LoadLifter 5000 Series plus Air Lift Pro Series Installation Guide

LoadLifter 5000 Series plus Air Lift Pro Series

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Specifications:

• Model: Air Lift LoadLifter 5000 series
• Vehicle Compatibility: Ford F350 Dual Rear Wheel
• Kits Available: 57380, 88380, 93380

Product Usage Instructions:

1. System Overview

The system overview provides a diagram (Fig. 1) showing the
components and their locations on the vehicle. Familiarize yourself
with the parts before starting the installation.

2. Hardware and Tools

Each kit includes common parts as well as unique parts specific
to the kit. Refer to the manual for a detailed list of included
hardware. Make sure you have all the necessary tools listed before
beginning the installation.

3. Installing the System

1. Prepare the Vehicle: Ensure the vehicle is
   parked on a level surface and secure it properly before
   starting.

2. Assembling the Air Springs: Follow the
   step-by-step instructions to assemble the air springs according to
   the kit you have.

3. Installing the Air Spring Assemblies: Mount
   the assembled air springs onto the vehicle following the provided
   guidelines.

4. Installing the Air Lines

Properly install the air lines according to the instructions
provided in the manual. Pay attention to details to ensure a secure
connection.

5. Finished Installation

After completing the installation, double-check all connections
and components to ensure everything is secured properly.

6. Before Operating

Review the installation checklist and maintenance guidelines
before operating the vehicle with the installed Air Lift load
support product.

FAQ:

Q: What should I do if I encounter missing or damaged parts

during installation?

A: If you find any missing or damaged parts, please contact Air
Lift customer service at 800-248-0892 for a replacement part.

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SERIES

• Installation Guide

Ford F350 Dual Rear Wheel

Watch the video
Info on Table of Contents page

Kits 57380 | 88380 | 93380

For maximum effectiveness and safety, please read these instructions completely before proceeding with installation.
MN-1193 · Revision 012402 · ERN 10252

Failure to read these instructions can result in an incorrect installation.

Protect your Air Lift Purchase by Completing your Warranty Registration
Thank you for purchasing an Air Lift load support product! Take a photo of your sales receipt and then scan the QR code to complete your online warranty registration.

TABLE OF CONTENTS
2 System Overview 3 Hardware and Tools 4 Introduction
Notation Explanation Identifying the Differences Between Kits
5 Installing the System
Prepare the Vehicle Assembling the Air Springs Installing the Air Spring Assemblies
12 Installing the Air Lines
Installing the Heat Shield
14 Finished Installation 15 Before Operating
Installation Checklist Maintenance and Use Guidelines
16 Limited Warranty and Return Policy
Video-enhanced installation guides
Visit airliftcompany.com/workshop/category/install-videos to access our installation video archive*.

• subject to availability

System Overview
P I D J E Q F
G
K

M H

B

C

VW

L

A V W

2

• Passenger’s (right) Side
  T U N R
  K
  F
  S
  Fig. 1
  MN-1193

Hardware and Tools
Common Parts Included in All 3 Kits

Unique Parts in Each Kit

Item Part# A 01531 B 03014 C 03223 D 07045 E 07220 H 11770 I 17361 J 17366 K 17387 L 17500 M 18404 P 18622 Q 18422 R 21837 V 18444 W 18435 AA 20086 BB 10466 CC 21230 DD 18411 EE 21234 FF 18501 GG 21233 HH 09484 II 10613 JJ 10741 KK* 10555

Description ……………………………………………… Qty Clamp bar ……………………………………………………. 2 Lower bracket, main plate ……………………………… 2 Lower bracket, cup ……………………………………….. 2 Upper bracket, frame…………………………………….. 2 Upper bracket, air spring ……………………………….. 2 U-bolt ………………………………………………………….. 2 3/8″-16 x 1 1/4″ Carriage bolt…………………………. 8 M10-1.5 x 35 Button-head cap screw ……………… 4 3/8″-16 x 10″ Carriage bolt…………………………….. 4 5/16″-18 x 3/4″ Carriage bolt………………………….. 2 5/16″-18 Serrated flange lock nut……………………. 2 M10-1.5 Universal nut……………………………………. 4 3/8″-16 Serrated flange lock nut……………………… 8 Push-to- connect (PTC) fitting …………………………. 2 3/8″ Flat washer……………………………………………. 8 3/8″-16 Nylon lock nut …………………………………… 8 Air line assembly…………………………………………… 1 Zip ties………………………………………………………… 6 Valve cap …………………………………………………….. 2 Star washer………………………………………………….. 2 Rubber washer …………………………………………….. 2 M8 Flat washer …………………………………………….. 2 5/16″ Hex nut ………………………………………………. 4 Thermal Sleeve …………………………………………….. 1 Heat Shield ………………………………………………….. 1 4 1/2″ Clamp ……………………………………………….. 2 3 1/2″ Clamp ……………………………………………….. 2

• These parts are not shown in the System Overview (Fig.1).

TOOLS NEEDED
Description…………………………………………………………………. Qty Standard and metric open-end or box wrenches ………………………… SET Ratchet …………………………………………………………………………………………………..1 Standard and metric sockets……………………………………………………………….SET 5/16″ drill bit (very sharp) ……………………………………………………………… 1 9/16″ Crow’s foot adapter …………………………………………………………….. 1 9/16″ ratchet combo wrench…………………………………………………………. 1 Heavy-duty drill …………………………………………………………………………… 1 Torque wrench…………………………………………………………………………….. 1 Standard and metric hex-key wrenches …………………………………………. 1 Flat-tip screwdriver………………………………………………………………………. 1 Hose cutter, razor blade, or sharp knife ………………………………………….. 1 Hoist or floor jacks ………………………………………………………………………. 1 Safety stands………………………………………………………………………………. 2 Safety glasses …………………………………………………………………………….. 1 Air compressor or compressed air source ………………………………………. 1 Spray bottle with dish soap/water solution……………………………………… 1
The photos in this manual show the LoadLifter 5000 kit.

KIT 57380

Item Part# F 11951 G 58437 N 18444 S 17215 T 17203 U 18427

Description ……………………………………………… Qty Roll plate (silver zinc-plated) …………………………… 4 Air spring……………………………………………………… 2 3/8″ Flat washer……………………………………………. 4 3/8″-24 x 3/4″ Flat-head socket-cap screw ……… 4 3/8″-24 x 7/8″ Hex-cap screw ………………………… 4 3/8″ Lock washer ………………………………………….. 4

KIT 88380

Item Part# F 11967 G 58496 N 18444 S 17215 T 17203 U 18427

Description ……………………………………………… Qty Roll plate (black powder coat) ………………………… 4 Air spring w/ jounce bumper…………………………… 2 3/8″ Flat washer……………………………………………. 4 3/8″-24 x 3/4″ Flat-head socket-cap screw ……… 4 3/8″-24 x 7/8″ Hex-cap screw ………………………… 4 3/8″ Lock washer ………………………………………….. 4

KIT 93380

Item Part# F 11951 G 58937 N 18507 S 17363 T 17284 U 18504 II* 21838

Description ……………………………………………… Qty Roll plate (silver zinc-plated) …………………………… 4 Air spring……………………………………………………… 2 3/8″ Stainless steel flat washer……………………….. 4 3/8″-24 x 3/4″ Stainless FHSC screw………………. 4 3/8″-24 x 7/8″ Stainless steel hex-cap screw……. 4 3/8″ Stainless steel lock washer …………………….. 4 Tee fitting……………………………………………………… 1

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

MN-1193

3

Introduction
The purpose of this publication is to assist with the installation and maintenance of the LoadLifter 5000 series and Air Lift ProSeries air spring kits. All LoadLifter 5000 series and Air Lift ProSeries 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 series and Air Lift ProSeries 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. Information 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 installation guide.
INDICATES IMMEDIATE HAZARDS WHICH WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH.
INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.

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 standard Air Lift ProSeries. The kits are easily identifiable by looking at the end caps on the air spring and the roll plates.
Standard LoadLifter 5000TM — Plastic end cap and Zinc-plated steel roll plates.
LoadLifter 5000TM Ultimate — Plastic end cap and Black powdercoated roll plates.
Standard Air Lift® ProSeries — Aluminum end cap and Zinc-plated steel roll plates.

LoadLifter 5000 Plastic end cap

LoadLifter 5000 silver zinc-plated steel roll plate

LoadLifter 5000 Ultimate Plastic end cap

LoadLifter 5000 Ultimate black powder-coated roll plate

INDICATES HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN DAMAGE TO THE MACHINE OR MINOR PERSONAL INJURY.

Used to help emphasize areas
NOTE of procedural importance and
provide helpful suggestions.
4

Air Lift ProSeries Aluminum end cap

Air Lift ProSeries silver zinc-plated steel roll plate
MN-1193

• Installing the System
  PREPARE THE VEHICLE
  1. Raise the vehicle and support it, using safety stands or equivalent, so that the axle can be safely lowered away from the frame. This needs to be done in order for the air spring assembly to be put into position between the axle and frame (Fig. 2).
  2. Unbolt and remove the jounce bumper assembly from under the frame on both sides (Fig. 3).
  3. Remove the clip-in studs by prying on the hinged end with a screwdriver. Pull all four (two from each side) out from the frame (Fig. 4).
  MN-1193

Fig. 2
Fig. 3
Fig. 4
5

4. Install the universal nuts (P) into the frame rail, lining up the holes in the frame and the threads in the nuts so that a bolt can be installed (Fig. 5).
TECH A flat-tip screwdriver works well in installing the TIP universal nut into position.

• P

Fig. 5
5. Insert the 3/8″-16 x 1 1/4″ carriage bolts (I) into the upper frame brackets (D). Install the upper bracket onto the frame using the M10-1.5 x 35mm button-head cap screws (J). The slot on the side of the bracket should be inboard of the frame rail (Fig. 6). The elongated hole should be toward the front of the truck (Fig. 7). Torque hardware to 38 lb.-ft. (52Nm).
Front of truck

Elongated hole

Inboard

Fig. 6

This slot in the bracket goes inboard, away from leaf spring and tire

ASSEMBLING THE AIR SPRINGS
1. Set a roll plate (F) on top of the air spring (G). The radiused, or rounded, edge of the roll plate should be toward the air spring so that it is seated inside the roll plate (Fig. 8). Install the 90-degree swivel fitting (R) into the port on top of the air spring finger-tight plus 1 1/2 turns.
G

6

Fig. 7
R F
Fig. 8
MN-1193

• 2. Set the upper air spring bracket (E) onto the top of the air spring using one set of holes with the 3/8″-24 x 7/8″ hex-cap screw (T), 3/8″ lock washer (U) and 3/8″ flat washer (N) (Fig. 9). Install the remaining air spring bracket onto the remaining air spring, using the opposite holes from those that were previously used. This makes the air spring assemblies into left- and right-hand units. Torque the hardware to no more than 20 lb.-ft. (27Nm).
  3. Flip the assemblies over and set a roll plate (F) onto the bottom of the air springs (Fig. 10).

Driver’s (left) side assembly
E

Passenger’s (right) side assembly

T U N
Fig. 9

F

4. Insert two 3/8″-16 X

10″ carriage bolts (K)

B

through the square holes

in the lower bracket main

plate (B) as shown. For

models with sway bars:

use the holes farthest

away from the flanges for the left (driver’s) side and the holes closest to the flanges for the right (passenger’s) side installation (Fig. 11). For all models without sway

For all models, left (driver side) only, use these holes for installing Carriage Bolts (B).

bars, use the square

holes farthest away from

the flange for both sides

of the installation.

MN-1193

Fig. 10

For models with sway bars, right (passenger side) only, use these holes for installing Carriage Bolts (B).

The assembly

being shown

is for sway

bar-equipped

K

Flange

vehicles and is right (passenger)

side specific.

Fig. 11

7

5. When installing the lower brackets onto the air spring assemblies already assembled (step 2, Fig. 9), if you have a sway bar-equipped vehicle, make sure the lower bracket assembly you assembled for the passenger’s (right) side is assembled on the passenger’s (right) side air spring assembly. Using the holes specified in step 4, for vehicles not equipped with sway bars, it will not matter which assembly the lower bracket fits on.
Set the lower bracket main plate assemblies onto the air springs with the roll plates installed. Attach with 3/8″-24 X 3/4″ flat-head socket-cap screws (S) (Fig. 12). Torque the hardware to no more than 20 lbs.-ft. (27Nm).

The flanges on the lower bracket must be installed so they are on the opposite side of the fitting that is on the top of the air spring.
S

The flange on the lower bracket must be on
NOTE the opposite side of the fitting that is located
on the top of the air spring.

Fig. 12

6. Install the lower bracket cup (C) onto the lower bracket main plate using the 5/16″-18 x 3/4″ carriage bolt (L) (Fig. 13). Cap with 5/16″-18 serrated flange lock nut (M) (Fig. 14) Snug bolt down but leave loose enough for bracket to move freely in slot.

C

L
Fig. 13
7. Figure 15 shows the driver’s (left) side and passenger’s (right) side assemblies.

M
Fig. 14

Driver’s (left) side assembly
8

Passenger’s (right) side assembly
Fig. 15

MN-1193

INSTALLING THE AIR SPRING ASSEMBLIES
1. Remove the left-side wire harness from the axle bracket and secure it to the right-side wire harness, as shown in Figure 16.

NOTE

If there is a sway bar, insert the carriage bolts through the clamp bar (A) while setting the assemblies into position over the axle (see Fig. 20).

2. With the vehicle supported by safety stands, drop the axle or raise the body so that the assemblies can be put into position in between the axle and frame.
3. Install the U-bolt (H) around the leaf pack spacer (Fig. 17).

BB

Fig. 16

Fig. 17

4. Install the U-bolt through the middle holes on the bracket as you install the assembly onto the vehicle (Fig. 18).

NOTE

On the driver’s (left) side, the long carriage bolt in the lower bracket main plate should be located between the hard brake line and axle (Fig. 23). On the passenger’s (right) side, the carriage bolt should be located on the backside of the brake line (Fig. 24).

5. Cap with the 3/8″ flat washer (V) and 3/8″ nylon lock nut (W) as shown in Figure 18. Snug bolts evenly, just enough to hold the lower bracket main plate flush against the stock U-bolts.

W

H

V

Fig. 18

MN-1193

9

6. Before proceeding, ensure the 90-degree fittings each point inboard toward the center of the vehicle. While raising the axle or lowering the body of the vehicle, align the previously installed upper frame bracket carriage bolts with the air spring bracket holes so the carriage bolts protrude through the air spring bracket. Cap the carriage bolts with the 3/8″ serrated flange lock nuts (Q) (Fig. 19). Snug the bolts down first then torque to 31 lb.-ft. (42Nm). Finish raising the axle or lowering the body and remove safety stands.

7. If not completed, set the lower clamp bars (A) over the carriage bolts located under the axle (Fig. 20). Attach with the 3/8″ flat washers (V) and 3/8″ nylon lock nuts (W). Evenly torque the lower clamp bar hardware to 16 lb.-ft. (22Nm). Finish tightening the U-bolt hardware previously snugged by torquing to 10 lb.-ft. (14Nm).

TECH TIP

For sway bar applications, it’s acceptable to tighten the front carriage bolt hardware down more than the rear to gain more clearance on the sway bar. Also, it may be necessary to use a 9/16″ crows foot adapter to properly torque the hardware.

8. If necessary, on vehicles that have a sway bar, cut the front carriage bolt just below the nut so it does not contact the sway bar (Fig. 21).

10

• Q
  Fig. 19
  A V W
  Fig. 20
  Fig. 21
  MN-1193

9. Snug the nut holding the lower bracket main plate and lower bracket cup together to finish the lower bracket installation (Fig. 22).

NOTE

This nut will be difficult to tighten. It may be necessary to flip the wrench over a couple of times and/or move from the front/back side of the axle to get this tightened.

10.Fig. 23 and Fig. 24 show the lower bracket installed.
PUSH THE HARD BRAKE LINE AWAY FROM THE LOWER BRACKET CARRIAGE BOLT IF THE LINE IS RESTING ON IT (FIG. 23 & FIG. 24).

Fig. 22

MN-1193

Fig. 23

If the hard brake line is resting on the lower bracket carriage bolts on either side, push or pull the brake line out of the way.

Fig. 24
11

• Installing the Air Lines
  1. Choose the locations for the Schrader valves and drill a 5/16″ (8mm) hole, if necessary.

A.

B.

A. Inside fuel tank filler door B. Inside rear wheel wells

MICHIGAN
XXX-XXX www.MICHIGAN.gov
C. C. License plate or
rear bumper area

KEEP AT LEAST 6″ (152MM) OF CLEARANCE BETWEEN ALL AIR LINES AND THE EXHAUST SYSTEM. AVOID SHARP BENDS AND EDGES.

2. Make clean, square cuts with a razor blade or hose cutter when cutting the air line (AA). Do not use scissors or wire cutters.

Good cut

Bad cut

3. Use zip ties (BB) to secure the air line to fixed points along the chassis. Do not pinch or kink the air line. Leave at least 2″ (51mm) of slack in the air line to allow for any movement that might pull on the air line. The minimum bend radius for the air line is 1″ (25mm).
4. Install the Schrader valve in the chosen location.

Vehicle body or bumper

Hex nuts (GG)

Schrader valve

Nylon air line (AA) routed to the air spring
Star washer (DD)

Valve cap (CC)

Rubber washer (EE)

Flat washer (FF)

5/16″ (8mm) hole

12

MN-1193

• INSTALLING THE HEAT SHIELD
  1. Attach the metal heat shield (II) to the exhaust pipe or exhaust resonator using the hose clamps (JJ, KK or both). Slide the air line thermal sleeve (HH) over the air line and place it where the air line is closest to the exhaust.

1/2″ (13MM)

DEAD AIR SPACE

KK

BETWEEN SHIELD

AND EXHAUST

II
DOUBLE HOSE CLAMPS IF NECESSARY

HH JJ KK OR BOTH

EXHAUST RESONATOR

II

BEND TABS

MN-1193

13

• Finished Installation
  This image shows the finished installation of the passenger’s (right) side.

Congratulations!
You are now the proud owner of an Air Lift air suspension system. Enjoy!

14

MN-1193

Before Operating
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 air lines. 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 — After 500 miles (800km), recheck all bolts for proper torque.
Road test — The vehicle should be road-tested after the initial tests. Inflate the air 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.
4. Upon successful completion of the installation, follow these pressure requirements for the air springs.

5 PSI .34BAR

100 PSI 7BAR

Minimum Recommended Air Pressure

Maximum Air Pressure

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

MN-1193

15

• Limited Warranty and Return Policy
  Air Lift Company provides a Limited Lifetime Warranty to the original purchaser of its load support products, 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 in the full Limited Warranty and Return Policy. Full Limited Warranty and Return Policy are available at www.airliftcompany.com/warranty and are subject to change.
  WARRANTY REGISTRATION & CLAIMS
  · To register your warranty, please visit https://www.airliftcompany.com/support/warranty/register/ · To submit a warranty claim, please visit https://www.airliftcompany.com/support/warranty /submit-claim/

16

MN-1193

Thank you for purchasing Air Lift Products!
Need Help?
Contact Air Lift Company Customer Service at 800-248-0892 or email service@airliftcompany.com.
For calls outside the U.S. or Canada, dial +1 517-322-2144.

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.

Printed in the USA JJC-0224

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

References

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

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