Hellwig 6406 User Manual

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

INSTALLATION INSTRUCTIONS

Thank you for purchasing a quality Hellwig Product.

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 [phone]

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