How to Install Air Lift 4-Way Manual Air Management System on your F-150

NPT ASSEMBLY INSTRUCTIONS

1. Inspect the port and fitting ensuring both are free of contaminants and excessive burrs and nicks.

2. Apply a stripe of liquid pipe sealant around the male threads leaving the first two threads uncovered.

3. Screw finger tight into the port.

4. Wrench tighten the fitting to the correct turns past finger tight position (see table 1).

NEVER BACK OFF AN INSTALLED PIPE FITTING TO ACHIEVE PROPER ALIGNMENT. LOOSENING INSTALLED PIPE FITTINGS WILL CORRUPT THE SEAL AND CONTRIBUTE TO LEAKAGE AND FAILURE.

HELPFUL TIPS: AIR LINE AND FITTINGS

1. Minimum hose bend radius • 1/4” hose = 1” hose bend radius.

2. Hose to fitting • No side loading on fitting from hose. • Hose straight for 1” before bending.

3. Hose cutting • Cut hose perpendicular to hose length. • Inspect hose for scratches that run lengthwise on hose prior to insertion. • Use proper hose cutter, cigar cutter, or razor on flat surface.

4. DOT/SAEJ844 air brake hose data • Maximum working pressure of 175 PSI. • Not to be used for frame (body) to un-sprung mass connection, use a braided leader hose for this moving connection.

Installing the Air Management System

INSTALL COMPONENTS

For a complete schematic, please see fig.

1. (pages 8 – 9) Layout 1. Plan component location first.

2. Prior to mounting components, check to make sure: • the compressor leader hose will reach the tank. • the plumbing will route cleanly through the vehicle. Be sure to install all components as far as possible from any heat sources. Plan and prepare wiring and plumbing routing thru the vehicle. Eliminate all sharp edges that could chafe. Use grommets when passing through compartment walls. Prepare and install the compressor

1. Prepare the compressor intake. If inside the vehicle, attach filter to port on end of compressor (fig. 1). If the compressor is located outside the vehicle, snorkel inlet filter to a dry location inside vehicle using components supplied with the compressor.

2. Center punch and drill four holes using the template on page 15.

3. Attach using the hardware supplied with the compressor. Air compressors ingest moisture and will deposit water in the tank. Tanks must be regularly purged to eliminate the possibility of water freezing inside the system or causing corrosion. Be sure to provide easy access to drain/fill valve (preferably outside the vehicle). The system does not include moisture separators or water traps, and does require periodic tank moisture drain. If using an engine driven compressor, proper oil and water filtration must be added as these compressors will contaminate the air suspension system. Water traps are available and sold separately through Air Lift Performance, part numbers: 21011 (1/4”), 21012 (3/8”), 21013 (1/2”). NOTE NOTE NOTE HELPFUL TIPS: AIR LINE AND FITTINGS

1. Minimum hose bend radius

• 1/4” hose = 1” hose bend radius.

2. Hose to fitting

• No side loading on fitting from hose.

• Hose straight for 1” before bending.

3. Hose cutting

• Cut hose perpendicular to hose length.

• Inspect hose for scratches that run lengthwise on hose prior to insertion.

• Use proper hose cutter, cigar cutter, or razor on flat surface.

4. DOT/SAEJ844 air brake hose data

• Maximum working pressure of 175 PSI.

• Not to be used for frame (body) to un-sprung mass connection, use a braided leader hose for this moving connection.

Table 2 MN-726 5 Air Lift Performance NOTE Tank pre-assembly (see fig. 1)

1. Determine tank location and orientation prior to installing fittings.

2. Apply thread sealant as necessary to all fittings.

3. Install the drain/fill PTC fitting in the lower most tank threaded port.

4. Choose a tank threaded port for the compressor fitting.

5. Choose the highest tank threaded port for air line supply.

6. Plug any remaining tank ports with hex plugs.

Tank install (see fig. 1)

1. Using the tank feet as a template, drill holes for hardware assembly.

2. Attach the tank using the supplied hardware.

3. Cut an appropriate length of hose from the manifold port T, to the PTC fitting on the tank.

4. Route the drain/fill air line with a schrader valve (preferably outside the vehicle). When cutting plastic air line, only use a standard hose cutter like (Air Lift part number 10530) or razorblade. Cut all hose ends square and as smoothly as possible. See hose cutting tips on page 4.

MOUNTING THE SWITCH PANEL

Refer to the switch panel template on page 13.

1. Find a location to mount the paddle switch mounting bracket (E).

2. Snap all four paddle switches (D) into the paddle switch mounting bracket (E) so the DEL is toward the top. You may select different locations for the paddle switches. The paddle switches do not need to be used with the supplied paddle switch mounting bracket.

3. Cut six pieces of air line (F) the same length (approximately 3”-6”).

4. Push four of these pieces onto the “SUP” port of the switch. Attach two Y fittings (II) to the air lines.

5. Push the other two pieces of line into the Y fittings (II).

6. Attach the last Y fitting (II) to the air lines.

7. Mount the paddle switch mounting bracket (E) with four screws (I). ATTACHING THE AIR LINES WHEN CUTTING OR TRIMMING THE AIR LINE, USE AN AIR LINE CUTTER (G), 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.

1. Run a length of air line (F) from the air fitting on the compressor to the end of the switch cluster.

2. Run a length of air line from the remaining air fittings on the switch to its respective air spring.

3. Repeat step 2 for the remaining air fittings and air springs.

4. Use a tee and connect into each one of the air spring lines to connect to it’s respective gauge port.

5. Test and make sure that the switches operate the appropriate air springs.

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. 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. 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. Tuning out these problems usually requires an increase in pressure.

Leak detection

1. A leak can be defined as a loss of pressure of more than 5 psi over an 8 hour period. Be aware that ambient temperature change has an effect on pressure that may seem like a leak. For example: a change of 10˚ Fahrenheit up or down from your baseline will have an approximate gain or loss of indicated pressure of 2 psi. If a leak is suspected after including any temperature change, then proceed to #2.

2. Spray soapy water (1/5 Dawn brand dish soap to 4/5 water) on suspect fittings and hose connections and look for any bubbling caused by air leakage.

3. Fix leaking connection (review pages 3 and 4 for help on NPT fittings and air line connections).

4. Wipe down sprayed connections with rag to remove any residual soapy water. Dawn brand dish soap will not corrode the metals (aluminum, brass, steel) with which it comes into contact.

NOTE: Air Lift recommends using a hose cutting tool to ensure a proper cut. If a hose connection has been disconnected the hose must be trimmed 1/2” back to provide for a leak free seal.