WORKING MAN’S LEVELING KIT

AIR LIFT’S LOAD LIFTER 7500 XL FOR ’17 SUPER DUTY FORDS

As payload and towing capacities for newer trucks continue to rise, owners are looking to haul more cargo than ever before. But as the real-world often reminds us, just because a truck is rated to handle a given amount of weight doesn’t guarantee everything will go off without a hitch (no pun intended). Excessive tongue weight, an unleveled payload, or an improperly positioned load can lead to a truck that squats, rides uncomfortably, and suffers from poor braking, steering, or headlight aim. To eliminate (or vastly reduce) any of the latter instances from occurring, thousands of truck owners have begun to turn to airspring suspension systems.

Air Lift recently debuted its strongest air spring kit yet: the Load Lifter 7500 XL system. Offering up to 7,500 pounds of load-leveling capacity, it’s designed to support the largest loads on the road. We stopped by Flynn’s Shop in Alexander, Illinois, where a ’17 F-350 was being fitted with the Load Lifter 7500 XL. Read on to see why this is the new king of the hill in aftermarket air spring systems.DW

FREQUENTLY ASKED QUESTIONS

What are the overall impressions of the Air Lift LoadLifter and WirelessONE system after installation?

After installing the Air Lift LoadLifter and WirelessONE system, users are generally impressed with the enhancements in both stability and ride quality. The improvements in handling are immediately noticeable, making the driving experience more comfortable and secure. Additionally, the system stands out for its user-friendly nature, from the initial setup to daily operation.

The air bags significantly enhance the vehicle’s performance, especially when towing, and the WirelessONE system adds a convenient layer of control, though it’s not strictly necessary for the airbags to function effectively. For anyone serious about optimizing their tow vehicle, this system is usually considered a must-have upgrade.

What challenges might be encountered during the installation of the air spring kit?

On trucks equipped with anti-sway bars, possible trimming of the front 10-inch carriage bolt may be required. This wasn’t the case in our install, but might be on other ’17 Super Duty trucks.

However, one of the more challenging aspects we encountered involved electrical connections. Specifically, attaching the ground wire required drilling a hole into the frame. The self-tapping screw provided in the kit fell short of expectations, leading us to drill a pilot hole. This task was complicated by the tight space between the frame and the body, which made maneuvering a drill cumbersome and time-consuming.

Key points to consider:

• Carriage Bolt Trimming:May be necessary on certain models with anti-sway bars.
• Ground Wire Installation:Be prepared for potential drilling challenges due to space constraints.

By keeping these challenges in mind, you can be better prepared for a smoother installation process.

What is a time-consuming aspect of the installation?

Drilling a pilot hole can take additional time, particularly when dealing with tight spaces that restrict tool movement.

What space constraints might affect the installation process?

Limited room between the frame and the body can make it challenging to use a drill, complicating certain tasks.

What difficulties might arise with the provided installation components?

The self-tapping screw included in the kit might not perform as expected, necessitating additional effort to complete the installation.

What specific tools or modifications might be needed during installation?

You may need to use a drill and drill bit to create a pilot hole if the provided self-tapping screw does not work effectively.

What is the installation process like for the Air Lift LoadLifter system and WirelessONE compressor?

Using a two-post lift, the folks at Flynn’s Shop raised the ’17 F-350 in a way that relaxed the rear suspension and allowed the axle to drop away from the frame. Then they got started by unbolting the bump stops (shown) and removing their respective clip-in studs from the frame with a flat head screwdriver. In place of the OEM clip-in studs, the supplied universal nuts were installed in the frame rail. Two M10-1.5 x 35mm button head cap screws thread into each universal nut, which effectively attaches the included upper chassis brackets to the frame rails.

Tools and Preparation

Before getting into the nitty-gritty of the installation, make sure you have a socket set, tube cutter, torque wrench, hex sockets, and maybe a drill with a 5/16” bit on hand. These basic tools will cover most of the installation needs.

Installation Process

With the supplied 3/8-inch x 1.25-inch carriage bolts inserted in the upper chassis brackets and the brackets’ large cut-outs facing inward, the aforementioned button head cap screws were installed and torqued to 38 ft-lb. Piecing together both air spring assemblies would come next. We were pleasantly surprised to find the supplied swivel elbow fittings pre-wrapped with Teflon tape. For extra insurance, the guys at Flynn’s added a light coat of sealant in addition to the existing Teflon tape, and then threaded them into the top of each air spring.

Once a roll plate had been placed on top of each air spring, the upper air spring brackets were installed. Here, the driver-side assembly is shown on the right and the passenger-side unit on the left. A pair of 10-inch-long, 3/8-inch carriage bolts anchor the lower portion of the air spring assemblies to the axle, with the aid of clamp bars and nylon lock nuts. In this photo, the supplied 3/8-inch x 7/8-inch hex bolts that secure the lower bracket to the air spring are being torqued to 20 ft-lb.

The roll plates that come with the Air Lift Load Lifter 7500 XL kit are responsible for increasing load capacity by up to 10 percent. An additional hidden benefit is that they protect the air springs from possible abrasion. Air Lift’sLoad Lifter 7500 XL kit only carries one part number for ’17 Super Duties (PN 57599), but comes with three different lower leg adapters for the lower air spring bracket—with each one being specific to a different truck model (F-250, F-350, or F-450). In order to install the correct adapter, the rear axle tube’s diameter must be measured. Being that our truck was an F-350, it came equipped with a 4.0-inch diameter axle (vs. 3.5-inch on the F-250 and 4.5-inch on the F-450).

Challenges and Solutions

The air spring assemblies were flipped over, fitted with a roll plate, and then the lower bracket cups were fastened to the lower brackets’ main plates (shown). The lower bracket cup is where the air spring assembly rides on the factory bump stop perch (i.e., striker plate). This is what the lower leg adapter looks like once installed. It’s a brace that adds support to the lower air spring mounting bracket and spans the distance from the bracket to the axle. On trucks equipped with anti-sway bars, possible trimming of the front 10-inch carriage bolt may be required. This wasn’t the case in our install, but might be on other ’17 Super Duty trucks.

Once the lower bracket cup was in position on the bump stop perch and the lower bracket was flush against the leaf spring stack, the driver-side air spring assembly was set in place. After the guys at Flynn’s confirmed that the lower bracket flanges were locked around the truck’s factory U-bolts, the supplied U-bolts were added as well (shown). One U-bolt effectively anchors each air spring assembly to its respective leaf spring pack. Cinching everything down comes by way of a clamp bar, which installs over the 10-inch-long carriage bolts and mates flush against the axle tube. The supplied 3/8-inch nylon lock nuts that secure the clamp bar get torqued to 16 ft-lb.

Routing and Finalizing

Utilizing the plastic air line supplied in the Air Lift kit, the guys at Flynn’s used compressed air to effectively raise the air springs up so that they could be connected to the upper chassis brackets. Otherwise, the truck would’ve had to have been lowered to the ground (and the suspension compressed). With the springs aired up, installing the supplied 3/8-inch nylon lock nuts to the upper chassis bracket carriage bolts was a piece of cake. Like the 3/8-inch nuts on the clamp bar, they too were torqued to 16 ft-lb.

It’s worth noting that a ’17 Super Duty equipped with a 5-inch-diameter aftermarket exhaust system and a conventional-exit tailpipe may have clearance issues near the passenger-side top roll plate. This is because of the larger roll plates being used to accommodate the larger diameter air springs in the Load Lifter 7500 XL system. From what we observed in our install, 4-inch aftermarket exhaust systems should be fine.

This burly upper frame brace reinforces the passenger-side air spring assembly. On trucks equipped with a factory-installed fifth-wheel hitch, installation of this brace calls for the removal of the fifth-wheel bracket hardware. The upper frame brace anchors to the frame by way of the supplied 4.5-inch-long, 5/8-inch Grade 8 bolts and the corresponding nuts and washers. The guys at Flynn’s torqued the upper frame brace bolts to 50 ft-lb. Like the driver side upper frame brace, 3/8-inch nylon lock nuts were used to tighten the frame brace to the upper chassis bracket.

With both air spring assemblies in place, each fastener was torqued for the final time. The axle tube vent (driver side) was then zip-tied to a soft brake line to ensure it never comes into contact with the driver side air spring. Then it was time to route the air lines and install the wireless control system. For hassle-free operation and utmost convenience, the truck’s owner opted for Air Lift’s Wireless Air Control System (PN 72000), which features an onboard air compressor, air manifold, air line, wire harness, and (of course) a wireless controller.

The Wireless Air system is universal and can work in conjunction with any Air Lift kit, or any aftermarket air spring system for that matter. Thanks to its compact size, the heavy-duty compressor can be mounted just about anywhere under the truck. The guys at Flynn’s chose to place it in front of the fuel tank, along the inside portion of the driver side frame rail. Mounting the compressor required four 7/32” holes being drilled in the frame. Weather-resistant and equipped with a filter that drains automatically, the air manifold supplied in the Wireless Air kit can keep pressure inside the springs within 3 psi of one another. And thanks to the supplied harness plugging into the manifold, the only time-consuming portion of wiring the system up entailed tapping into the truck’s ignition circuit for a 15-amp power source.

User Experience

The Wireless Air controller provides complete control at your fingertips. Beyond the easy-to-read LCD screen, programmable settings can be established (for the trailers or loads you haul most often), pressure adjustments can be made on the fly, and any leaks or other problems can be relayed to the driver through the handheld device.

With these comprehensive steps and insights, even those with moderate mechanical skills can tackle this installation, transforming their truck’s suspension system with confidence.

What challenges might arise, and how can they be addressed?

A common challenge is grounding the compressor, as drilling a hole might be necessary. If the self-tapping screw does not work well, drilling a pilot hole can help.

What are some practical tips or shortcuts during installation?

One practical tip is that removing the wheels is not strictly necessary, though it can make the process easier. Using a jack is only needed to lift the rear end slightly.

Are there any preparatory steps or considerations before starting the installation?

It’s beneficial to review the provided instructions and watch installation videos online to become familiar with the process before beginning.

How accessible is the installation process for an average handyman?

The process is straightforward and accessible, even for those who consider themselves average handymen, thanks to clear instructions and available online resources.

What tools are needed for installation?

The installation requires basic tools such as a socket set, tube cutter, torque wrench, hex sockets, and possibly a drill with a 5/16” bit.

What is the main purpose of the Air Lift LoadLifter 7500 XL Air Spring Kit?

Air Lift recently debuted its strongest air spring kit yet: the LoadLifter 7500 XL system. Offering up to 7,500 pounds of load-leveling capacity, it’s designed to support the largest loads on the road.

For those considering an upgrade to a fifth-wheel trailer or simply wanting the peace of mind that comes with extra capacity, this kit perfectly fits the bill. While it may seem like overkill for smaller trailers, having the additional support can make all the difference when towing heavier loads.

Whether you’re hauling a bumper pull trailer today or planning for future upgrades, the LoadLifter 7500 XL ensures you’re always prepared for whatever the road throws your way.

What potential future use is anticipated?

There is a possibility of switching to a fifth-wheel trailer in the future, which requires more robust load support, justifying the choice of the LoadLifter 7500 XL.

Is the LoadLifter 7500 XL necessary for the current application?

While the kit may exceed current needs, the additional capacity is considered advantageous, ensuring readiness for heavier loads without compromising performance.

Why was the LoadLifter 7500 XL chosen?

The LoadLifter 7500 XL was selected to enhance the load-leveling capacity, particularly in anticipation of potentially upgrading from a bumper pull trailer to a fifth wheel, which demands greater support.

How did the ride quality change after installing the Air Lift LoadLifter 7500 XL system?

Essentially, good ride quality can still be enjoyed no matter the load with the Load Lifter 7500 XL system. The transformation in ride dynamics is immediately noticeable. With the weight distribution hitch engaged, the previously persistent bucking while towing is substantially reduced. This improvement enhances comfort and control on the road.

Moreover, even when the hitch isn’t in use, the system’s benefits are clear. The bucking is significantly decreased, ensuring a smoother ride. When not under any load, there is a slight increase in stiffness at the back end. This added firmness contributes to a stable and well-balanced drive, highlighting the system’s versatility across various conditions.

In summary, the Load Lifter 7500 XL system elevates ride quality, providing a consistently reliable and comfortable experience, whether you’re towing a heavy load or driving without one.

Can the Air Lift air spring system be used without the WirelessONE compressor?

Thanks to its compact size, the heavy-duty compressor can be mounted just about anywhere under the truck. The guys at Flynn’s chose to place it in front of the fuel tank, along the inside portion of the driver side frame rail. Mounting the compressor required four 7/32” holes being drilled in the frame.

If you’re wondering whether you can use the air spring system without the WirelessONE compressor, the answer is yes. If budget is a concern, you can initially opt for just the air bags and consider adding the WirelessONEcompressor later. This modular approach allows you to spread out the cost while still benefiting from the system’s essential functions.

With this setup, you have the flexibility to upgrade when you’re ready, making it a practical choice for those looking to improve their vehicle’s performance without breaking the bank.

What should I do if I’m on a tight budget?

If budget constraints are a concern, begin with the air bags and plan to upgrade to the full kit when your finances allow.

Is it possible to upgrade the system later?

Absolutely, you can enhance your setup by adding the WirelessONE compressor at a later time.

Can the Air Lift air spring system be used without the WirelessONE compressor?

Yes, you can start with just the air bags and add the WirelessONE compressor later if desired.

What are the benefits of using the WirelessONE compressor with air springs?

For hassle-free operation and utmost convenience, the truck’s owner opted for Air Lift’s Wireless Air Control System (PN 72000), which features an onboard air compressor, air manifold, air line, wire harness, and (of course) a wireless controller. The Wireless Air system is universal and can work in conjunction with any Air Lift kit, or any aftermarket air spring system for that matter.

User Experience Benefits

Once you have the presets programmed, the system allows for a one-touch operation, making inflating and deflating air springs quick and effortless. This simplicity can be a game-changer, especially in everyday scenarios like pulling up to a storage unit or campsite. Imagine the ease of just inflating the bags without having to remember to do it beforehand or carrying an extra piece of equipment.

Thanks to its compact size, the heavy-duty compressor can be mounted just about anywhere under the truck. The guys at Flynn’s chose to place it in front of the fuel tank, along the inside portion of the driver side frame rail. Mounting the compressor required four 7/32” holes being drilled in the frame. Weather-resistant and equipped with a filter that drains automatically, the air manifold supplied in the Wireless Air kit can keep pressure inside the springs within 3 psi of one another.

Convenience On-the-Go

The versatility of being able to adjust air pressure on the fly means you can easily explore without being tethered to equipment. The Wireless Air controller provides complete control at your fingertips. Beyond the easy-to-read LCD screen, programmable settings can be established (for the trailers or loads you haul most often), pressure adjustments can be made on the fly, and any leaks or other problems can be relayed to the driver through the handheld device.

The supplied harness plugs into the manifold, and the only time-consuming portion of wiring the system up entailed tapping into the truck’s ignition circuit for a 15-amp power source. This thoughtful design reduces hassle, ensuring that the system is as user-friendly as it is functional.

With these features combined, the Wireless Air system not only enhances your vehicle’s functionality but also simplifies your life, whether you’re on the road or at a campsite.

Is the system beneficial when making unscheduled or last-minute adjustments?

Yes, the system is very adaptable for unscheduled or last-minute adjustments, allowing for quick inflation or deflation without pre-planning, making it perfect for on-the-go changes.

What are the advantages of using the WirelessONE system over manual inflation?

The WirelessONE system offers the convenience of not having to carry extra equipment or manually check PSI levels. Its automated features save time and effort.

In what practical situations does the WirelessONE system prove beneficial?

The system is beneficial in various scenarios, such as when retrieving a trailer from storage or while camping. It allows for quick inflation of the air springs whenever necessary.

How easy is it to use the WirelessONE compressor?

The WirelessONE compressor is designed for simplicity with its one-touch operation, especially once you’ve set up the presets. This makes it exceptionally user-friendly and efficient for quick adjustments.

What features does the WirelessONE compressor offer for air spring adjustments?

“For hassle-free operation and utmost convenience, the truck’s owner opted for Air Lift’s Wireless Air Control System (PN 72000), which features an onboard air compressor, air manifold, air line, wire harness, and (of course) a wireless controller. The Wireless Air system is universal and can work in conjunction with any Air Lift kit, or any aftermarket air spring system for that matter. Thanks to its compact size, the heavy-duty compressor can be mounted just about anywhere under the truck. The guys at Flynn’s chose to place it in front of the fuel tank, along the inside portion of the driver side frame rail. Mounting the compressor required four 7/32” holes being drilled in the frame. Weather-resistant and equipped with a filter that drains automatically, the air manifold supplied in the Wireless Air kit can keep pressure inside the springs within 3 psi of one another. And thanks to the supplied harness plugging into the manifold, the only time-consuming portion of wiring the system up entailed tapping into the truck’s ignition circuit for a 15-amp power source.

Real-World Convenience

The Wireless Air controller provides complete control at your fingertips. Beyond the easy-to-read LCD screen, programmable settings can be established for the trailers or loads you haul most often. Pressure adjustments can be made on the fly, and any leaks or other problems can be relayed to the driver through the handheld device.

Imagine pulling up to a storage unit and effortlessly inflating the air springs with just a touch. This kind of convenience is invaluable, especially when remembering to inflate beforehand is often overlooked. The ability to adjust air pressure on the go means you can set off on an adventure without the hassle of additional equipment or manual PSI checks.

Whether you’re at a campsite or on a quick detour, the versatility of this system ensures your truck is always ready. With the WirelessONE, you experience seamless air spring adjustments without unnecessary distractions, making it a worthy consideration for those who value simplicity and efficiency.”

What tools are required for installing the Air Lift LoadLifter air springs?

Installation Tools and Procedure for Air Lift Load Lifter 7500 XL

Before diving into the installation process, it’s crucial to gather the necessary tools. Here’s a comprehensive list to ensure a smooth installation:

• Socket Set: Essential for handling various nuts and bolts throughout the process.
• Tube Cutter: Useful for precisely cutting the airline to the desired length.
• Torque Wrench: To accurately apply the specified torque settings.
• Hex Sockets: Needed for installing certain bolts and screws.
• Drill with 5/16” Bit: May be required for drilling tasks during installation.

While Flynn’s Shop installed a system on a ’17 Ford Super Duty for this story, the 7500 XL is also available for 2011-16 Super Duties, 2011-17 Chevy/GMC HDs, 2003-13 Ram 2500 models, and 2003-17 Ram 3500s. Made by Goodyear, the commercial-grade, double-convolute air springs included in the Air Lift Load Lifter 7500 XL system employ layers of rubber and cords to control growth. Their 7-inch diameter (vs. The 6-inch diameter in Load Lifter 5000 systems) provides 20 percent more air spring volume and allows greater leveling strength at lower pressures. Essentially, good ride quality can still be enjoyed no matter the load with the Load Lifter 7500 XL system.

Using a two-post lift, the folks at Flynn’s Shop raised the ’17 F-350 in a way that relaxed the rear suspension and allowed the axle to drop away from the frame. Then they got started by unbolting the bump stops (shown) and removing their respective clip-in studs from the frame with a flathead screwdriver. In place of the OEM clip-in studs, the supplied universal nuts were installed in the frame rail. Two M10-1.5 x 35mm button head cap screws thread into each universal nut, which effectively attaches the included upper chassis brackets to the frame rails. With the supplied 3/8-inch x 1.25-inch carriage bolts inserted in the upper chassis brackets and the brackets’ large cut-outs facing inward, the aforementioned button head cap screws were installed and torqued to 38 ft-lb.

Piecing together both air spring assemblies would come next. We were pleasantly surprised to find the supplied swivel elbow fittings pre-wrapped with Teflon tape. For extra insurance, the guys at Flynn’s added a light coat of sealant in addition to the existing Teflon tape, and then threaded them into the top of each air spring. Once a roll plate had been placed on top of each air spring, the upper air spring brackets were installed. Here, the driver-side assembly is shown on the right and the passenger-side unit on the left. A pair of 10-inch-long, 3/8-inch carriage bolts anchor the lower portion of the air spring assemblies to the axle, with the aid of clamp bars and nylon lock nuts. In this photo, the supplied 3/8-inch x 7/8-inch hex bolts that secure the lower bracket to the air spring are being torqued to 20 ft-lb.

The roll plates that come with the Air Lift Load Lifter 7500 XL kit are responsible for increasing load capacity by up to 10 percent. An additional hidden benefit is that they protect the air springs from possible abrasion. Air Lift’s Load Lifter 7500 XL kit only carries one part number for ’17 Super Duties (PN 57599), but comes with three different lower leg adapters for the lower air spring bracket—with each one being specific to a different truck model (F-250, F-350, or F-450). In order to install the correct adapter, the rear axle tube’s diameter must be measured. Being that our truck was an F-350, it came equipped with a 4.0-inch diameter axle (vs. 3.5-inch on the F-250 and 4.5-inch on the F-450).

Next, the air spring assemblies were flipped over, fitted with a roll plate, and then the lower bracket cups were fastened to the lower brackets’ main plates (shown). The lower bracket cup is where the air spring assembly rides on the factory bump stop perch (i.e., striker plate). This is what the lower leg adapter looks like once installed. It’s a brace that adds support to the lower air spring mounting bracket and spans the distance from the bracket to the axle. On trucks equipped with anti-sway bars, possible trimming of the front 10-inch carriage bolt may be required. This wasn’t the case in our install, but might be on other ’17 Super Duty trucks.

Once the lower bracket cup was in position on the bump stop perch and the lower bracket was flush against the leaf spring stack, the driver-side air spring assembly was set in place. After the guys at Flynn’s confirmed that the lower bracket flanges were locked around the truck’s factory U-bolts, the supplied U-bolts were added as well (shown). One U-bolt effectively anchors each air spring assembly to its respective leaf spring pack. Cinching everything down comes by way of a clamp bar, which installs over the 10-inch-long carriage bolts and mates flush against the axle tube. The supplied 3/8-inch nylon lock nuts that secure the clamp bar get torqued to 16 ft-lb.

Utilizing the plastic air line supplied in the Air Lift kit, the guys at Flynn’s used compressed air to effectively raise the air springs up so that they could be connected to the upper chassis brackets. Otherwise, the truck would’ve had to have been lowered to the ground (and the suspension compressed). With the springs aired up, installing the supplied 3/8-inch nylon lock nuts to the upper chassis bracket carriage bolts was a piece of cake. Like the 3/8-inch nuts on the clamp bar, they too were torqued to 16 ft-lb.

It’s worth noting that a ’17 Super Duty equipped with a 5-inch-diameter aftermarket exhaust system and a conventional-exit tailpipe may have clearance issues near the passenger-side top roll plate. This is because of the larger roll plates being used to accommodate the larger diameter air springs in the Load Lifter 7500 XL system. From what we observed in our install, 4-inch aftermarket exhaust systems should be fine.

This burly upper frame brace reinforces the passenger-side air spring assembly. On trucks equipped with a factory-installed fifth-wheel hitch, installation of this brace calls for the removal of the fifth-wheel bracket hardware. The upper frame brace anchors to the frame by way of the supplied 4.5-inch-long, 5/8-inch Grade 8 bolts and the corresponding nuts and washers. The guys at Flynn’s torqued the upper frame brace bolts to 50 ft-lb. Like the driver side upper frame brace, 3/8-inch nylon lock nuts were used to tighten the frame brace to the upper chassis bracket.

With both air spring assemblies in place, each fastener was torqued for the final time. The axle tube vent (driver side) was then zip-tied to a soft brake line to ensure it never comes into contact with the driver side air spring. Then it was time to route the air lines and install the wireless control system.