AIR LIFT LoadLifter 5000 Ultimate Plus Air Suspension Kit Installation Guide

AIR LIFT LoadLifter 5000 Ultimate Plus Air Suspension Kit

Specifications:

• Product: Air Lift LoadLifter 5000 Series
• Model : RAM 1500
• Kits Available: 57375, 88375, 89375
• Drive Type: 4WD

Product Usage Instructions

• Installation Diagram
  • Refer to the provided diagram for a visual guide on how to install the Air Lift LoadLifter 5000 Series.
• Hardware and Tools Lists
  • Make sure you have all the necessary hardware and tools listed before starting the installation process.
• Introduction
  • Get familiar with the product and its components by reading through the introduction section.
  • Notation Explanation: Understand the symbols and notations used in the manual for better comprehension.
  • Installing the LoadLifter 5000 Series System
• Preparing the Vehicle:
  • Ensure the vehicle is properly prepared for installation, following the outlined steps in the manual.
• Assembling the Air Springs:
  • Follow the instructions to assemble the air springs correctly for optimal performance.
• Installing the Upper Brace:
  • Securely install the upper brace according to the provided guidelines.
• Installing the Assemblies:
  • Properly install the assemblies as directed in the manual to ensure stability and functionality.

Installing the Air Lines

• Installing Nylon Air Lines:
  • Step-by-step instructions on how to install and connect the nylon air lines are included in the kit.
• Installing Braided Stainless Steel Air Lines:
  • If applicable, follow the specific instructions for installing braided stainless steel air lines for enhanced durability.
• Installing the Heat Shield:
  • Ensure proper installation of the heat shield to protect the airlines and maintain optimal performance.

Finished Installation

• Installation Checklist:
  • Review the installation checklist to confirm all steps have been completed accurately.
• Maintenance and Use Guidelines:
  • Find guidelines on how to maintain and use the Air Lift LoadLifter 5000 Series for longevity and efficiency.
• Limited Warranty and Return Policy:
  • Refer to the warranty and return policy information provided for any queries regarding product coverage.

FAQ :

• Q: How do I identify which kit I have?
  • A : Check the roll plates and airlines as described in the manual. Standard LoadLifter 5000 has zinc-plated steel roll plates and black nylon air lines, while LoadLifter 5000 Ultimate has black-powder-coated roll plates and black nylon air lines. LoadLifter5000 Ultimate Plus features stainless steel roll plates, braided stainless steel air lines, and stainless steel air spring mounting hardware.

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.

IDENTIFYING

IDENTIFYING THE DIFFERENCES BETWEEN KITS

Should you need to contact Air Lift customer service, you will need to know which kit you are inquiring about standard LoadLifter 5000, LoadLifter 5000 Ultimate or LoadLifter 5000 Ultimate Plus. The kits are easily identifiable by looking at the roll plates and airlines.

• Standard LoadLifter 5000 — Zinc-plated steel roll plates and black nylon air lines.
• LoadLifter 5000 Ultimate — Black powder-coated roll plates and black nylon air lines.
• LoadLifter 5000 Ultimate Plus — Stainless steel roll plates, braided stainless steel air lines, stainless steel air spring mounting hardware.

Air Lift offers two Ultimate Plus upgrade kits:

• 52300 – Braided stainless steel air line and fittings.
• 52301 – Stainless steel roll plates, air spring mounting hardware, braided stainless steel air lines and fittings.

Installation Diagram

• CAUTION
  • PROFESSIONAL MECHANIC SKILLS ARE REQUIRED TO COMPLETE THE INSTALLATION OF THIS KIT.

Hardware and Tools Lists

Common Parts Included in All 3 Kits

• These parts are not shown in the Installation Diagram (Fig. A.1).

TOOLS LIST

The photos in this manual show the LoadLifter 5000 kit.

Unique Parts in Each Kit

LoadLifter 5000″ KIT 57375

LoadLifter 5000

**Load Lifter 5000***

Missing or damaged parts? Call Air Lift customer service at 800-248-0892 for a replacement part.

Introduction

The purpose of this publication is to assist with the installation and maintenance of the LoadLifter 5000 series air spring kits. All LoadLifter 5000 series kits utilize sturdy, reinforced, commercial-grade single or double, depending on the kit, convolute bellows.

The air springs are manufactured like a tire with layers of rubber and cords that control growth. LoadLifter 5000 kits provide up to 5,000 pounds (2,268kg) of load-leveling support with air adjustability from 5-100 PSI (.34-7BAR).

It is important to read and understand the entire installation guide before beginning installation or performing any maintenance, service or repair.

NOTATION EXPLANATION

Hazard notations appear in various locations in this publication. The 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.

• DANGER?: INDICATES IMMEDIATE HAZARDS THAT WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH.
• WARNING: INDICATES HAZARDS OR UNSAFE PRACTICES THAT COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.
• CAUTION: INDICATES HAZARDS OR UNSAFE PRACTICES THAT COULD RESULT IN DAMAGE TO THE MACHINE OR MINOR PERSONAL INJURY.

Installing the LoadLifter 5000 Series System

PREPARING THE VEHICLE

1. Lift the vehicle and support the frame with safety stands. Leave enough room to drop the axle down low enough to set the air spring assemblies into position between the frame and axle (Fia D 1)
2. Twist and pull the jounce bumpers to remove them from the mounting cups (Fig. D.2).
3. Strike a line using a china marker or equivalent, on the jounce bumper bracket, beside and above the bottom of the frame (Fig. D.3). Use a die grinder or angle grinder with a cut-off wheel to cut along the line on the bracket. Stop slightly short of the frame
   • It may be necessary to grind down some weld if the weld travels under your cut on the bracket and frame.
   • NOTE: DO NOT CUT INTO THE FRAME WITH THE CUT-OFF WHEEL. STOP SHORT AND TAP
   • CAUTION: THE BRACKET WITH A HAMMER FOR FINAL REMOVAL FROM THE FRAME.

4. Remove the sharp edges with the cut-off wheel. Clean and paint the exposed surfaces of the remainder of the jounce bumper bracket that will be left on the frame (Fig. D.4).
5. The brake line holder that is on the inside of the left side frame, above the axle, will need to be spaced up to make room for the upper brace (Fig. D.5). Do this by removing the stock bolt (discard), then insert the spacer (F) between the holder and bracket; finally attach the line holder back onto the bracket using the M8-1.25 x 35 hex flange bolt (H). Tighten securely.

ASSEMBLING THE AIR SPRINGS

Place the roll plates (D) on the air springs (Fig. D.6). Install the elbow swivel air fittings (J) on the air springs (E). Tighten the air fittings finger-tight plus 1 1/2 turns.

1. Place the roll plates (D) on the air springs (Fig. D.6). Install the elbow swivel air fittings (J) on the air springs (E). Tighten the air fittings finger-tight plus 1 1/2 turns. These assemblies will be left- and right-hand specific once assembled.
   • NOTE: These assemblies will be left- and right-hand specific once assembled.
2. For LoadLifter 5000 Ultimate Plus, install the braided stainless steel air line (DD) (Fig. D.7). Tighten the air line hex nut finger-tight, then use 2 wrenches to turn 1 additional flat (1/6 of one full turn). Do not over-tighten. For additional information on installing the braided stainless steel air line, see E. Installing the Air Lines — Installing Braided Stainless Steel Air Lines.
3. Attach the upper brackets (B) and roll plates with 3/8”-24 x 7/8” hex cap screws (L), 3/8” split lock washers (M) and 3/8” flat washers (N). Leave loose at this time.
4. Attach the roll plate, left-hand lower bracket (A1) and right-hand lower bracket (A2)with 3/8”-24 x 3/4” flat-head socket cap screws (K) and torque to no more than 20 lb.-ft. (27Nm).
   • Note: the orientation of the brackets in Fig. D.6.
5. Fig. D.8 shows the completed air spring assemblies for LoadLifter 5000 and LoadLifter 5000 Ultimate kits. LoadLifter Ultimate Plus kits would have the braided stainless steel air line.

INSTALLING

INSTALLING THE UPPER BRACE

1. Using the 3/8” wire bolt leader tools (O), thread over two 3/8”-16 x 1” carriage bolts (G) (Fig. D.9).
2. Insert the tools with the carriage bolts, through the two slots using the square hole in the frame to guide them through (Fig. D.10).
3. Once the carriage bolts are in position, insert the tools through the holes in the brace (C) (Fig. D.11) and push the brace up against the frame.
4. Carefully remove (twist off) the tool from the top carriage bolt first and install the 3/8”-16 serrated flange nuts (I). Tighten the nuts finger-tight only (Fig. D.12). Carefully remove the tool from the bottom carriage bolt and repeat. Leave both nuts loose.Repeat for the right side.

INSTALLING THE ASSEMBLIES

1. Index a 3/8”-16 x 1” carriage bolt (G) into the opening on the front of the driver’s (left) side assembly as shown (Fig. D.13).
2. Drop the axle if not done so already, to gain clearance to put the two assemblies into position on the axle.
3. Set the driver’s (left) side assembly into position with the carriage bolt (previously installed) still in the slot. Set into place on the axle, making sure the back of the bracket is “hooked” below the jounce bumper strike plate. Push the assembly forward while lining up the carriage bolt with the existing hole in the front of the lower jounce bumper strike plate (Figs. D.14 & D.15). Install a 3/8”-16 serrated flange nut (I) onto the carriage bolt (G), but leave loose at this time.
4. Insert another 3/8” carriage bolt (G) through the corresponding hole in the front side of the bracket (Fig. D.16).
5. It will be necessary to use a socket with an extension to reach the inside threads on the carriage bolt previously set into position (Figs. D.17 & D.18) to install the 3/8”-16 serrated flange nut (I). It may be helpful to pull the carriage bolt out slightly so that it can be angled enough to get the nut started on the threads.
6. Install the passenger’s (right) side in the same way and torque all of the lower hardware to 31 lb.-ft. (42Nm).
7. Raise the axle up just enough so that the upper brackets meet the braces. Insert the 3/8”-16 x 1” carriage bolts (G) up through the square holes in the upper brackets and through the braces (Fig. D.19). Install the 3/8”-16 serrated flange nuts (I) onto the carriage bolts. Snug the nuts but do not tighten at this time.
   • TECH TIP: It may be helpful to use a pair of needle nose pliers to help guide the carriage bolts into place.
8. Making sure that the upper brackets are flat to the frame (Fig. D.20). Push the upper assembly forward as far as it can go until the upper brace butts against the jounce bumper bracket that was left on the frame (Fig. D.21). Torque the frame brace hardware first, then the upper bracket to brace hardware to 31 lb.-ft. (42Nm).
   • NOTE: The lower nut on the frame/brace interface may be hard to get to on the passenger’s (right) side because of the exhaust, if it is not accessible with the torque wrench and socket, use a ratcheting wrench and tighten securely
9. Raise the axle and remove the safety stands.
10. Adjust the upper air spring assembly so it is as close to perpendicular as possible to the upper and lower brackets by moving it within the slot in the upper bracket (Fig. D.22).
11. Tighten the upper bracket/air spring hardware using a 3/8” ratcheting wrench. Since there is no way to access these bolts with a torque wrench, snug the bolts only. Do not over-tighten.
    • NOTE: The air spring assemblies will not be perfectly aligned when complete. This is an acceptable condition.

Installing the Air Lines

Airlines are routed from the air springs to Schrader valves. LoadLifter 5000 series air lines come in two styles: nylon and braided stainless steel. Begin by choosing locations for the Schrader valves and drill a 5/16” (8mm) hole, if necessary (Fig. E.1).

CAUTION: KEEP AT LEAST 6” (150) OF CLEARANCE BETWEEN ALL AIRLINES AND THE EXHAUST SYSTEM. AVOID SHARP BENDS AND EDGES.

INSTALLING NYLON AIRLINES

1. For nylon air line, it is recommended that the airline be routed along the top of the frame, forward of the axle, then down to the fitting (Fig. E.2). After cutting the airline to length, install the air line thermal sleeve over the airline on the passenger’s(right) side before inserting into the fitting. Secure the airlines to the upper coil spring mount with zip ties (BB) supplied. Also, see Figure E.8.
2. Cut the air line in half. Make clean, square cuts with a razor blade or hose cutter (Fig. E.3). Do not use scissors or wire cutters.
3. Use zip ties to secure the air line to fixed points along the chassis. Do not pinch or kink the air line. The minimum bend radius for the airline is 1” (25mm). Leave at least 2” (50mm) of slack in the air line to allow for any movement that might pull on the airline.
4. Install the Schrader valve in the chosen location (Fig. E.4).

INSTALLING BRAIDED STAINLESS STEEL AIR LINES

• *  **CAUTION:** KEEP THE AIRLINE AWAY FROM THE FUEL LINE, BRAKE LINES AND ELECTRICAL WIRES.

  • NOTE: The braided stainless steel airline must be routed to the rear of the vehicle. Install the air line through one of the openings between the upper coil spring mount and the frame and then back to the rear where the inflation valves will be mounted (Fig. E.5).

1. Use zip ties to secure the airline to fixed points along the chassis every 6” to 8” (150- 200mm). Leave at least 2” (50mm) of slack to allow for any movement that might pull on the air line.
2. Tighten the airline hex nut finger-tight, then use 2 wrenches to turn 1 additional flat (1/6 of one full turn). Do not overtighten (Figs. E.6 or E.7). The easiest way to tighten the fitting is off the vehicle. Install the Schrader valve in the chosen location.
3. Coil and secure any excess airline in an area where it will not be susceptible to damage. The braided stainless steel air line cannot be trimmed.

Air Line Setup for Compressor Integration

INSTALLING THE HEAT SHIELD

1. Attach the metal heat shield to the exhaust where it is closest to the passenger’s (right) side air spring (Fig. E.8).

Finished Installation

1. The images show the finished installation of both sides (Figs. F.1, F.2, F.3 & F.4).

INSTALLATION CHECKLIST

• Clearance test — Inflate the air springs to 40-60 PSI (2.8-4.1BAR) and make sure there is at least 1/2” (13mm) clearance from anything that might rub against each sleeve. Be sure to check the tire, brakes, frame, shock absorbers, and brake cables.
• Leak test before road test — Inflate the air springs to 40-60 PSI (2.8-4.1BAR) and check all connections for leaks. All leaks must be eliminated before the vehicle is road-tested.
• Heat test — Be sure there is sufficient clearance from heat sources, at least 6” (152mm) for air springs and airlines. If a heat shield was included in the kit, install it. If there is no heat shield, but one is required, call Air Lift customer service at 800-248-0892.
• Fastener test — Recheck all bolts for proper torque.
• Road test — The vehicle should be road tested after the preceding tests. Inflate the springs to recommended driving pressures. Drive the vehicle 10 miles (16km) and recheck for clearance, loose fasteners, and air leaks.
• Operating instructions — If professionally installed, the installer should review the operating instructions with the owner. Be sure to provide the owner with all of the paperwork that came with the kit.

MAINTENANCE AND USE GUIDELINES

1. Check air pressure weekly.
2. Always maintain normal ride height. Never inflate beyond 100 PSI (7BAR).
3. If the system develops an air leak, use a soapy water solution to check all air line connections and the inflation valve core before deflating and removing the air spring.

CAUTION: FOR SAFETY AND TO PREVENT POSSIBLE DAMAGE TO THE VEHICLE, DO NOT EXCEED THE MAXIMUM GROSS VEHICLE WEIGHT RATING (GVWR) OR PAYLOAD RATING, AS INDICATED BY THE VEHICLE MANUFACTURER.

CAUTION: ALTHOUGH THE AIR SPRINGS ARE RATED AT A MAXIMUM INFLATION PRESSURE OF 100 PSI (7BAR), THE AIR PRESSURE ACTUALLY NEEDED IS DEPENDENT ON LOAD AND GROSS VEHICLE WEIGHT RATING.

LIMITED WARRANTY AND RETURN POLICY

Air Lift Company provides a limited lifetime warranty to the original purchaser of its load support products, 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 in the full Limited Warranty and Return Policy that is available at www.airliftcompany.com/warranty.

For additional warranty information contact Air Lift Company customer service.

Thank you for purchasing Air Lift Products — the Authorized Installer’s choice!

Need Help?

• Contact Air Lift Company’s customer service department by calling 800-248-0892.
• For calls from outside the USA or Canada, dial 517-322-2144.
• Need Help?
• Contact Air Lift Company Customer Service at 800-248-0892 or email [email protected].
• For calls outside the U.S. or Canada, dial 517-322-2144.
• Air Lift Company
• 2727 Snow Road
• Lansing, MI 48917 or P.O. Box 80167
• Lansing, MI 48908-0167

Air Lift Company reserves the right to make changes and improvements to its products and publications at any time. For the latest version of this manual, contact Air Lift Company at 800-248-0892 or visit airliftcompany.com

California:

• WARNING: Cancer and Reproductive Harm
• www.P65Warnings.ca.gov

References

• SOM - State of Michigan
• P65Warnings.ca.gov

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