Kit 57230 Dodge 1500 MN-917 • (011312) • ERN 7756 4-Wheel Drive 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Notation Explanation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation Diagram . . . . . . . . . . . . . . .
LoadLifter 5000 Introduction 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 lbs.
LoadLifter 5000 Installation Diagram This bolt is only used as an option. see the Tech Tip Option section. fig.
LoadLifter 5000 Hardware and Tools Lists HARDWARE LIST Item A B C D E F G H I J K L M N O AA BB CC DD EE FF GG Part # 07057 07058 03062 58437 11951 01663 17361 17420 17366 18435 18444 17215 17365 21837 17151 20086 10466 21230 18501 21234 18411 21233 Description..........................................................QTY Upper Frame Bracket..............................................2 Upper Bellows Bracket............................................2 Lower Bracket.......................................
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. Drop the axle or raise the frame up to make room for the assemblies to be put into position between the frame and axle. 3. Remove the jounce bumper from under the frame rail (Fig. 3). fig. 3 Jounce Bumper 4. Attach the upper frame bracket (A) to the frame using the two M10-1.
LoadLifter 5000 TECH TIP OPTION If by chance one of the jounce bumper bolts broke upon removal, bolt the bracket to the frame as noted above using the jounce bumper mounting hole the other bolt was removed from, to align the bracket. 1. Line up the hole in the upper bracket over the broken bolt (as if being bolted as stated above). 2. Center punch and drill a 5/16” hole in the center of the outside hole next to the broken bolt hole (Fig. 5). Broken bolt hole fig. 5 3.
LoadLifter 5000 ASSEMBLING THE AIR SPRING ASSEMBLIES 1. Set a roll plate (E) over the top of each air spring (D). NOTE 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 fitting (N) into the top of the air spring finger tight plus one and a half turns (Fig. 7). (N) (E) (D) fig. 7 3.
LoadLifter 5000 (E) (L) (C) fig. 9 7. Figure 10 shows the finished assemblies. fig. 10 ATTACHING THE UPPER BRACKETS 1. Set the assemblies onto the axle with the fittings to the inside of the frame (Fig. 11). Align the upper air spring and frame bracket (A) (that was previously installed) slots and attach using two 3/8”-16 X 1.25” carriage bolts (G), two flat washers (K) and two nyloc nuts (J). Repeat for the opposite side and leave hardware loose at this time. (G) (K) (G) (J) fig.
LoadLifter 5000 ATTACHING THE LOWER BRACKETS 1. Raise the axle or lower the frame and make sure the lower bracket has nested over the jounce bumper strike plate (Figs. 12 & 13). (J) (K) Jounce Bumper Strike Plate (H) Finished view of installed Lower Bracket (K) (F) fig. 12 fig. 13 2. Attach the lower bracket by inserting a hex head bolt (H) through a flat washer (K) and J-clamp (F). Install the J-clamp with the short end under the jounce bumper strike plate with the bolt through the lower bracket.
LoadLifter 5000 HEAT SHIELD INSTALLATION NOTE The heat shield is installed on the exhaust pipe at the closest point to the air spring to protect the unit from the radiant heat of the exhaust system. 1. Attach radiator clamps loosely around the exhaust pipe nearest to the spring. 2. Bend the heat shield tab out at a 90˚ angle and again half the distance up at a 90˚ angle to form an “L” shape (Fig. 14). Repeat on the other tab.
LoadLifter 5000 VIEWS OF THE INSTALLED ASSEMBLY 1. Front view of the right (passenger) side assembly (Fig. 17). fig. 17 2. Rear view of the left (driver) side assembly (Fig. 18). fig.
LoadLifter 5000 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 NOTE 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.
LoadLifter 5000 Option 1 Option 2 fig. 21 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). CHECKING FOR LEAKS 1. Inflate the air spring to 30 PSI. 2.
LoadLifter 5000 Before Operating INSTALLATION CHECKLIST (To be completed by installer) Clearance test — Inflate the air springs to 60 PSI and ensure there is at least 1/2” 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. Leak test before road test — Inflate the air springs to 60 PSI, check all connections for leaks with a soapy water solution.
LoadLifter 5000 Product Use, Maintenance and Servicing Minimum Recommended Pressure Maximum Air Pressure 5 PSI 100 PSI MAINTENANCE GUIDELINES NOTE By following the steps below, vehicle owners will obtain the longest life and best results from their air springs. 1. Check the air pressure weekly. 2. Always maintain normal ride height. Never inflate beyond 100 PSI. 3.
LoadLifter 5000 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 GVWR is dangerous and voids the Air Lift warranty. Q. Is it necessary to keep air in the air springs at all times and how much pressure will they need? For LoadLifter 5000 Ultimate, the recommended minimum air pressure is 5 PSI, but it can safely be run at zero air pressure. Q.
LoadLifter 5000 GUIDELINES FOR ADDING AIR 1. Start with the vehicle level or slightly above. 2. When in doubt, always add air. 3. If the front of the vehicle dives while braking, increase the pressure in the front air bags, if equipped. 4. If it is ever suspected that the air bags have bottomed out, increase the pressure (Fig. 2.4). 5. Adjust the pressure up and down to find the best ride. 6. If the vehicle rocks and rolls, adjust the air pressure to reduce movement. 7.
LoadLifter 5000 Choosing the Right On-Board Air Compressor System Add an on-board air compressor sytem to inate and deate your air springs automatically or with the touch of a button — from inside or outside of the vehicle. • For convenient, on-the-go control of your air springs, add an Air Lift on-board air compressor system. • Air Lift on-board air compressor systems eliminate the search for gas stations that have a working compressor, saving you time, energy and money.
LoadLifter 5000 Limited Warranty and Return Policy WHAT THIS WARRANTY COVERS Air Lift Company provides a warranty to the original purchaser of its Load Support Products, for the periods of time listed below, by product line, from the date of original purchase, that the products will be free from defects in workmanship and materials when used on cars and trucks as specified by Air Lift Company and under normal operating conditions, subject to the requirements and exclusions set forth below.
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.
Need Help? Contact our customer service department by calling (800) 248-0892, Monday through Friday. For calls 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.airliftcompany.
