is compatible with the vehicle's specifications.
Installation Procedure
The installation of the LoadLifter 5000 system involves several key steps, from preparing the vehicle to mounting the air springs and connecting the air line assembly. The following is a step-by-step overview based on the official installation guide:
Step 1: Vehicle Preparation
Before beginning the installation, it is essential to ensure the vehicle is in a safe and stable position. Use a hoist or floor jacks to lift the vehicle, and secure it with safety stands. Always wear safety glasses and follow proper lifting and handling procedures.
Step 2: Mounting the Upper and Lower Brackets
The upper and lower brackets are critical components that secure the air springs between the vehicle's frame rail and leaf spring assembly. These brackets must be mounted correctly to ensure proper alignment and function.
- Attach the upper bracket to the frame rail using the provided bolts, washers, and nuts.
- Attach the lower bracket to the leaf spring using the clamp bar and appropriate fasteners.
- Ensure that the brackets are aligned with the "FORWARD" and "INBOARD" directions as indicated in the installation diagram.
Step 3: Installing the Air Springs
Once the brackets are mounted, the air springs can be installed between the upper and lower brackets.
- Insert the air spring into the brackets, ensuring it is positioned correctly.
- Secure the air spring in place with the appropriate bolts, washers, and nuts.
- Check for proper clearance between the air spring and surrounding components such as the frame, shock absorbers, and brake cables.
Step 4: Connecting the Air Line Assembly
The air line assembly connects the air springs to the control system and provides a means of inflating and deflating the air springs.
- Attach the elbow fitting to the air spring using the provided fittings and hardware.
- Route the air line assembly according to the installation diagram, ensuring it is clear of any moving parts or potential points of abrasion.
- Secure the air line with tie straps, ensuring they are not too tight and do not restrict airflow.
Step 5: Installing the On-Board Air Compressor (Optional)
For added convenience, an on-board air compressor can be installed to allow for easy inflation and deflation of the air springs. Air Lift offers both single and dual path systems, as well as wireless and analog control options.
- Single Path Systems: Inflates both air springs at the same time. Ideal for evenly distributed loads.
- Dual Path Systems: Allows for individual inflation of each air spring. Ideal for uneven or top-heavy loads.
- Wireless Systems: Provides in-cab or remote control without the need for wiring.
- Analog Systems: Provides in-cab control at a lower cost.
To install an on-board air compressor system:
- Choose the appropriate system based on the vehicle’s needs.
- Mount the compressor and controller according to the manufacturer’s instructions.
- Connect the air line assembly to the compressor and ensure all connections are secure.
Safety and Precautions
Several safety precautions must be followed during and after the installation of the LoadLifter 5000 system to ensure safe operation and prevent damage to the vehicle or injury to the installer.
Safety Notices
- The installation of this kit does not alter the vehicle’s GVWR or payload capacity. Always check the vehicle’s owner's manual and do not exceed the maximum load limit.
- If the vehicle is equipped with a rear brake proportioning valve, the installation of a load assist product may affect brake performance. Consult with the vehicle’s dealer before installation.
- Always add air to the air springs in small quantities and check the pressure frequently.
- If the vehicle needs to be raised by the frame, ensure the system is at minimum pressure (40 PSI) to reduce tension on suspension and brake components.
- Periodically check the air spring system for fastener tightness and signs of rubbing. Realign if necessary.
- Clean the air springs with a garden hose to remove abrasive debris such as mud, sand, and gravel.
Post-Installation Checklist
After installation, it is important to perform a series of checks to ensure the system is functioning properly and is safe for use.
- Clearance Test: Inflate the air springs to 60 PSI and ensure there is at least 1/2" clearance around each bellow, away from any components that might rub against them.
- Leak Test: Use a soapy water solution to check all connections for leaks. Ensure all leaks are eliminated before road testing.
- Heat Test: Ensure sufficient clearance from heat sources (at least 6" for air springs and air lines). If a heat shield was included, install it. If not, contact Air Lift for assistance.
- Fastener Test: Recheck all bolts for proper torque. Axle clamp bar carriage bolt lock nuts should be torqued to 16 ft/lbs. Retorque after 100 miles.
- Road Test: Road test the vehicle after the preceding tests. Inflate the air springs to 25 PSI (50 PSI if the vehicle is loaded). Drive the vehicle 10 miles and recheck for clearance, loose fasteners, and air leaks.
Maintenance and Troubleshooting
Proper maintenance is essential to ensure the longevity and performance of the LoadLifter 5000 system. The following are some key maintenance tips and troubleshooting steps.
Maintenance Guidelines
- Periodically check the air spring system fasteners for tightness.
- 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 to remove mud, sand, gravel, or other abrasive debris.
- Always add air to springs in small quantities, checking the pressure frequently.
Troubleshooting Steps
If the air spring system is not functioning properly, the following troubleshooting steps can be taken:
- Leak Test: Inspect the air line connections, the threaded connection into the air spring, and all fittings in the control system for leaks.
- Air Line Inspection: Ensure the air line is not pinched, kinked, or folded. Reroute if necessary.
- Tie Strap Check: Tie straps may be too tight; loosen or replace the strap and replace any leaking components.
- Air Line Condition: Inspect the air line for holes and cracks. Replace as needed.
- Air Spring Failure: If the preceding steps do not solve the problem, it may be caused by a failed air spring (factory defect or operating problem). Contact Air Lift at (800) 248-0892 for assistance.
Frequently Asked Questions
Q: Will installing air springs increase the weight ratings of a vehicle?
A: No. The installation of air springs does not alter the vehicle’s GVWR or payload capacity. Always check the vehicle’s owner's manual and do not exceed the maximum load limit specified by the manufacturer.
Conclusion
The Air Lift LoadLifter 5000 is a robust and reliable air spring system designed to provide load-leveling support for a variety of 3/4- and 1-ton pickups and SUVs with leaf springs. Proper installation, maintenance, and understanding of the system are essential to ensure safe and effective operation. By following the step-by-step installation guide, using the correct tools and hardware, and adhering to the safety precautions, users can maximize the performance and longevity of the LoadLifter 5000 system.
For additional support or to order replacement parts, users are encouraged to contact Air Lift directly or consult an authorized dealer. Detailed installation instructions and troubleshooting guides are available in the official manual and technical documentation provided by the manufacturer.