INSTALLATION INSTRUCTIONS 6111 Air Spring Kit
2011+ Ford F250/F-350 Single Wheel 2WD 2011+ Ford F350 Dually 2WD
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING YOUR INSTALLATION
IMPORTANT NOTES
DO NOT INFLATE ANY AIR SPRING ASSEMBLY UNLESS IT HAS BEEN PROPERLY INSTALLED ON VEHICLE.
DO NOT INFLATE AIR SPRINGS OVER 100 PSI
A MINIMUM OF 5-10 PSI MUST BE MAINTAINED IN AIR SPRINGS AFTER INSTALLATION FOR WARRANTY TO BE VALID. FAILURE TO KEEP MINIMUM PRESSURE IN AIR SPRINGS WILL VOID WARRANTY.
THIS UNIT IS DESIGNED TO INCREASE THE LEVEL LOAD CARRYING
CAPACITY OF YOUR VEHICLE. NEVER LOAD THE VEHICLE THIS
UNIT IS INSTALLED ON BEYOND THE MANUFACTURER’S MAXIMUM
GROSS VEHICLE WEIGHT RATING.
BEFORE STARTING YOUR PROJECT
WHEN LIFTING A VEHICLE WITH A JACK, BE SURE TO SET THE PARKING BRAKE AND USE SAFETY STANDS.
ENSURE THAT THE INSTALLATION OF COMPONENTS WILL NOT CRUSH OR DAMAGE FUEL AND BRAKE LINES OR ELECTRICAL HARNESSES.
BEFORE DRILLING ANY HOLES, ENSURE THAT ALL ELECTRICAL WIRES, FUEL LINES, BRAKE LINES, BRAKE HOSES AND ANY OTHER COMPONENTS ARE MOVED OR
PROTECTED TO AVOID DAMAGE FROM DRILLING ANY HOLES .
DO NOT ATTEMPT ANY MODIFICATIONS TO THE VEHICLE OTHER THAN THOSE
OUTLINED IN THIS INSTRUCTION SHEET. IF ANY INTERFERENCE WITH THE GAS TANK, FUEL LINES, BRAKE LINES, EXHAUST PIPE, ETC. EXISTS, STOP YOUR INSTALLATION AND CALL HELLWIG PRODUCTS FOR TECHNICAL HELP.
IF WHEELS ARE REMOVED FOR INSTALLATION OF KIT, CHECK MANUFACTURERS SPECIFICATIONS FOR PROPER LUG NUT TORQUE BEFORE REINSTALLING WHEELS.
WHEN CUTTING AIR BRAKE TUBING, A SQUARE CUT IS REQUIRED AND THE HOSE END MUST NOT BE DEFORMED OR LEAKAGE MAY RESULT.
1. Park vehicle securely and set parking brake and chock wheels. Jack up frame of vehicle to allow clearance to install air spring assembly. Rest frame of vehicle on jack stands before working on or under vehicle.
3. Install fitting in port of air spring. Torque fitting to approximately 20 ft-lb.
2. Remove factory bump stops from vehicle by removing nuts from studs using a 15mm wrench or socket.
4. Install frame bracket to air spring with 3/8 X 1” bolts.
Install heat shield as shown for passenger side only.
Torque nuts to 20 ft-lb. In- stall 3/8” X 2” threaded stud into frame bracket as shown.
5. Attach axle bracket to bot- tom of air spring using 3/8” X 1” bolts and washers leave loose for adjustment later.
3/8 X 1” Bolts torque to 20 ft-lb.
3/8” X 2”
threaded stud to be inserted into hole on frame for bump stop stud
4
5
Torque Air fitting to 20 ft-lb.
Heat Shield—
pass side only
3. Disconnect brake hose bracket from axle by remov- ing vent tube fitting from axle.
Reconnect vent tube fitting without brake bracket.
Brake bracket will be attached to a new bracket later.
Brake hose bracket—
leave loose to be at- tached to a new bracket later.
Axle vent fitting 3
5. Attach axle bracket to bottom of air spring using 3/8” X 1” bolts and washers as shown in photos. Axle bracket must be attached so that it is located under the frame bracket with exposed slotted holes oriented outboard. For single rear wheel models (not required for dual wheel applications with single rear brake hose) - Attach brake relocation bracket to driver side as shown in pho- tos. Make sure that threaded stud and flange nut can be installed when brake re- location bracket is installed. Torque bolts to 20-25 ft-lb.
5
Attach axle bracket so that it is located under frame bracket with exposed slotted holes ori- ented outboard.
DRIVER SIDE ONLY—for single wheel models (not required for dual wheel applications with single rear brake hose)— Attach brake relocation bracket as shown with bracket pointing inboard on the rear side of assembly as shown. Use 3/8” X 1-1/4” bolts and washers. Torque to 20-25 ft-lb.
Make sure brake relocation bracket is installed so that threaded stud and flange nut can be installed.
Outside of Frame
FrontofVehicle
6. Driver Side: Before installing air spring assembly, remove 8mm bolt in location shown in figure 6a. This bolt will be replaced with a M8-1.25xX40 bolt and washer kit after installing air spring assembly. To install air spring assembly, insert between frame and axle as shown with the axle bracket resting on axle—note fit of brackets to frame and axle. Stud on frame bracket will install in hole where bump stops were attached. Fasten stud on frame bracket to frame rail with 3/8” lock nut and washer. Install 3/4” bolt, washer and nut through hole in frame rail. No washer will be used between the head of the 3/4” bolt and the inside of the frame rail on the driver side. After aligning assembly to rail, Tighten M8-1.25 bolt to 15 ft- lb. Then tighten nut on stud to 20 ft-lb. Finally tighten 3/4” bolt to 100-125 ft-lb. If bolt is used by fifth wheel hitch mounting brackets, tighten bolt to hitch manufacturer’s specifica- tions. Special Note: If vehicle has factory installed fifth wheel hitch, do not install 3/4”
bolts. See step 7 for instructions.
Passenger Side : To install air spring assembly, insert between frame and axle as shown with the axle bracket resting on axle -note fit of brackets to frame and axle. Stud on frame bracket will install in hole where bump stops were attached. Fasten stud on frame bracket to frame rail with 3/8” lock nut and washer. Install 3/4” bolt, washer and nut through hole in frame rail. Then tighten nut on stud to 20 ft-lb. Finally tighten 3/4” bolt to 100-125 ft-lb. If bolt is used by fifth wheel hitch mounting brackets, tighten bolt to hitch manufacturer’s specifica- tions. Special Note: If vehicle has factory installed fifth wheel hitch, do not install 3/4”
bolts. See step 7 for instructions.
6a 6b 6c
Remove 8mm bolt before installing air spring as- sembly. Replace with M8-1.25xX40 bolt and washer included in kit.
Driver Side Driver Side Passenger Side
3/4” bolt without washer on inside of frame.
Factory Installed 5th Wheel Only
7
7. If vehicle has factory installed 5th wheel, it will cover the mounting holes for the 3/4” bolt. Do not install 3/4” bolt.
Drill 2 holes in each frame rail using the frame bracket as a guide and fasten to rail using 3/8X1-1/4” Grade 8 bolts, washers and locknuts as shown. BEFORE DRILL- ING ANY HOLES IN THE RAIL—
RELOCATE AND/OR PROTECT ANY FUEL, ELECTRICAL OR BRAKE LINES THAT MAY INTERFERE WITH THE DRILL BIT OR INSTALLATION.
3/8” Bolts
8. Install threaded rods and flanged locknuts as shown in picture.
Threaded rods should be installed so that the threads slightly protrude above top of axle bracket. Tighten flanged lock nuts to 20 ft-lb to lock threaded rods to bracket. Attach saddle
bracket to threaded rods as shown with 3/8” locknuts and washers. Reposition brake lines or cables so that they will not interfere with the bracket or the threaded rods. Tighten locknuts to 20- 25 ft-lb.
Saddle Bracket Flanged Locknut
Threaded Rod
Locknut 8
10. Check your installation to ensure that all fasteners are tight and that the assembly and all fasteners clear brake and fuel lines, emergency brake ca- bles, fuel tanks, wiring harnesses, etc.
Make sure that heat shields are posi- tioned for maximum protection of air spring.
9. Attach brake hose bracket to brake relocation bracket as shown using 3/8X1”
bolts, washers and locknuts. Tighten bolts to 20-25 ft-lb. Reposition brake lines as required to avoid any contact with shock absorber. Note location of brake hoses, electrical lines or any other component that may contact air spring assembly and reposition as required.
10a
Single Brake Line does not require relocation
Brake Relocation Bracket 3/8X1” Bolt
9b Dual Brake Line requires relocation
Brake hose bracket Axle Vent
11. Complete passenger and driver’s side installation of air spring assembly.
12.Select a location for the air inflation valves. The location can be on the
bumper or body of the vehicle where an air chuck can be used to inflate the air springs. Select a location where the valve will not be damaged or interfere with the operation of other components.
13.Cut air brake lines to length and connect air lines to fittings by pushing the air line into the air fittings as far as possible. A length of heat shielding is provided to protect the air line as it exits the passenger side air spring.
14. Inflate air springs to 40 psi and check for leaks. A soapy water solution can be used to find slow leaks.
15.When satisfied with integrity of the system, adjust air pressure to desired level.
The air springs can be inflated to any level between 10 and 100 psi. DO NOT run the air springs empty or warranty will be void. MINIMUM air spring pres- sure is 5 psi. Failure to keep air in the air springs will void the warranty. For best RIDE use only enough air pressure as required to level the vehicle. If a firmer ride is desired, more pressure can be used.
16.Check air pressure in the system regularly to ensure system performance and maintenance of warranty. Just like tires, the air pressure in the system will vary due to temperature changes. For your air spring system to function prop- erly it must be checked on a regular basis.
SUSPENSION SYSTEMS HELLWIG SUSPENSION
