Air Lift LoadLifter 5000 ULTIMATE 88237Air LiftOriginal price was $857.99. Current price is $621.99.In Stock
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2002 - 2008 Workhorse W20
Confirmed to Fit
2002 - 2008 Workhorse W22
Confirmed to Fit
2004 - 2008 Workhorse W24
Confirmed to Fit
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LoadLifter 5000 ULTIMATE with internal jounce bumper to absorb shock for best ride comfort
Adjustable air spring kit for leaf springs
Rear
Safely run w/zero air pressure
LoadLifter 5000 ULTIMATE adjustable air spring kits feature all of the benefits of our heaviest rated air spring with the addition of an internal jounce bumper inside the spring for the ultimate in ride comfort. An Air Lift exclusive product! Fits vehicles with in-bed hitches. Tow and haul the heaviest loads with safety and comfort with LoadLifter 5000 ULTIMATE. Works with vehicle's leaf springs to provide up to 5,000 lbs. of front load leveling capacity and keeps the vehicle riding stable, level and comfortable whether loaded or unloaded. Fully adjustable from 5 to 100 PSI. The closed-cell urethane foam jounce bumper inside the ULTIMATE air springs provide a cushion of air that absorbs shock, eliminates harsh jarring on rough roads and protects vehicles carrying heavy loads. Never bottom out again with the ULTIMATE! LoadLifter 5000 ULTIMATE air springs are maintenance free! Safely run with zero air pressure because of the internal jounce bumper. Replaces factory jounce bumper that is sometimes removed when adding air springs. Includes industry-exclusive 60 Day No Questions Money Back Guarantee! Includes the most comprehensive Lifetime Warranty in the industry---covers all kit contents including brackets, fittings and air line. Air springs are built like a tire and are reinforced by durable, 2-ply fabric for maximum strength. Exclusive upper and lower roll plates included. Protect the springs from sharp edges, such as brackets or the frame. The kit includes 2 air springs, brackets, air lines, Schrader valve and all of the hardware needed for installation. Includes fully illustrated instruction manual. Add an Air Lift on-board air compressor system to inflate and deflate air springs with the touch of a button from inside or outside of the vehicle.
Air Lift Company has developed dependable air spring suspension products since our inception in 1949. Our original product, a rubber air spring inserted into a car’s factory coil spring, was created and patented in 1950. We’ve come a long way since 1949 and are proud to be a dedicated suspension specialist company.
Today, Air Lift load support products are sold worldwide and are engineered to fit over 540 vehicles. Our extensive product line offers air helper springs for trucks, RVs, SUVs, CUVs, and vans, as well as the most technologically advanced on-board air compressor systems for on-the-go air spring control.
Air Lift leads the industry in no-drill applications – kits that bolt onto your vehicle’s frame, speeding the installation process. Our teams work constantly to bring innovative products to you and upgrade existing products with the latest technology.
All of our efforts are spent ensuring your safety and comfort by designing, engineering, and manufacturing the highest quality suspension products. We are a family-owned business based in Lansing, Michigan, and make your family and cargo’s safety our top priority.
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Call 888-634-9494Limited Lifetime
3 compatible vehicles
| Year | Make & Model | Notes |
|---|---|---|
| 2002 - 2008 | Workhorse W20 | — |
| 2002 - 2008 | Workhorse W22 | — |
| 2004 - 2008 | Workhorse W24 | — |
Yes, the Air Lift LoadLifter 5000 ULTIMATE 88202 (Part #BBCG88202) is designed to fit the 2002-2008 Workhorse W20.
The Air Lift LoadLifter 5000 ULTIMATE 88202 (Part #BBCG88202) fits the following vehicles: 2002-2008 Workhorse W20; 2002-2008 Workhorse W22; 2004-2008 Workhorse W24. Always verify your specific year, make, and model before ordering.
The Air Lift LoadLifter 5000 ULTIMATE 88202 (Part #BBCG88202) fits 2002-2008 Workhorse W20 models. The 2008 model year is the last year covered by this part number. For newer models, check for an updated version.
The Air Lift LoadLifter 5000 ULTIMATE 88202 (Part #BBCG88202) Refer to the included instructions for installation details. Basic hand tools are typically all you need.
The LoadLifter 5000 Ultimate is an adjustable air helper spring system that provides load leveling support for 3/4 and 1 ton pickups, SUVs, and motorhomes with leaf springs. It uses reinforced commercial-grade convolute bellows and includes an internal jounce bumper that absorbs shock and allows the springs to safely run at zero air pressure. The kit provides up to 5,000 lbs of load leveling support with air adjustability from 5–100 PSI.
No. Installing air springs does not alter the Gross Vehicle Weight Rating (GVWR) or payload of your vehicle. You must check your vehicle's owner's manual and never exceed the maximum load listed for your vehicle. Exceeding the GVWR is dangerous and voids the Air Lift warranty.
Kit 88202 is designed for most 3/4 and 1 ton pickups and SUVs with leaf springs, and is also used in motorhome rear kits and some motorhome fronts where leaf springs are used. For specific vehicle compatibility, contact Air Lift customer service at (800) 248-0892.
Kit 88202 includes: 2 bellows (P/N 58496), 2 upper brackets (P/N 07475), 2 lower brackets (P/N 03102), 4 roll plates (P/N 11967), 2 elbow fittings (P/N 21837), 4 U-bolts 4.5" (P/N 10583), 16 3/8" nylock nuts (P/N 18435), 16 3/8" flat washers (P/N 18444), 8 3/8" lock washers (P/N 18427), 8 3/8" large flat washers (P/N 18447), 8 3/8" x 1.5" HWH bolts (P/N 17159), 8 3/8" x 7/8" HH bolts (P/N 17203), 4 3" spacer bars (P/N 01426), 1 air line assembly (P/N 20086), 6 tie straps (P/N 10466), 2 valve caps (P/N 21230), 2 5/16" flat washers (P/N 18405), 2 rubber washers (P/N 21234), 2 small star washers (P/N 18411), and 4 5/16" hex nuts (P/N 21233).
The manual does not provide a specific tool list. However, installation requires: a jack and jackstands to raise and support the vehicle; a drill with a 3/8" bit for frame holes and a 5/16" bit for inflation valve holes; a hose cutter (Air Lift P/N 10530), razor blade, or sharp knife to cut air lines; a wrench for tightening fasteners; and a valve core tool for checking the inflation valve. Contact Air Lift at (800) 248-0892 for a complete tool list.
The manual does not mention disconnecting the battery. However, before drilling the frame, you must check the back-side of the frame for clearance issues with brake lines, gas lines, and electrical lines, and temporarily relocate any obstacles to clear the drilling area.
Raise the vehicle, remove the wheels, and support the axle with jackstands. Obtain the normal ride height. Then remove the jounce bumper and bracket from the side of the frame above the leaf spring.
1. Set a roll plate (D) on both ends of the air spring (A) with the radiused edge toward the air spring so it is seated in both roll plates. 2. Install a 90° swivel air fitting (E) finger tight plus 1½ turns—do not overtighten. 3. Place the upper bracket (B) onto the top of the bellow and roll plate with legs facing down. 4. Set the air spring on the lower bracket (C), aligning the two holes in the base of the air spring with the two outer slots in the top of the lower bracket. 5. Loosely attach the upper bracket using flat washers (H), lock washers (I), and hex head bolts (L). 6. Loosely attach the lower bracket using flat washers (H), lock washers (I), and hex head bolts (L).
1. Set the assembly over the center spring retainer. 2. Install two spacers (M) between the lower bracket and the spring. 3. Bolt the lower bracket (C) to the spring using two U-bolts (F), four flat washers (H), and four nylock nuts (G). Torque to 16 ft. lbs. 4. Trim the inside U-bolt if necessary to keep the bolt from hitting the upper bracket.
There should be a minimum of 6 inches between the upper and lower brackets. Mount the upper bracket as high on the frame as possible. The top two holes may be above or even with the frame; if so, use the two lower holes in the upper bracket for mounting.
Yes. Drilling is required in three locations: 1. One 3/8" locator hole through the frame for the upper bracket, then the remaining holes after alignment. 2. A 3/8" hole above the axle in the bottom of the frame flange for the jounce bumper relocation. 3. A 5/16" hole at your chosen location (wheel well flange, license plate recess, under gas cap door, or through license plate) for the inflation valves. Before drilling the frame, check the back-side for clearance issues with brake lines, gas lines, and electrical lines, and temporarily relocate any obstacles.
Yes. Trim the inside U-bolt if necessary to keep the bolt from hitting the upper bracket. This is done after bolting the lower bracket to the spring.
Cut the air line assembly (AA) in two equal lengths. Use a hose cutter (Air Lift P/N 10530), a razor blade, or a sharp knife to make a clean, square cut. Do not use wire cutters or scissors, as these tools may flatten or crimp the air line, causing it to leak around the O-ring seal inside the elbow fitting. After cutting, leave approximately 12" of extra air line, then insert the air line into the 90° swivel fitting until it bottoms out (9/16" of air line should be in the fitting).
Torque the lower bracket U-bolts to 16 ft. lbs.
After drilling the remaining holes and installing the appropriate hardware, torque the upper bracket nuts to 44 ft. lbs.
Tighten both upper and lower bellows mounting bolts to a maximum of 20 ft. lbs.
Install the 90° swivel air fitting (E) finger tight plus 1½ turns. Do not overtighten.
Choose a convenient location for mounting the inflation valves. Popular locations include: the wheel well flanges, the license plate recess in the bumper, under the gas cap access door, or through the license plate. Make sure there is enough clearance around the inflation valves for an air chuck. Drill a 5/16" hole to install the inflation valves.
There must be at least 6 inches of clearance between the air lines and any heat sources such as exhaust pipes, muffler, or catalytic converter. Avoid sharp bends and edges. Leave at least 2" of slack when securing the air lines to allow for any movement that might pull on the air line.
The minimum recommended air pressure is 5 PSI, but the system can safely be run at zero air pressure. The maximum air pressure is 100 PSI. Never exceed 100 PSI.
Loaded vehicles require at least 25 PSI or more. A "loaded vehicle" refers to a vehicle with a heavy bed load, a trailer, or both. The springs support approximately 40 lbs of load (combined on both springs) for each 1 PSI of pressure. The required air pressure will vary depending on the state of the original suspension and your load. Always adjust the air pressure to maintain normal ride height. Never exceed your vehicle's GVWR, regardless of air spring pressure or other load assist.
Yes. The LoadLifter 5000 Ultimate can safely be run at zero air pressure because it includes an internal jounce bumper that absorbs shock and eliminates harsh jarring. However, the recommended minimum air pressure is 5 PSI.
The vehicle can be lifted on a hoist for short-term service work such as tire rotation or oil changes. However, if the vehicle will be on the hoist for a prolonged period of time, support the axle with jack stands to take the tension off the air springs. If you need to raise the vehicle by the frame, make sure the system is at minimum pressure (5 PSI) to reduce the tension on the suspension and brake components. Use of on-board leveling systems does not require deflation or disconnection.
Complete the following post-installation checks: 1. Clearance test—Inflate to 60 PSI and ensure at least ½" clearance around each bellow away from tire, brake drum, frame, shock absorbers, and brake cables. 2. Leak test—Inflate to 60 PSI and check all connections with soapy water solution. All leaks must be eliminated before road testing. 3. Heat test—Ensure at least 6" clearance from heat sources. 4. Fastener test—Recheck all bolts for proper torque. Axle clamp bar carriage bolt lock nuts should be torqued to 16 ft/lbs and re-torqued after 100 miles. 5. Road test—Drive 10 miles and recheck for clearance, loose fasteners, and air leaks.
1. Inflate the air spring to 30 PSI. 2. Spray all connections and the inflation valves with a solution of 1/5 liquid dish soap and 4/5 water. Look for bubbles in the soapy water to spot leaks. 3. After the test, deflate the springs to the minimum pressure required to restore normal ride height, but not less than 10 PSI. 4. Check the air pressure again after 24 hours. A 2 to 4 PSI loss after initial installation is normal. Retest for leaks if the loss is more than 5 lbs.
Check the air pressure weekly. Always maintain normal ride height. Never inflate beyond 100 PSI.
1. Check air pressure weekly and maintain normal ride height. 2. Never inflate beyond 100 PSI. 3. If you develop an air leak, use a soapy water solution (1/5 liquid dish soap and 4/5 water) to check all air line connections and the inflation valve core before deflating. 4. Periodically check the air spring system fasteners for tightness and check the air springs for signs of rubbing; realign if necessary. 5. On occasion, give the air springs a hard spray with a garden hose to remove mud, sand, gravel, or other abrasive debris. 6. Recheck the air spring system after 30 days or 500 miles, whichever comes first. If any part shows signs of rubbing or abrasion, identify and move the source if possible. Check all fasteners for tightness.
If the air springs are properly installed and maintained, they can last indefinitely.
1. Leak test the air line connections, the threaded connection into the air spring, and all fittings in the control system. 2. Inspect the air lines to be sure none are pinched. Tie straps may be too tight; loosen or replace the strap. 3. Inspect the air line for holes and cracks and replace as needed. 4. Look for a kink or fold in the air line and reroute as needed. If these steps do not solve the problem, call Air Lift at (800) 248-0892 for assistance.
1. 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, ensuring the cut is clean and square. Reinsert the air line into the push-to-connect fitting. 2. Check the threaded connection by tightening the swivel fitting another ½ 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.
1. Check the valve core by tightening it with a valve core tool. 2. Check the air line connection by removing the air line from the barbed type fitting. 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.
If the vehicle's headlights are shining into the trees or the vehicle is leaning to one side, it is not level. Raise the air pressure to correct either of these problems and level the vehicle. 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. As much as a 50 PSI difference is not uncommon.
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. If the vehicle rocks and rolls, adjust the air pressure to reduce movement. If stability issues such as bounce, dive during braking, or sponginess occur, usually an increase in pressure is required.
If the front of the vehicle dives while braking, increase the pressure in the front air bags, if equipped.
If it is ever suspected that the air bags have bottomed out, increase the pressure.
Kit 88202 is designed for most 3/4 and 1 ton pickups and SUVs with leaf springs, and motorhome rear kits and some motorhome fronts with leaf springs. For specific vehicle compatibility, contact Air Lift at (800) 248-0892.
You will need a jack and jackstands, a drill with 3/8" and 5/16" bits, a hose cutter or sharp knife, a wrench, and a valve core tool. For a complete tool list, contact Air Lift at (800) 248-0892.
Lower bracket U-bolts: 16 ft. lbs. Upper bracket nuts: 44 ft. lbs. Bellows mounting bolts: maximum 20 ft. lbs. Axle clamp bar carriage bolt lock nuts: 16 ft/lbs, re-torque after 100 miles.
The maximum air pressure is 100 PSI. Never exceed 100 PSI. The minimum recommended pressure is 5 PSI, but the system can safely run at zero air pressure.
No. Installing air springs does not alter your vehicle's GVWR or payload. You must never exceed the maximum load listed in your vehicle's owner's manual.
Check the air pressure weekly. Always maintain normal ride height and never inflate beyond 100 PSI.
Perform a clearance test at 60 PSI, a leak test with soapy water, a heat test (6" minimum from heat sources), a fastener torque check, and a 10-mile road test. All leaks must be eliminated before road testing.
Air leaks can be caused by: pinched air lines (check tie strap tightness), holes or cracks in the air line, kinks or folds in the air line, loose or improperly installed swivel fittings, loose or faulty inflation valve cores, or improper air line connections. Use a soapy water solution (1/5 liquid dish soap and 4/5 water) to identify the leak location by looking for bubbles.
If headlights shine into the trees or the vehicle leans to one side, the air pressure is insufficient. Raise the air pressure to level the vehicle. Different pressures may be needed on each side if loads such as water, fuel, or appliances cause uneven weight distribution. Pressure differences up to 50 PSI are not uncommon.
A rough or harsh ride may be caused by either too much or too little air pressure. Try different pressures to find the best ride comfort. If the vehicle rocks and rolls, increase air pressure to reduce movement. If bounce, dive during braking, or sponginess occurs, increase pressure.
A 2 to 4 PSI loss after initial installation is normal. However, if the loss is more than 5 lbs after 24 hours, retest for leaks using a soapy water solution. If pressure continues to drop more than 5 PSI after the vehicle has been used for 24 hours, there is a leak that must be fixed.
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