Hellwig Air 6005 User Manual

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

INSTALLATION INSTRUCTIONS

6005 Air Spring Kit

1988-98 Chevrolet/GMC 1500 2WD & 4WD

Thank you for purchasing a quality Hellwig Product.

PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING

YOUR INSTALLATION

IMPORTANT NOTES

DO NOT INFLATE AIR SPRING ASSEMBLY UNLESS IT HAS BEEN

PROPERLY INSTALLED ON VEHICLE.

DO NOT INFLATE AIR SPRINGS OVER 100 PSI

A MINIMUM OF 5-10 PSI MUST BE MAINTAINED IN AIR SPRINGS
AFTER INSTALLATION FOR WARRANTY TO BE VALID. FAILURE TO
KEEP MINIMUM PRESSURE IN AIR SPRINGS WILL VOID WARRANTY.

THIS UNIT IS DESIGNED TO INCREASE THE LEVEL LOAD CARRYING
CAPACITY OF YOUR VEHICLE. NEVER LOAD THE VEHICLE THIS
UNIT IS INSTALLED ON BEYOND THE MANUF ACTURER’S MAXIMUM
GROSS VEHICLE WEIGHT RATING.

OVERINFLATION AND IMPROPER USE MA Y RESULT IN PERSONAL
INJURY AND/OR DAMAGE TO YOUR VEHICLE AND PROPERTY.

6005 ( R-6005 ) 11/17/06

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

BEFORE STARTING YOUR PROJECT

WHEN LIFTING A VEHICLE WITH A JACK, BE SURE TO SET THE PARKING BRAKE AND USE
SAFETY STANDS.

ENSURE THAT THE INSTALLATION OF COMPONENTS WILL NOT CRUSH OR DAMAGE
FUEL AND BRAKE LINES OR ELECTRICAL HARNESSES.

BEFORE DRILLING ANY HOLES, ENSURE THAT ALL ELECTRICAL WIRES, FUEL LINES,
BRAKE LINES, BRAKE HOSES AND ANY OTHER COMPONENTS ARE MOVED OR
PROTECTED TO AVOID DAMAGE FROM DRILLING ANY HOLES .

DO NOT ATTEMPT ANY MODIFICATIONS TO THE VEHICLE OTHER THAN THOSE
OUTLINED IN THIS INSTRUCTION SHEET. IF ANY INTERFERENCE WITH THE GAS TANK,
FUEL LINES, BRAKE LINES, EXHAUST PIPE, ETC. EXISTS, STOP YOUR INSTALLATION AND
CALL HELLWIG PRODUCTS FOR TECHNICAL HELP.

IF WHEELS ARE REMOVED FOR INSTALLATION OF KIT, CHECK MANUFACTURERS
SPECIFICATIONS FOR PROPER LUG NUT TORQUE BEFORE REINSTALLING WHEELS.

WHEN CUTTING AIR BRAKE TUBING A SQUARE CUT IS REQUIRED OR LEAKAGE MAY
RESULT.

Remove Brake
bracket bolts

Bump Stop

1

Remove Brake
clip bolt

1. Park vehicle securely and set parking brake and chock wheels. Remove factory
bump stops from vehicle by removing nuts from studs using a 15mm wrench or socket.
Disconnect brake line clip and bracket from frame rail.

6005 ( R-6005 ) 11/17/06

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

Brake clip bolt hole

Bump Stop holes

2. Slide angle bracket behind brake line and brake bracket as shown. Align
bracket with existing hole in frame for brake line clip and bump stop holes.

Front of Vehicle

Attach air spring to plate us­ing forward most countersunk
hole

3. Lay out base plate as shown in photo. Attach air spring to base plate using 3/8” x
1” flat head cap screw in forward most hole. Torque to 20-25 ft-lb.

6005 ( R-6005 ) 11/17/06

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

4

4. Install heat shield and frame bracket as shown. (Passenger side shown.
Driver’s side does not require heat shield.) Torque nuts to 20 ft-lb.

5

5. Place air spring assembly between frame rail and axle pad as shown. Attach
frame bracket to rail and angle bracket using 3/8 x 1-1/4 bolts and flange nuts.
LEAVE LOOSE FOR ADJUSTMENT LATER.

6005 ( R-6005 ) 11/17/06

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

Drill holes and attach angle bracket here

Tighten frame bracket bolts to 25 ft-lb

6. Drill 13/32” holes in frame using existing holes in angle bracket as a guide.
Attach angle bracket using 3/8” x 1” bolts and flange nuts with a washer placed
under the bolt head. Reattach brake line brackets using factory fasteners and
tighten to factory specification. Tighten frame bracket and angle bolts to 25 ft-lb.

7. Insert carriage bolts into slotted holes in axle
plate as shown in photo. Attach axle strap using
washers and flange nuts. Tighten nuts until arms
of axle strap flex slightly. It may be necessary to
unclip the brake line from the axle and place axle
strap under brake line if required for clearance.
Check your installation to ensure that all fasteners
are tight and that the assembly and all fasteners
clear brake and fuel lines, emergency brake cables,
fuel tanks, wiring harnesses, etc.

7

6005 ( R-6005 ) 11/17/06

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

8. Complete passenger and driver’s side installation of air spring assembly.

9. .Select a location for the air inflation valves. The location can be on the
bumper or body of the vehicle where an air chuck can be used to inflate the air
springs. Select a location where the valve will not be damaged or interfere
with the operation of other components.

10.Cut air brake lines to length and connect air lines to fittings by pushing the air
line into the air fittings as far as possible. WHEN CUTTING AIR BRAKE

TUBING, A SQUARE CUT IS REQUIRED AND THE HOSE END MUST
NOT BE DEFORMED OR L EAKAGE MAY RESULT. IF DEFORMA­TION OF THE HOSE END OCCURS, THE HOSE END MUST BE RE­WORKED SO THAT IT IS ROUND. Engagement of the sealing O-ring

will be felt when the air line has been inserted properly into the fitting. Fittings
may be disconnected if required by pushing down on the outer ring while pull­ing firmly on the air line. Route air lines away from exhaust pipes or any other
sources of heat and ensure that the air lines are protected from sharp edges. A
length of heat shielding is provided to protect the air line as it exits the passen­ger side air spring.

11.Inflate air springs to 40 psi and check for leaks. A soapy water solution can be
used to find slow leaks.

12. When satisfied with integrity of the system, adjust air pressure to desired
level. The air springs can be inflated to any level between 10 and 100 psi. DO
NOT run the air springs empty or warranty will be void. MINIMUM air spring
pressure is 5 psi. Failure to keep air in the air springs will void the warranty.
For best RIDE use only enough air pressure as required to level the vehicle. If
a firmer ride is desired, more pressure can be used.

13.Check air pressure in the system regularly to ensure system performance and
maintenance of warranty. Just like tires, the air pressure in the system will
vary due to temperature changes. For your air spring system to function prop­erly it must be checked on a regular basis.

ATT ENTION INSTALLER: BE SURE THAT THE CUSTOMER

RECEIVES THIS INSTRUCTION SHEET, ALL IMORT ANT NOTE
CARDS AND THE WARRANTY FORM.

6005 ( R-6005 ) 11/17/06