Air Line

This procedure covers the removal and replacement of air suspension lines on the 2015-2020 Ford F-150 5.0L V8 RWD. The job involves safely depressurizing the air suspension system, replacing damaged or leaking air lines, and verifying proper system operation.

Warnings

Tools required

Parts

• Air suspension line × 1 — Use OEM specification - length and routing specific to location
• Air line quick-connect fittings × 2 — Use OEM specification if damaged

Preparation

1. Park vehicle on level ground and apply parking brake
2. Turn off air suspension system using the switch in the rear cargo area (if equipped) or turn ignition off
3. Place wheel chocks at front wheels
4. Allow at least 10 minutes for air suspension system to fully depressurize
5. Raise and support vehicle on jack stands at frame contact points
6. Remove rear wheels to access air suspension components

Procedure

1. 1

   Locate damaged air line
   Identify the specific air suspension line requiring replacement. Common failure points include lines running from the air compressor to the air springs, or from the manifold to individual corners. Trace the line from end to end noting its routing and any clips or brackets securing it.
2. 2

   Depressurize system and disconnect battery
   Verify air suspension system is fully depressurized by checking that the vehicle has settled to its lowest position. Disconnect the negative battery cable to prevent accidental system activation during repair. Wait 2 minutes for any stored electrical charge to dissipate.
   ⚠️Disconnecting air lines under pressure can cause violent release of compressed air and potential injury.
3. 3

   Remove interior trim panels if necessary
   If replacing lines that run through the vehicle interior (compressor to manifold lines), carefully remove the necessary interior trim panels using trim removal tools. For lines running along the frame, skip this step. Common panels include rear quarter trim, rear seat base, or cargo area side trim.
4. 4

   Disconnect air line at compressor or manifold end
   Locate the quick-connect fitting at the air compressor or manifold. Press the release collar on the fitting while pulling the air line straight out. Do not twist or bend excessively. If the fitting is corroded or stuck, use a small amount of penetrating oil and allow it to soak for 5 minutes before attempting removal again.
5. 5

   Disconnect air line at spring end
   Access the air spring connection point, typically located on top of the rear air spring assembly. Press the release collar on the quick-connect fitting and pull the air line straight out. Note the orientation of any retaining clips or grommets for reinstallation.
6. 6

   Remove routing clips and brackets
   Trace the entire length of the air line and remove all mounting clips, brackets, or ties securing it to the frame, body, or suspension components. Take photos or make notes of the exact routing path to ensure correct installation of the new line. Pay special attention to areas where the line passes through grommets or protective sleeves.
7. 7

   Remove old air line
   Carefully extract the damaged air line from the vehicle, feeding it through any grommets or tight spaces. Inspect the routing path for any sharp edges, rust, or debris that could damage the new line. Clean the routing path and apply edge protectors if necessary.
8. 8

   Prepare and route new air line
   Compare the new air line to the old one to verify correct length and fitting types. If cutting to length is required, use a plastic tubing cutter to ensure a clean, square cut. Route the new line through the same path as the original, ensuring it does not contact sharp edges, moving suspension components, or the exhaust system. Maintain at least 2 inches clearance from exhaust components.
   ⚠Ensure air lines are not kinked, twisted, or under tension. Any restriction will reduce system performance and may cause premature failure.
9. 9

   Connect air line to spring end
   Push the new air line firmly into the quick-connect fitting at the air spring until you feel and hear a distinct click. Gently tug on the line to verify it is securely locked in place. The line should not pull out with moderate force.
10. 10

    Connect air line to compressor or manifold end
    Push the other end of the air line firmly into the quick-connect fitting at the compressor or manifold until you hear and feel a click. Verify the connection by pulling gently on the line. Ensure the line is fully seated and the release collar has returned to its locked position.
11. 11

    Secure air line with clips and brackets
    Reinstall all mounting clips and brackets along the air line routing path, following your notes or photos from disassembly. Ensure the line is properly supported every 12-18 inches and is not in contact with any moving parts. Verify adequate clearance from the exhaust system and suspension travel limits.
12. 12

    Reinstall trim panels
    If interior trim panels were removed, reinstall them in reverse order of removal. Ensure all clips are fully seated and panels are secure. Verify that the air line is not pinched or kinked behind any trim pieces.
13. 13

    Reinstall wheels and lower vehicle
    Reinstall rear wheels and hand-tighten lug nuts in a star pattern. Lower the vehicle until the tires just contact the ground but weight is still on jack stands. Torque lug nuts to specification in a star pattern. Remove jack stands and lower vehicle completely to the ground.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)
14. 14

    Reconnect battery and activate system
    Reconnect the negative battery cable. Turn the ignition to the ON position without starting the engine. Turn on the air suspension switch if it was turned off. The system will begin to inflate automatically. Listen carefully for any air leaks at the new connections.

Reassembly

1. Verify all quick-connect fittings are fully seated and locked
2. Confirm air line routing provides adequate clearance from exhaust and moving components
3. Ensure all mounting clips and brackets are properly installed
4. Double-check that interior trim panels are fully secured if removed

Verification

• Start the engine and allow the air suspension system to fully inflate all corners. This may take 2-3 minutes
• Listen for air leaks at all connection points. Apply soapy water to fittings and look for bubbles if a leak is suspected
• Use the air suspension controls (if equipped) to raise and lower the vehicle, verifying proper operation
• Perform a visual inspection of the new air line under the vehicle, checking for proper routing and clearance
• Test drive the vehicle at low speed and verify the air suspension maintains proper ride height
• After test drive, recheck all connections for leaks and verify the system holds pressure overnight

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