Hellwig Air 6102 - Manual

559-734-7451 800-367-5480 FAX 559-734-7460
INSTALLATION INSTRUCTIONS
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING YOUR INSTALLATION
TORQUE TABLE
BOLT THREAD DIAMETER : 3/8” = 20-30 ft. lbs. – 7/16” = 35-45 ft. lbs. – ½” = 50-70 ft. lbs. – 9/16” = 70-90 ft. lbs.
NOTE : THESE AIR SPRINGS ARE DESIGNED TO MOUNT TO THE AXLE AND THE FRAME , SOME DRILLING
ON THE VEHICLES FRAME MAY BE NECESSARY.
NOTE : IT MAY BE NECESSARY TO JACK THE VEHICLE BY THE FRAME TO MAKE ENOUGH SPACE BETWEEN
THE AXLE AND THE FRAME TO INSTALL THE AIR SPRING. REMOVAL OF THE REAR TIRES MAY BE NEC-
ESSARY TO GAIN ACCESS TO THE AREA ON THE FRAME WHERE THE HOLES ARE TO BE DRILLED. NOT
ALL VEHICLES WILL REQUIRE REMOVAL OF THE REAR TIRES. RAISE THE VEHICLE BY THE FRAME TO
CHECK FOR ACCESS CLEARANCE.
NOTE : IF THE REAR TIRES ARE TO BE REMOVED SUPPORT THE VEHICLES FRAME BY USING JACK STANDS AND
BLOCKING THE FRONT VEHICLES TIRES.
1. As per the diagrams , attach the air spring to the frame bracket with the locknuts provided. On the air spring that
mounts on the passenger side of the vehicle , install the heat shield between the air spring and the vehicles frame.
Tighten just slightly to allow for adjustment later.
2. Use the 3/8” bolt and lock washer provided attach to the lower axle bracket at the bottom of the air spring. There are a
variety of drilled holes on this bracket. It may be necessary to change holes after mounting for best fit so that the air
spring is properly aligned on your particular vehicle. Leave loose at this time to allow for adjustment later.
3. Install the brass air fitting into the top of the air spring. Tighten the fitting completely so that some of the thread seal-
ant gets down inside the threads of the air spring. Align the air fitting so that the air hose points in the direction de-
sired for your particular vehicle.
4. Locate the rubber bump stop bracket that is mounted to the bottom of the vehicles frame and directly above the vehi-
cles axle. Remove the bump stop brackets , these items will not be reused.
5. Place the air spring assembly on top of the vehicles axle. Place the frame bracket on the outside of the vehicles frame.
The frame bracket needs to be up against the bottom and flat to the outside of the vehicles frame. The frame bracket
should nest into the radius and be up against the bottom of the vehicles frame. The lower holes on the side of the
frame bracket are for clearance over the rivets that are on the vehicles frame. If your vehicle does not have rivets on
the frame these holes will not be used.
6. With the assembled air spring in position, align the brackets so that the air spring is as straight as possible. The frame
bracket should be centered on the reinforced area for the bump stop bracket. With the brackets in the proper position
use the upper holes in the upper frame brackets to mark the locations on the vehicles frame, where the mounting holes
will be drilled for mounting. Before drilling the vehicles frame make sure and move any wires , hoses or any other
items from inside the frame to avoid any damage when drilling the mounting holes. Do the same on opposite frame.
7. Using a 7/16” drill bit , drill the two holes on the vehicles frame. Place the air spring into position , insert the bolts
with washers provided through the frame brackets and the vehicles frame. The threaded end of the bolts will be on the
inside of the vehicles C-channel frame. The inner frame bracket will mount flush against the inside of the frame and
to the top of the air spring. There are two inner frame brackets per air spring they are bent opposite each other. One
on the front and one on the rear , when properly installed the bent legs of the brackets will be facing each other. The
small corners that are trimmed off on the inner frame brackets will mount towards the brass air line fitting. Remove
the air spring upper lock nut , insert through the frame bracket re-install the lock nut do not over tighten. Leave loose
to allow for adjustment later. The inner frame brackets are designed to allow for a tunnel next to the vehicles frame
so any electrical wires , fuel lines or hoses can be placed back against the frame as before. Use the plastic insulator
covers that are supplied for protection as needed.
NOTE : use bracket # 20800247 if extra clearance is required for relocating wires, fuel and brake lines in the
frame rails ( SEE LAST PAGE FOR ILLISTRATION ).
6102 ( R-6102 ) 09 -17-07