How to Install Air Lift Performance RideControl (97-03 All) on your Ford F-150

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.

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

3. Measure the distance between the frame and the tire. This kit requires a minimum of 6” of clearance for a fully infl ated air spring (Figure 3).

1. Raise the vehicle and remove the wheels.

2. Check the distance between the center of the hub and the bottom edge of the wheel to ensure that it is at the normal ride height recorded above. If not, raise the frame or lower the axle as necessary to restore the original distance.

a. If the vehicle is raised with an axle contact hoist, place axle stands under the frame and lower the axle as needed.

b. If the vehicle is raised with a frame contact hoist, place axle stands under the axle and lower the frame as needed.

c. If the vehicle is raised with a jack and supported with axle stands on the frame, use a fl oor jack to lower the axle.

The tool provided with this kit will assist in proper setup and alignment of the air spring and will also position the upper bracket for drilling the bolt holes. The tool attaches to the upper and lower brackets and is rigid so that it will self-align the upper bracket. The threaded section of the upper part of the tool ensures that the air spring can only be mounted at the correct height. The air spring will work throughout the entire threaded range on the tool. Correct placement depends on the particular vehicle application.

1. Secure the upper bracket (A) to the installation tool (M) using the provided nylon nut (L) (Figure 4).

2. Loosely attach the tool to the lower bracket (B) using 1/2” fl at washer (K) and 1/2” bolt (J). Refer to Figure 4. Leave loose for adjustment.

1. Set the assembly on the leaf spring, over the axle.

2. Secure the lower bracket to the leaf spring with the provided U-bolts (D), fl at washers (F), and lock nuts (E). Torque to 16 ft/lbs.

3. The air spring will expand to 5.1” in diameter at maximum infl ation pressure. Check horizontally along the shaft of the installation tool for suffi cient clearance of 2.50” clearance all around the tool (Figure 8). Be sure to check and adjust any fasteners coming through the frame from the inboard side.

1. Using the slot in the lower bracket, push the upper bracket against the frame rail.

2. Use two nylon nuts on the threaded portion of the tool to adjust the upper bracket so that the legs are fl at against the frame rail and all four holes are in the middle section of the frame rail. The mounting holes must not fall on the rounded edges of the frame rail and at least 1.5” must be left above the top of the upper bracket for air fi tting clearance.

1. CAUTION: Before drilling, check the back side of the frame for clearance issues such as, brake lines, gas lines, electrical lines, etc. Any obstacles will need to be temporarily relocated to clear the area.

2. Center punch the lower rear hole and drill a 3/8” hole.

3. Loosely install a washer head frame bolt (G), large fl at washer (H), and nylock nut (E). Refer to Figure 1.

4. Center punch and drill the forward lower hole.

5. Remove the tool by removing the bolt securing the tool to the lower bracket. Swing the bracket up and remove the nylon nut on the top of the upper bracket. Remove the tool. Save the removed hardware, as it will be reused to mount the air spring.

6. Replace the upper bracket to the mounting location and secure at the lower, forward mounting hole using washer head frame bolt (G), large fl at washer (H), and nylock nut (E) as shown in Figure 1. Tighten securely.

7. Center punch and drill the remaining holes. Insert the washer head frame bolt (G), large fl at washer (H), and a nylock nut (E). Tighten all frame bolts to 44 ft/lbs.

1. Install 90 degree air swivel fi tting (I) to the top of the air spring (Q) (Figure 1). Use a 7/16” open end wrench being careful to tighten on the metal hex nut only. Tighten 1 and 1/2 turns. Do not over tighten. NOTE: This fi tting is precoated with sealant.

2. Guide the fi tting through the center mounting hole in the upper bracket (Figure 1).

3. Attach the air spring to the lower bracket using fl at washer (K) and bolt (J). Leave loose for later adjustment.

4. Install a nylon nut (L) over the air fi tting and onto the upper threadpost of the air spring (Figure 1). Tighten to 4 ft/lbs.

1. IMPORTANT: With the bottom and top of the air spring still loose, infl ate the air spring to approximately 10 p.s.i.

2. Use the slotted adjustment in the lower bracket to correctly align the air spring between the upper and lower brackets. This can be accomplished by lightly 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 7).

3. Tighten the lower mounting bolt with a 3/4” wrench. Hand tight is suffi cient. Do not attempt to hold the air spring with any type of tool.

4. Repeat entire installation procedure for other side.

1. Infl ate the air spring to 30 p.s.i.

2. Spray all connections and the infl ation valves with a solution of 1/5 liquid dish soap and 4/5 water to check for leaks. You should be able to spot leaks easily by looking for bubbles in the soapy water.

3. After the test, defl ate the springs to the minimum pressure required to restore the Normal Ride Height, but not less than 5 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.

1. If there is a problem with the swivel fi tting,

a. Check the air line connection by defl ating the spring and removing the line by pulling the collar against the fi tting and pulling fi 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 fi tting.

b. Check the threaded connection by tightening the swivel fi tting another 1/2 turn. If it still leaks, defl ate the air spring, remove the fi 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.

2. If there is a problem with the infl ation valve,

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

b. Check the air line connection by removing the air line from the barbed type fi tting. CAUTION: Do not cut it off, as this will usually nick the barb and render the fi tting useless. Cut air line off a few inches in front of the fi tting and use a pair of pliers or vice-grips to pull/twist the air line off the fi tting.

3. If the preceding steps have not resolved the problem, call Air Lift Technical Service at 1-800-248-0892 for assistance.

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. See Section XI to repair.

2. Leak test the infl ation valve for leaks at the air line connection or dirt or debris in the valve core. See Section XI to 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.

4. Inspect air line for holes and cracks. Replace as needed.

5. A kink or fold in the air line. Reroute as needed.

You have now tested for all of the most probable leak conditions that can be easily fi xed. 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.

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):

1. Clearance Test - Infl ate the air springs to 60 p.s.i. and ensure there is at least 1/2 “ 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 – Infl ate the air springs to 30p.s.i., check all connections for leaks with a soapy water solution. See pages 8-10 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 suffi 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:

3/8 “ Frame Bolts 44 ft–lbs

U-bolt Lock Nuts 16 ft–lbs

5. Road Test – The vehicle should be road tested after the preceding tests. Infl 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 the air pressure after 24 hours. If the pressure has dropped more than 5 p.s.i., you have a leak that must be fi xed. Either fi x the leak yourself (see page 7) 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 infl 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 fi rst. If any part shows signs of rubbing or abrasion, the source should be identifi ed and moved. 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.

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 infl 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 infl ation valve core before defl ating and removing the air spring. (See page 7).

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 infl 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 infl 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 defl ation or disconnection.

Pressure determination comes down to three things - level vehicle, ride comfort and stability. 

1. Level vehicle  

If the vehicle’s headlights are shining into the trees or the vehicle is leaning to one side, then it is not level (Fig. 39). Raise the air pressure to correct either of these problems and level the vehicle.  

2. Ride comfort  

If the vehicle has a rough or harsh ride it may be due to either too much pressure or not enough (Fig. 40). Try different pressures to determine the best ride comfort.  

3. Stability  

Stability translates into safety and should be the priority, meaning the driver may need to sacrifice a perfectly level and comfortable ride. Stability issues include roll control, bounce, dive during braking and sponginess (Fig. 41). Tuning out these problems usually requires an increase in pressure. 

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. 42).
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. It may be necessary to maintain different pressures on each side of the vehicle.
Loads such as water, fuel, and appliances will cause the vehicle to be heavier on one
side (Fig. 43). As much as a 50 PSI difference is not uncommon.