How to Install Air Lift Performance RideControl (02-08 RAM 1500) on your Dodge RAM

IMPORTANT: This kits mounts behind the axle. Figure 1 shows the installation for the driver side only. Refer to Figure 7 for the passenger side installation.

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.

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 floor jack to lower the axle.

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

b. Loosely install a 3/8” washer head bolt (N), a large flat washer (M), and nylock nut (K). Figure 7 Passenger Side

c. Center punch the forward lower hole and drill a 3/8” hole through the frame.

d. 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 hardware, as it will be reused to mount the air spring.

e. Replace the upper bracket to the mounting location and secure at the forward, lower mounting hole location using 3/8” washer head bolt (N), large flat washer (M) and nylock nut (K) as shown in Figure 1.

f. Center punch and drill a 5/16” hole for the forward upper hole and install a 3/8” self tapper (O). Tighten to 16 ft-lbs (Figure 1).

g. Drill the remaining hole out to a 3/8” diameter and install a 3/8” washer head bolt (N), a large flat washer (M), and a nyloc nut (K).

3. PASSENGER SIDE INSTALLATION: Install the passenger side assembly in the same manner, with the exception to the forward upper hole location. Drill this hole to a 3/8” diameter and install a 3/8” washer head bolt (N), a large flat washer (M), and a nyloc nut (K). No self tapper is used on the passenger side. Refer to Figure 7.

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

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

3. Attach the air spring to the lower bracket using flat washer (H) and bolt (G). Carefully hand turn the air spring onto the lower mounting bolt. Leave loose for later adjustment.

4. Loosely, install nylon nut (F) over the air fitting and onto the upper threadpost of the air spring (Figure 1).

3. Cut the air line assembly (AA) in two equal lengths. CAUTION: When cutting or trimming the air line, use a hose cutter, a razor blade or a sharp knife. A clean, square cut will ensure against leaks. 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.

4. Place a 5/16 “ nut (GG) and a star washer (FF) on the air valve. Leave enough of the inflation valve in front of the nut to extend through the hole and have room for the rubber washer (EE), flat washer (DD), and 5/16 “ nut (GG) and cap (CC). There should be enough valve exposed after installation - approximately 1/2 “ - to easily apply a pressure gauge or an air chuck (Figure 9).

5. Push the inflation valve through the hole and use the rubber washer (EE), flat washer (DD), and another 5/16 “ nut (GG) to secure it in place. Tighten the nuts to secure the assembly in place (Figure 9).

6. Route the air line along the frame to the air fitting on the air spring. Keep at least 6” of clearance between the air line and heat sources, such as the exhaust pipes, muffler, or catalytic converter. Avoid sharp bends and edges. Use the plastic tie straps (BB) to secure the air line to fixed, non-moving points along the chassis. Be sure that the tie straps are tight, but do not pinch the air line. 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 fitting. This is a push to connect fitting. Simply push the air line into the 90° swivel fitting until it bottoms out (9/16” of air line should be in the fitting).

8. Install the minimum/maximum air pressure decal in a highly visible location. We suggest placing it on the driver’s side window just above the door handle.

1. Inflate the air spring to 30 p.s.i.

2. Spray all connections and the inflation 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, deflate 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 fitting, then:

a. Check the air line connection by deflating the spring and removing the line by pulling the collar against the fitting and pulling firmly 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 fitting.

b. Check the threaded connection by tightening the swivel fitting another 1/2 turn. If it still leaks, deflate the air spring, remove the fitting, 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 inflation valve, then:

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 fitting. 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 fitting and use a pair of pliers or vise-grips to pull/twist the air line off the fitting.

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 inflation 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 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 - Inflate 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 – Inflate the air springs to 60 p.s.i., check all connections for leaks with a soapy water solution. See page 6 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 sufficient 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 16 ft-lbs
U-bolt Lock Nuts 16 ft-lbs

5. Road Test – The vehicle should be road tested after the preceding tests. Inflate 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 8 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 fixed. Either fix the leak yourself (see page 6) 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 inflate 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 first. If any part shows signs of rubbing or abrasion, the source should be identified 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.

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 inflate 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 inflation valve core before deflating and removing the air spring (see page 6).

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 inflation 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 inflate 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.