Hellwig 1901 User Manual

559-734-7451 800-367-5480 FAX [phone]

INSTALLATION INSTRUCTIONS

Thank you for purchasing a quality Hellwig Product.

1 2 3

EMERGENCY BRAKE
CABLE

POLYURETHANE
CROSSBAR INSULATOR

( R-1901 ) 09/14/04

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559-734-7451 800-367-5480 FAX [phone]

TORQUE TABLE

BOLT SIZE: 3/8” = 20-30 ft. lbs. – 7/16” = 35-45 ft. lbs. – ½” = 50-70 ft. lbs. – 9/16” = 70-90 ft. lbs.

IMPORTANT: PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING YOUR

INSTALLATION.

SAFETY: PARK YOUR VEHICLE ON A FLAT LEVEL SURFACE, SET THE PARKING AND CHOCK THE

FRONT TIRES.

IMPORTANT NOTE: HELLWIG HELPER SPRINGS ARE DESIGNED TO INCREASE THE LOAD LEVEL

CARRYING CAPACITY OF YOUR VEHICLE. NEVER LOAD THE VEHICLE THIS
UNIT IS BEENING INSTALLED ON BEYOND THE MANUFACTURERS MAXIMUM
GROSS VEHICLE WEIGHNOTE: THIS KIT INCLUDESLOCK NUTS WHICH REQUIRE

NOTE: THIS KIT INCLUDES LOCK NUTS WHICH REQUIRE TIGHTENING WITH A WRENCH AFTER

BEING STARTED BY HAND.

1. Install the eye plates using the 1/2” x 1-1/4” cap screws, flat washers and lock nuts provided in this

kit. SEE PHOTO ONE (1).

2. Install the plastic insulator pads on the diagonal cut ends of the leaf spring with the hole. Place one
pad between the leaf and mounting point under the axle. Install one washer and plastic insulator pad
on the 1/2” x 2-1/2”bolt provided and install thru the hole in bottom of the mounting point. Mounting
will be as follows bolt, washer, insulator pad, mounting point, insulator pad, leaf spring, insulator
pad, washer and lock nut. ( SEE PHOTO (2). Leave loose at this time to allow for adjustment

later.

3. With the end loosely attached at the mounting point under the axle. Lift the other end of the spring
until contact is made with the eye plate. Visually make note and mark the contact area. This area is
where the friction pad will be placed on the leaf spring. Install by applying the adhesive side of the
friction pad to the top of the leaf spring. SEE PHOTO THREE (3).

4. Approximately 12” forward of the front mounting bolt on the lower trailing arm. Slide the 9” U-bolts
provided over the frame with the legs pointing to the ground. Be sure the U-bolt is under any wires

or lines routed along the top side of the frame rail, and between the frame rail and emergency
brake cable. SEE PHOTO FOUR (4).

5. After proper location for the U-bolts has been determined. Slide the polyurethane insulator over the
crossbar. Install the crossbar on the U-bolt so that the raised part of the insulator will fit into the
U-bolt saddle of the leaf spring. Tighten evenly with the flat washers and double nut. Tighten the U­bolts until there is approximately 3/4” of clearance between the bottom of the frame and the top of
the U-bolt saddle of the leaf spring. Do not overtighten beyond this point. SEE PHOTO FIVE (5).

6. Tighten all hardware to the specified torque rate. Bounce the vehicle and check for clearance on all
under carriage components.

7. After one week of driving recheck your installation, re-torque as necessary. Recheck your installation
on a monthly regular basis thereafter.

ATTENTION INSTALLER: BE SURE THE CUSTOMER RECEIVES THIS INSTRUCTION SHEET,

ALL IMPORTANTNOTE CARDS, WARNING CARDS, AND THE
WARRANTY FORM.

( R-1901 ) 09/14/04