Air Lift 59537 Installation guide

Technical Support

1-800-248-0892

Ext. 2

MN-461

(021108)

ECR 7136

Please read these instructions completely before proceeding with installation

Air Spring Kit Parts List

Item Description Quantity

A Air Sleeves 2

B Upper Brackets 2

C Lower Brackets 2

D Jounce Bumper Spacer 2

E LowProleElbowFitting 2

Air Spring Attaching Hardware

Item Description Quantity

/2 “ x

/8 “ Hex Head Bolts 2

/4 “ Hex Jam Nut 2

/2”FlatWashers 2

AirLineAssemblyParts

List

Item Description Quantity

AA AirLineAssembly 1

BB Tie Strap 6

CC Valve Caps 2

/16”FlatWasher 2

EE RubberWasher 2

FF SmallStarWasher 2

/16” Hex Nut 4

HH Hose Clip 4

CC EE FFDD

Bracket Attaching Hardware

Item Description Quantity

F

/8 “-16 U-Bolts 2

G Clamp Bar 2

/8 “NylockNuts 6

/8 “FlatWashers 6

/8 “x1”WHST 6

/8 “ x 1” HHCS 2

Kit No. 59537

Technical Support

1-800-248-0892

Ext. 2

Tools Needed

IMPORTANT:Yourvehiclemaybeequippedwitharearbrakeproportioningvalve.Anytypeofloadassist

productcouldaffectbrakeperformance.Werecommendthatyoucheckwithyourdealerbeforeinstalling

thistypeofproduct.IfyourvehicleDOESNOThavearearbrakeproportioningvalveorisequippedwithan

anti-locktypebrakesystem,installationofaloadassistproductwillhaveNOEFFECTONBRAKESYSTEM

PERFORMANCE.

IMPORTANT: Failuretomaintaincorrectminimumpressure(orpressureproportionaltoload),bottoming

out,overextension,orrubbingagainstanothercomponentwillvoidthewarranty.

DANGER:Compressedaircancauseinjuryanddamagetothevehicleandpartsifitisnothandledproperly.

Foryoursafety,donottrytoinatetheairspringsuntiltheyhavebeenproperlysecuredtothevehicle.

Standardandmetricopenendorboxwrenches

Ratchet with

/8”,

/2”,&

/16” deep well sockets

/16”drillbit(verysharp)

/16”&

/16” Nut Drivers

HeavyDutyDrill

TorqueWrench

HoseCutter,RazorBlade,orSharpKnife

HoistorFloorJacks

SafetyStands

SafetyGlasses

AirCompressor,orCompressedAirSource

SprayBottlewithDishSoap/WaterSolution

I.GettingStarted

1.Determine the Normal Ride Height.The Normal Ride

Height is the distance between the bottom edge of the

wheel-well and the center of the hub with the vehicle

in the “as delivered” condition.Insomecases,Normal

RideHeightisnotperfectlylevel.

a. Removeunusualloadsandexamineyourvehiclefrom

thesidetoensureitisonalevelsurface(Figure1).

b. If necessary (in cases where your leaf springs are

saggingbadly),useajacktoraisetherearendsothat

the vehicle achieves the original “as delivered” ride

height.

2.Measurethedistancebetweenthecenterofthehuband

thebottomedgeofthewheelwell(Figure2).Thisisthe

NormalRideHeight.Enterthemeasurementbelow:

 NORMAL

 RIDEHEIGHT:__________inches

Figure 1

Figure 2

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Ext. 2

II.AssemblingtheAirSpringUnit

1.Install90degreeairswiveltting(E)tothetopoftheair

spring.Useanopenendwrenchbeingcarefultotighten

onthemetalhexnutonly.Tighten1and

/2turns(Figure

3).Donotovertighten.

NOTE: This fitting is precoated with sealant.

2.Set upper bracket (B) over the tting and thread post

(Figure4).Positiontheelbowtowardsthefrontorrearof

the vehicle depending on which direction will allow easier

accessfortheairline.

3.Threadnylonnut(M)ontothethreadpost,makingsure

thattheatsideisup(Figure5).

4.Tightenthenylonnut.Handtightissufcient.

IMPORTANT: Ensure that the bracket is tight and flat

to the roll plate on both sides.

5.Looselyattachthelowerbracket(E)tothebottomofthe

air spring with

/2”atwasher(N)and

/2” Hex Head Cap

Screw(L).SeeFigure6.

Figure 3

Figure 4

Figure 5

Figure 6

3/4" Nylon Nut

Air Spring

Upper Bracket

Nylon nut must be threaded

on the thread post with the

curved edge toward the

sleeve.

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III.InstallingtheJounceSpacer

1.Forheavyloadusage,werecommendinstallingajounce

bumperstrikeplatespacer(D)underthestockstrikeplate

(Figure7).

2.Position the strike plate spacer (D) ush with the back

bottom edge of the stock strike plate and mark the

mountingholelocationusingapencilormarker(Figure

8).

3.Centerpunchanddrilla

/8”holeinthestockstrikeplate.

NOTE: In order to gain more accessibility for drilling

the mounting hole, it may be necessary to drop the

axle. Keep safety in mind and use safety stands if

needed.

4.Boltthestrikeplatespacertostockstrikeplateusinga

/8”

bolt(K),twowashers(I),andanylocknut(H).SeeFigure

10.Torqueto16ft-lbs.

IV.MountingtheLowerBracket

IMPORTANT: If the axle was dropped to install the jounce

strike plate spacer, it will be necessary to raise it back to

the normal ride height recorded on page 2.

1.Withthevehicleatnormalrideheight,withthehookendof

thelowerbracketoverthefactoryU-bolt,settheairspring

assemblyonthe leafspringforwardof theaxle(Figure

11).

2.SecurethelowerbrackettotheleafspringusingU-bolt

(F),clampbar(G),atwasher(I),andnylocknut(H).See

Figure12.Tightento16ft-lbs.

Figure 7

Figure 8

Figure 10

Figure 9

Figure 11

Jounce

Strike Plate

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V.LocatingtheUpperBracket

1. Theupperbracketmustbeparallelandperpendiculartothe

lowerbracketasshownintheillustrationinFigure13.

2.Aligntheupperbracketsothattheshortlegoftheupper

brackettouchesthebottomoftheframerail(Figure14).

3.Usingtheupperbracketasatemplate,centerpunchone

hole(Figure15).AweldingclamporC-clampmayassist

inholdingtheupperbrackettotheframe.

NOTE: It is necessary to use at least three of the five

pre-drilled holes in the upper bracket for mounting.Any

combinationofthethreeispermissible.

4.CAUTION: Before drilling, be sure to check the back

side of the frame rail for brake lines, gas lines, or

electrical lines that may be in the way. It is necessary

to move any interfering lines prior to drilling.

5.Drillone

/16”holeandinstalloneWHST(J).SeeFigure

16.Tightento15ft-lbs.

IMPORTANT: Check again to make sure that the upper

and lower brackets are parallel and perpendicular to

each other (Figure 13).

6.Centerpunch and drill remaining two holes and install

theWHST(J).Again, torque to15ft-lbs.Donot over

tighten.

VI.InstallingtheOtherSide

1. Installtheminimum/maximumairpressuredecalinahighly

visiblelocation.

2.Repeatentireinstallationprocedureforremainingside.

3.ContinuewithsectionVII,InstallingtheAirLines.

Figure 12

Figure 13

Figure 15

Figure 14

Figure 16

Frame

Rail

Upper

Bracket

Fitthebottom

oftheupper

brackettightto

theframerail

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/16” Nut

RubberWasher

FlatWasher

/16” Nut

StarWasher

VehicleBodyor

Bumper

VII.InstallingtheAirLines

1.Chooseaconvenientlocation for mounting the ination

valves.Popularlocationsfortheinationvalveare:

a. Thewheelwellanges.

b. Licenseplaterecessinbumper.

c. Underthegascapaccessdoor.

d. Throughlicenseplateitself.

NOTE: What ever the chosen location is, make sure

there is enough clearance around the inflation valves

for an air chuck.

2.Drilla

/16 “holetoinstalltheinationvalves.

3.Cuttheairlineassembly(AA)intwoequallengths(Figure

17).

CAUTION: When cutting or trimming the air line, use a

hose cutter (Air Lift P/N 10530), a razor blade or a sharp

knife. A clean, square cut will ensure against leaks.

(Figure 18a). Do not use wire cutters or scissors to

cut the air line. These tools may flatten or crimp the

air line, causing it to leak around the O-ring seal inside

the elbow fitting (Figure 18b).

4.Placea

/16 “nut(GG)andastarwasher(FF)ontheair

valve.Leaveenoughoftheinationvalveinfrontofthenut

toextendthroughtheholeandhaveroomfortherubber

washer (EE), at washer (DD), and

/16 “ nut (GG) and

cap(CC).Thereshouldbeenoughvalveexposedafter

installation-approximately

/2 “-toeasilyapplyapressure

gaugeoranairchuck(Figure19).

5.Push the ination valve through the hole and use the

rubberwasher(EE),atwasher(DD),andanother

/16 “

nut(GG)tosecureitinplace.Tightenthenutstosecure

theassemblyinplace(Figure20).

Figure 17

Figure 18a Figure 18b

Figure 19

Good cut – clean and

square

Badcut–attened

Figure 20

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6.Routetheairlinealongtheframetotheairttingontheair

spring.Keepatleast6”ofclearancebetweentheairline

andheatsources,suchastheexhaustpipes,mufer,or

catalyticconverter.Avoidsharpbendsandedges.Use

theplastictiestraps(BB)tosecuretheairlinetoxed,

non-movingpointsalongthechassis(Figure21).Besure

thatthetiestrapsaretight,butdonotpinchtheairline.

Wheretherearenoholestosecurethestrapsto,usethe

airlineclip(HH)andselftapper(II)tosecuretheairlineto

theframe(Figure22).Leaveatleast2”ofslacktoallow

foranymovementthatmightpullontheairline.

7.Cutoffairlineleavingapproximately12”ofextraairline.

Acleansquarecutwillensureagainstleaks.Insertthe

airlineintotheairtting.Thisisapushtoconnecttting.

Simplypushtheairlineintothe90°swivelttinguntilit

bottomsout(

/16”ofairlineshouldbeinthetting).

Figure 21

Figure 22

Figure 23

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VIII.AligningtheAirSprings

1.IMPORTANT:Withthebottomoftheairspringstillloose,

inatetheairspringtoapproximately10p.s.i.Usethe

slottedadjustmentinthelowerbrackettocorrectlyalign

theairspringbetweentheupperandlowerbracket.This

canbeaccomplishedbytappingitinboardoroutboardfor

properalignment.Thereshouldbeasymmetricalcushion

of air around the base of the air spring when correctly

positioned.Figure24representsamisalignedairspring.

Figure25showsaproperlyalignedairspring.

2.When aligned, tighten the lower end by holding the air

springandturningtheboltwitha

/4” open end wrench

(Figure26).Snug(10ft-lbs)willbesufcientandwillalso

preventstrippingthethreads.Do not attempt to hold the

air spring with any type of tool.

3.Figure27showsthecompletedinstallation.

Figure 24

Figure 25

Figure 26

Figure 27

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Valve

Core

Barbed

Air Line

Connection

IX.CheckingforLeaks

1.Inatetheairspringto60p.s.i.

2. Sprayallconnectionsandtheinationvalveswithasolution

of

/5liquiddishsoapand

/5watertocheckforleaks(Figure

28).Youshouldbeabletospotleakseasilybylookingfor

bubblesinthesoapywater.

3.Afterthetest,deatethespringstothe minimumpressure

requiredtorestoretheNormalRideHeight,butnotless

than10p.s.i.

4. IMPORTANT:Checktheairpressureagainafter24hours.

A2to4p.s.i. lossafterinitialinstallationisnormal.Retest

forleaksifthelossismorethan5lbs.

X.FixingLeaks

Ifthereisaproblemwiththeswiveltting,then:

a. Checktheairline connectionbydeatingthespring

andremovingthelinebypullingthecollaragainstthe

ttingandpullingrmlyontheairline.Trim1”offthe

endoftheairline.Besurethecutiscleanandsquare.

Reinserttheairlineintothepush-to-connecttting.See

Figure29.

b. Checkthethreadedconnectionbytighteningtheswivel

tting another

/2 turn.If it still leaks, deate the air

spring,removethetting,andre-coatthethreadswith

thread

sealant.Reinstallbyhandtighteningasmuch

aspossible,thenuseawrenchforanadditionaltwo

turns.SeeFigure29.

2.Ifthereisaproblemwiththeinationvalve,then:

a. Checkthevalvecorebytighteningtheitwithavalve

coretool.

b. Checktheairlineconnection(Figure30)byremoving

the air line from the barbed type tting.CAUTION:

Do not cut it off. As this will usually nick the barb

and render the fitting useless. Cutairlineoffafew

inchesinfrontofthettinganduseapairofpliersor

vise-gripstopull/twisttheairlineoffthetting.

3.If the preceding steps have not resolved the problem,

call Air Lift Technical Service at 1-800-248-0892 for

assistance.

Figure 28

Figure 29

Figure 30

Air Line

Connection

Collar

SwivelFitting

Threaded

Connection

Technical Support

1-800-248-0892

Ext. 2

Figure 31

Figure 32

Figure 33

Figure 34

XI.TroubleshootingGuide

Problems maintaining air pressure, without on-board

compressor.

1.Leaktesttheairlineconnectionsandthreadedconnection

oftheelbowintotheairspring(Figure28).SeeSection

Xtorepair.

2.Leak test the inflation valve for leaks at the air line

connectionordirtordebrisinthevalvecore(Figure31).

SeeSectionXforrepair.

3. Inspectairlinestobesureitisnotpinched.Tiestrapsmay

betootight.Loosenorreplacestrap.Replaceleaking

components(Figure32).

4.Inspectairlineforholesandcracks(Figure33).Replace

asneeded.

5.A kink or fold in the air line (Figure 34).Reroute as

needed.

You have now tested for all of the most probable leak

conditions that can be easily fixed. At this point the

problem is most likely a failed air spring - either a factory

defect or an operating problem. Please call Air Lift at 1-800-

248-0892 for assistance or a replacement air spring.

Technical Support

1-800-248-0892

Ext. 2

XI.Checklist

You can protect your warranty on this product and prevent unnecessary wear by ensuring the following

checks have been made:

SectionI–Installation(Tobecompletedbytheinstaller):

SectionII-PostInstallationChecklist(Tobecompletedbytheowner):

1. ClearanceTest-Inatetheairspringsto60p.s.i.andensurethereisatleast

/2 “ clearance around

eachsleevefromanythingthatmightrubagainstthem.Besuretocheckthetire,brakedrum,frame,

shockabsorbersandbrakecables.

2. LeakTestBeforeRoadTest–Inatetheairspringsto60p.s.i.,checkallconnectionsforleakswith

asoapywatersolution.Seepages9and10ofthemanualfortipsonhowtospotleaks.Allleaks

mustbeeliminatedbeforethevehicleisroadtested.

3. HeatTest–Besurethereissufcientclearancefromheatsources-atleast6”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1-800-248-0892.

4. FastenerTest–Recheckallboltsforpropertorque.

TorqueGuide:

 WHST     15ft-lbs

 U-boltLockNuts   16ft-lbs

 LowerBoltforAirSpring  10ft-lbs

5. RoadTest–Thevehicleshouldberoadtestedaftertheprecedingtests.Inatethespringsto25

p.s.i.(50p.s.i.ifvehicleisloaded).Drivethevehicle10milesandrecheckforclearance,loose

fastenersand/orairleaks.

6. OperatingInstructions–Ifprofessionallyinstalled,

theinstallershould

reviewtheoperatinginstructions

onpage12withtheowner.Besuretoprovidetheownerwithallofthepaperworkthatcamewith

thekit.

1.OvernightLeakdownTest–Recheckairpressureaftervehiclehasbeenusedfor24hours.If

pressurehasdroppedmorethan5p.s.i.then,youhavealeakthatmustbexed.Eitherxthe

leakyourself(seepages9and10)orreturntotheinstallerforservice.

2.AirPressureRequirements–Iunderstandthattheairpressurerequirementsofmyairspring

systemareasfollows:

   Minimum___________Maximum___________

IalsounderstandthatImustinatetheairspringsuntiltheRideHeightmeasurementthatwas

recordedonpage2hasbeenrestored.Regardlessofload,theairpressureshouldalwaysbe

adjustedsothattheRideHeightismaintainedatalltimes.

3.ThirtyDayor500MileTest.IunderstandthatImustrechecktheairspringsystemafter30

daysor500miles,whichevercomesrst.Ifanypartshowssignsofrubbingorabrasion,the

sourceshouldbeidentiedandmoved,ifpossible.Ifit isnotpossibletorelocatethecauseof

theabrasion,the

airspringmayneedtoberemounted.If

professionallyinstalled,theinstaller

shouldbeconsulted.Checkallfastenersfortightness.

Technical Support

1-800-248-0892

Ext. 2

“The Choice of the Professional Installer”

ForTechnicalAssistancecall1-800-248-0892

Thank you for purchasing Air Lift Products

MailingAddress: StreetAddress:

AIRLIFTCOMPANY AIRLIFTCOMPANY

P.O.Box80167 2727SnowRd.

Lansing,MI48908-0167 Lansing,MI48917

LocalPhone:(517)322-2144

Fax:(517)322-0240

Printed in the USA

XII.MaintenanceandOperations

Byfollowingthesesteps,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inatebeyond100p.s.i.

3.Ifyoudevelopanairleakinthesystem,useasoapywatersolutiontocheckallairlineconnectionsand

theinationvalvecorebeforedeatingandremovingtheairspring.(Seepage9.)

4.Whenincreasing load,alwaysadjusttheairpressuretomaintaintheNormalRideHeight.Increase

ordecreasepressurefromthesystemasnecessarytoattainNormalRideHeightforoptimalrideand

handling.Rememberthatloadscarriedbehindtheaxle(includingtongueloads)requiremoreleveling

force(pressure)thanthosecarrieddirectlyovertheaxle.

5.IMPORTANT:Foryoursafetyandtopreventpossibledamagetoyourvehicle,do not exceed maximum

Gross Vehicle Weight Rating (GVWR), as indicated by the vehicle manufacturer.Althoughyour

airspringsareratedatamaximuminationpressureof100p.s.i.Theairpressureactuallyneeded

isdependantonyourloadandGVWR,whichmaybelessthan100p.s.i.Checkyourvehicleowners

manualanddonotexceedthemaximumloadlistedforyourvehicle.

6.Alwaysaddairtospringsinsmallquantities,checkingthepressurefrequently.Sleevesrequirelessair

volumethanatireandinatequickly.

7.Should it become necessary to raise the vehicle by the frame, make sure the system is at minimum

pressure (5 p.s.i.) to reduce the tension on the suspension/brake components. Use of on–board

leveling systems do not require deflation or disconnection.

5p.s.i.

100p.s.i.

Failure to maintain correct minimum pressure (or pressure proportional to

load), bottoming out, over-extension, or rubbing against another component

will void the warranty.

Maximum Air PressureMinimum Air Pressure

Air Lift 59537 Installation guide

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