Hellwig 61905 User Manual

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

INSTALLATION INSTRUCTIONS

Thank you for purchasing a quality Hellwig Product.

PLEASE READ THISINSTRUCTION SHEETCOMPLETELY BEFORE STARTINGYOUR INSTALLATIONPROCEDURES.

Hat Section

Leaf Stack

Second Leaf

Crossbar

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

SAFETY: PARKYOUR VEHICLE ON A FLAT LEVEL SURFACE, SET THE PARKING AND CHOCK THE FRONT TIRES.
NOTE: THIS KIT INCLUDESLOCKNUTSWHICHREQUIRETIGHTENING WITH A WRENCH AFETRBEING STARTEDBY

HAND.

NOTE: IF YOUR VEHICLEIS EQUIPPED WITH A BRAKE FLUIDPROPORTIONING VALVEON THE REAR AXLE READ

INSERT(R-362)

Offset U-bolts

TORQUE TABLE

Straight U-bolt

Main Leaf

Main Spring

Qty 2 Crossbars
on axle u-bolts

Silencer Bushing

Leaf Tip

NOTE: Your spring may have a small hole in the end, this is for our manufacturing process and will not be used.

IMPORTANT NOTE: IF YOUR VEHICLE IS EQUIPEDWITH A FACTORY CONTACTOVER LOAD IT MUST BE REMOVED

BEFORE INSTALLINGTHE NEW HELPER SPRINGS.

IMPORTANT NOTE:HELLWIG HELPER SPRINGS ARE DESIGNEDTO INCREASE THE “LEVEL LOAD” CARRYING

CAPACITYOF YOUR VEHICLE.NEVER LOAD THE VEHICLE THAT THIS UNIT IS INSTALLEDON BEYOND THE
MANUFACTURER’S MAXIMUM GROSS VEHICLE WEIGHT RATING.

1. Raise the rear of the vehicle by the frame so that the rear tires are just slightly contacting the floor. Be sure to
block the front tires and use Jack Stands to support the vehicle by the frame.

2. Lay out the spring leaves into two (2) sets. Each will consist of a main leaf with u-bolt cups and a second leaf

without cups. Lay the leaves so that the long ends are all in the same direction. Stack the leaves so that the
main leaf is on top. The long end of the spring stack must be installed toward the rear of the vehicle and the
short end toward the front.

3. Place the spring stack on top of the main spring with the long end toward the rear of the vehicle.

4. Place the U-bolts with the straight legs in the cups at the ends of the spring with the silencer bushing between

the main spring and the helper spring as shown in the diagram. Loosely install a single crossbar on the end U­bolts using the hardware provided.

5. Adjust the crossbars on the end of the springs so that the adjacent leaf tip will not make contact with the

crossbar when the spring is deflected. It may be necessary to move the spring stack fore or aft for best
alignment.

6. Install the offset U-bolts with the offset toward the axle as shown in the diagram. The U-bolt should be

fastened as close to the hat section as possible. If you are working on 2-1/2” wide springs position the
outboard U-bolt leg against the outboard edge of the main spring to maximize brake hose, caliper, and backing
plate clearance. The U-bolts may also be installed with the legs pointing up and crossbars on top of spring to
provide additional clearance if required. Stack two (2) crossbars and place over legs of U-bolts. Attach with
the washers and nuts to connect to the main spring. Torque the nuts to 65 ft-lb and double nut.

905 ( R-905) 12/16/2011

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

7. Adjust the U-bolts at the end to desired preload. The minimum tension adjustment is having enough tension on
the end U-bolts so that they do not loosen or rattle and move when the vehicle is driven over rough or bumpy
surfaces. Maximum adjustment is when the leaf cups have been deflected two (2) inches from their free state.
DO NOT EXCEED THE MAXIMUM ADJUSTMENT OF 2 INCHES.

8. When adjustment is complete, double nut to lock in adjustment.

9. Lower vehicle to the ground and check your installation for clearance on all undercarriage components; wires,
fuel, brake, and air conditioning lines. Test drivethe vehicle and recheck your installation, adjust as needed.
Recheck on a monthly basis thereafter.

IMPORTANT NOTE: CHECK YOURINSTALLATION. ARE ALL NUTS AND BOLTS SECURELY

TIGHTENED AND DOUBLE NUTTED WHERE PROVIDED? BOUNCE THE VEHICLE CHECKING
FOR CLEARANCE ON ALL UNDERCARRAIGECOMPONENTS, MUFFLERS, GAS FILLER PIPES,
BRAKE LINES, EMERGENCY BRAKE CABLE, AIR CONDITIONING LINES, RUBBER BOTTOMING
PADS, ETC.

IMPORTANT NOTES, WARNINGSAND TIPS

Before attempting the installation of any Hellwig Accessory Spring , be sure and identify the vehicle to which the
accessory spring will be installed as either being or not being equipped with height sensing brake fluid proportioning
valve. If a vehicle is equipped with the brake fluid proportioning valve on the rear axle, it is recommended that any
Hellwig Full Time Accessory Spring NOT be installed. Only the Progressive Rate Accessory Springs are to be in­stalled on these vehicles. Some of the vehicles manufacturers (FORD, GM, DODGE) have recommended an adjust­ment or modification of the brake system. If the vehicles height or weight requirements have been changed due to the
suspension modifications or unusual load situations, contact your local dealer for correct adjustment after installation.

If you have any questions about the application, please contact Hellwig Products Company.

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

ALL IMORTANTNOTE CARDS AND THE WARRANTY FORM

905 ( R-905) 12/16/2011