Hellwig 6406 User Manual

559-734-7451 800-367-5480 FAX 559-734-7460
INSTALLATION INSTRUCTIONS
PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING
YOUR INSTALLATION
IMPORTANT NOTES
DO NOT INSTALL THIS UNIT ON CAB AND CHASSIS TRUCKS. THIS UNIT WILL INTERFERE WITH THE REAR TIRES ON CAB AND CHASSIS TRUCKS CAUSING DAMAGE TO THE AIR SPRING OR TIRES, OR TO BOTH. THIS KIT IS DESIGNED FOR USE ON PICKUP TRUCKS ONLY
DO NOT ATTEMPT ANY MODIFICATIONS TO THE VEHICLE OTHER THAN THOSE OUTLINED IN THIS INSTRUCTION AND WARNING SHEET. IF ANY INTERFERENCE WITH THE GAS TANK , FUEL OR BRAKE LINES, EXHAUST PIPE ETC.. STOP YOUR INST ALLATION AND CALL HELLWIG PRODUCTS FOR TECHNICAL HELP OR INSTRUCTIONS.
NEVER LOAD THE VEHICLE THIS UNIT IS INSTALLED ON BEYOND THE VEHICLES MANUFACTURER’S MAXIMUM GROSS WEIGHT RATING.
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.-5/8”=120 ft. lbs.
IMPORTANT WARN-
TIRE (7) SEVEN INCHES
MINIMUM CLEARANCE REQUIRED BETWEEN OUTSIDE OF FRAME AND INSIDE OF TIRE
SEVERE TIRE AND AIR SPRING DAMAGE WILL OCCUR IF THIS DISTANCE IS NOT PRESENT
FRAME MOVE ANY
WIRES, LINES OR HOSES PRIOR TO
FIG # 1 TIRE TO WHEEL CLEARANCE FIG # 2 CONTACT OVERLAOD INSTALLATION
AIR SPRING
CONTACT OVERLOAD ASSY LOWER STEP BRACKET (REVERSE FOR CLEAR-
LEAF SPRING ASSY CROSSBAR
WASHER AND LOCKNUTS LONG BOLTS AND LOCKNUTS ( TRIM TO LENGTH AS NEEDED ) AXLE ASSY
ON VEHICLES WITH CONTACT OVERLOAD LEAVES, MOUNT THIS UNIT TO THE TOP OF THE CONTACT LEAF, IF YOUR VEHICLE DOES NOT HAVE ENOUGH SPACE FOR THE AIR SPRING ASSY,REMOVAL OF THE CONTACT OVERLOAD
6400 ( R-6400 ) 12/20/06
559-734-7451 800-367-5480 FAX 559-734-7460
NOTE: THIS UNIT IS DESIGNED TO MOUNT TO THE SIDE OF THE FRAME AND TO THE LEAF
SPRING ABOVE THE AXLE. DRILLING HOLES IN THE SIDE OF THE FRAME WILL BE NECESSARY. IT WILL BE NECESSARY TO REMOVE THE TIRES, SUPPORT THE VEHICLE BY THE AXLE WITH SAFETY STANDS AND BLOCK THE FRONT TIRES.
IMPORTANT: BEFORE BEGINNING THE INSTALLATION, CHECK TO BE SURE THERE IS ENOUGH
CLEARANCE BETWEEN THE FRAME AND THE TIRE FOR THIS ASSEMBLY. 1994 AND NEWER DODGE 4-WHEEL DRIVE PICKUPS MINIMUM CLEARNACE DISTANCE IS (7) INCHES. SEE DIAGRAM DETAILING FENDER WELL MODIFICATIONS NECES­ SARY FOR THIS INSTALLATION. ( SEE FIG # 7 )
1. This unit is designed to be fully adjustable, the upper frame brackets and top air spring plate are
made up from three different brackets. Attach the air spring to the top plate with the 3/8” lock- nuts provided. Be sure the air line fitting hole aligns with the large hole on the plate, the bent lips on the upper plate go upwards away from the air spring. Tighten to 20 ft. lbs. max.. Install the air line fitting into the large hole in the top of the air spring. Tighten completely so that some of the red sealant is down inside the threaded hole. Align the hose port on the fitting to point towards the expected air line route. Be careful not to damage the hose nut or the inner hose sleeve when tightening the fittings. ( SEE FIG # 3 OR # 5 )
2. Attach the lower step bracket to the bottom of the air spring. Use the small bolt and lock washer provided. A variety of slots are provided to assure proper air spring alignment. Tighten to be snug. 20 ft lbs. max.. Reverse direction or switch holes or positions as to best fit your particular vehicle. ( SEE FIG # 3 OR # 5 )
3. Place the assembly onto the leaf springs above the axle. The frame mount brackets are reversi­ble above or below the top plate, however, there is a right and a left side. The left side below the plate is the right side above the plate. Position the mount brackets to attach to the top of the up­per air spring plate and so the frame mounting holes are against the side of the frame rail. At­tach the frame mount brackets to the upper plate with the shortest 3/8” bolts provided. Be sure to place the heads of the bolts on the air spring side of the bracket. Adjust the frame brackets to compensate for any contours on your particular frame. Snug these bolts, DO NOT TIGHTEN. ( SEE FIG # 4 OR # 6 )
4. Adjust the upper brackets on the frame so the air spring is as straight up and down as possible. Set the air spring to be between 5 and 6-1/2 inches between the brackets. The air springs come shipped at approximately 6”, this is a good set up height. Use the (4) extra crossbars provided as spacers to elevate one end of the step brackets on the leaf springs to make the assembly as level as possible. ( SEE FIG # 3 )
5. With the air spring straight and at the desired setup height, use the holes in the frame brackets and mark the locations to drill the holes, make the mark in the center of the slots to allow for adjustment. Be sure to double check all dimensions. ( SEE FIG # 3 OR # 5 )
6. Being sure to move any lines or wires inside the frame to avoid damaging with the drill. Drill the (4) mount holes with a 7/16” drill bit. Repeat this process for the other side.
7. Place the remaining short 3/8” bolts provided through the frame brackets and frame so the threads are under the vehicle. Place the flat plates inside the frame on the bolts and attach with the locknuts provided. Tighten only to be snug. Be sure not to pinch any lines, hoses or wires inside the frame with the flat plates. ( SEE FIGURE # 4 OR # 6 )
6400 ( R-6400 ) 12/20/06
Loading...
+ 4 hidden pages