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559-734-7451 800-367-5480 FAX 559-734-7460
INSTALLATION INSTRUCTIONS
Lifted ApplicationAir Spring Kit
2001-08 Chevrolet/GMC 2500 HD
6in front/4in rear lift
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET COMPLETELYBEFORE STARTING
YOUR INSTALLATION
IMPORTANT NOTES
DO NOT INFLATE AIR SPRINGASSEMBLY UNLESS IT HAS BEEN
PROPERLY INSTALLED ON VEHICLE.
DO NOT INFLATE AIR SPRINGS OVER 100 PSI
AMINIMUM OF 5-10 PSI MUST BE MAINTAINED INAIR 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 OFYOUR VEHICLE. 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 DAMAGE TOYOUR VEHICLE AND 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.
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
1
2. Install fitting in port of air spring. Torque fitting
to approximately 20 ft-lb.
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3
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. Insert a carriage bolt in the forward square hole
and attach air spring to plate using the 3/8 x 3/4”
flat head cap screw provided. Torque to 20-25 ft-
4
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5. Place heat shield over top of air spring assembly
as shown. (Passenger side shown. Drivers side heat
shield is oriented to front of vehicle) Driver’s side
heat shield must be oriented to keep emergency
brake cable from rubbing on air spring.
5
6. Place frame bracket over air spring assembly and
attach using 3/8” locknut and washer. Torque nuts to
20 ft-lb. Passenger side shown.
6
7. Compress air spring assembly and
place on top of the axle pad. MAKE
SURE THAT THE ASSEMBLY
WILL NOT DAMAGE OR CRUSH
BRAKE LINES, WIRING HARNESSES, OR EMERGENCY
BRAKE CABLES.
Axle Pad
7
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Shock Bracket
8. Attach assembly to frame rail using 3/8 x 1-1/2 bolts, washers, and locknuts. Check alignment of heat shield and torque nuts to 30 ft-lb.
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9. It may be necessary to
trim the corner of the
shock bracket 1/16” 1/8” to allow the plate to
sit flush on axle pad.
Shock Bracket9
10. When the assembly is aligned
properly, install axle strap using carriage bolts and remaining nuts and
washers. It may be necessary to flex
the brake lines slightly to allow clearance for the axle strap. MAKE SURE
AXLE STRAPAND CARRIAGE
BOLT WILL NOT CONTACT
BRAKE LINE. Tighten nuts until the
strap ends flex slightly. The carriage bolts are designed to be long
enough for the 3500 HD installation.
For 2500 HD applications they can be
cut shorter if desired.
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11.Complete passenger and driver’s side installation of air spring assembly.
12.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.
13.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 CUTTINGAIR 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. A length of heat shielding is provided to protect the air line as it
exits the passenger side air spring.
14.Inflate air springs to 40 psi and check for leaks. Asoapy water solution can be
used to find slow leaks.
15.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.
16.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 THAT THE CUSTOMER
RECEIVES THIS INSTRUCTION SHEET, ALL IMORTANT NOTE
CARDS AND THE WARRANTY FORM.
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