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INSTALLATION INSTRUCTIONS
6012Air Spring Kit
1999-2006 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 SPRINGASSEMBLYUNLESS IT HAS BEEN
PROPERLY INSTALLED ON VEHICLE.
DO NOT INFLATE AIR SPRINGS OVER 60 PSI
AMINIMUM OF 5-10 PSI MUST BE MAINTAINED IN AIR SPRINGS
AFTER INSTALLATION FOR WARRANTYTO BE VALID. FAILURE TO
KEEPMINIMUM PRESSURE INAIR SPRINGS WILLVOID WARRANTY.
THIS UNIT IS DESIGNED TO INCREASE THE LEVELLOAD CARRYING
CAPACITY OFYOURVEHICLE. NEVER LOAD THE VEHICLE THIS
UNIT IS INSTALLED ON BEYOND THE MANUFACTURER’S MAXIMUM
GROSS VEHICLE WEIGHT RATING.
OVERINFLATIONAND IMPROPER USE MAY RESULT IN PERSONAL
INJURYAND/OR DAMAGETO YOUR VEHICLEAND PROPERTY.
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BEFORE STARTINGYOUR 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.
2 Wheel Drive 4Wheel Drive
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
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socket
2. Install elbow fitting in port of air spring. Torque fitting to
approximately 20 ft-lb. Make sure that fitting is oriented as
shown in photo.
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Short End to front of vehicle
Front of Vehicle (Pass Side Shown)
This side toward wheel
Attach air spring to plate using countersunkhole.
Long End to rear of vehicle
This side toward center of axle
3. Lay out base plate as shown in photo. The air spring mounting hole is countersunk
on both sides to allow the plate to be oriented correctly for both the left and right sides
of the vehicle. (Passenger side shown) Attach air spring to plate using 3/8” flathead
bolt. Tighten to 20 ft-lb.
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.
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Early Model Late Model
5. If you have an early model with the brake line tee mounted on the driver’s side
axle tube as shown in photo, proceed to step 6. If you have a later model with
the brake line tee mounted from the center section of the axle skip to step 11.
6. Using a 13mm wrench, remove bolt
connecting brake tee to axle bracket and
save for use later. Bend tab flat with pliers as shown in photo.
6
7. Attach brake line spacer tab to axle bracket
using bolt removed in step 6. Place washer
under head of bolt to prevent bolt from bottoming on axle. Align tab as shown in photo
with new brake tee attachment point 1/2” inboard of previous location to prevent brake
hose from rubbing on air spring. Do not
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connect brake line tee to bracket at this time.
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8. Place air spring assembly between frame rail and
axle pad as shown and align frame bracket with
holes in frame rail. .
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Brake hose
9. Connect brake line tee to spacer tab using 5/16 bolt, washer and locknut. Rotate
brake line tee gently to position tee so that
brake hose has at least 1/2” clearance to air
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spring. The brake lines can be flexed
slightly for best location of tee and brake
hose. Notice new location of brake line
tee is 1/2” inboard of old location. Tighten
5/16” bolt to 15 ft-lb.
10. Gently reposition brake line to
match profile as shown in photo. Take
care not to kink or deform brake line.
Make sure that there is adequate clearance between brake line and shock absorber, axle bracket and other components. Proceed to step 12.
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11. Place air spring assembly between frame
rail and axle pad as shown.
Spacer Plate
12. Insert spacer plate with two slotted holes between frame rail and frame
bracket as shown. Insert 3/8 X 1-1/4 bolts into holes in frame and attach using
flange nuts. Tighten to 25 ft-lb.
13. Insert carriage bolts into square holes
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 relocate brake
lines slightly to provide clearance to carriage bolt and axle strap. MAKE SURE
AXLE STRAPAND CARRIAGE BOLT
WILL NOT CONTACT BRAKE LINE.
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Tie Strap
14. Tie off emergency brake cable to
hole in passenger side frame bracket
using tie strap to avoid interference
with air spring.
15. 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.
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16. Complete passenger and driver’s side installation of air spring assembly.
17.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.
18.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 LEAKAGE 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. Alength of heat shielding is provided to protect the air line as it
exits the passenger side air spring.
19.Inflate air springs to 40 psi and check for leaks. A soapy water solution can be
used to find slow leaks.
20.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 60 psi. DO NOT
EXCEED THE GVW RATING OF THE VEHICLE. 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.
21.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.
ATTENTION INSTALLER: BE SURE THATTHE CUSTOMER
RECEIVES THIS INSTRUCTION SHEET, ALL IMORTANT NOTE
CARDS AND THE WARRANTY FORM.
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