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559-734-7451 800-367-5480 FAX 559-734-7460
INSTALLATION INSTRUCTIONS
6091Air Suspension Kit (pat. pending)
1999-2006 Tahoe, Suburban, Avalanche, Yukon
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET COMPLETELYBEFORE STARTING
YOUR INSTALLATION
IMPORTANT NOTES
IF EQUIPPED WITH FACTORY PREMIUM RIDE OR
AUTOLEVELSUSPENSION, CONTACT HELLWIG
PRODUCTS CO. FOR FURTHER INSTRUCTIONS.
DO NOT INFLATE ANYAIR SPRINGASSEMBLY UNLESS IT HAS BEEN
PROPERLY INSTALLED ON VEHICLE.
DO NOT INFLATE AIR SPRINGS OVER 100 PSI
CHECK AIR PRESSURE IN THE SYSTEM DAILY TO ENSURE
SYSTEM PERFORMANCE AND MAINTENANCE OF
WARRANTY.
AMINIMUM OF 25 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 LEVEL LOAD CARRYING
CAPACITY OF YOUR 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 TO YOUR VEHICLEAND PROPERTY.
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559-734-7451 800-367-5480 FAX 559-734-7460
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 ANYHOLES, ENSURE THAT ALL ELECTRICAL WIRES, FUELLINES, 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 THEGAS TANK, FUEL LINES, BRAKE LINES, EXHAUST
PIPE, ETC. EXISTS, STOP YOUR INSTALLATIONAND CALL HELLWIG PRODUCTS FOR TECHNICAL HELP.
IF WHEELS ARE REMOVED FOR INSTALLATIONOF KIT, CHECK MANUFACTURERS SPECIFICATIONS FOR
PROPER LUG NUT TORQUE BEFORE REINSTALLING WHEELS.
WHEN CUTTING AIRBRAKE TUBING, A SQUARE CUT IS REQUIRED AND THE HOSE END MUST NOT BE
DEFORMED OR LEAKAGEMAY RESULT. IF DEFORMATION OF THE HOSE END OCCURS, THE HOSE END
MUST BE REWORKED SO THAT IT IS ROUND.
ENGAGEMENTOF THE SEALING O-RING WILL BE FELT WHEN THE AIR LINE HAS BEEN INSERTED
PROPERLY INTO THE FITTING. FITTINGS MAY BE DISCONNECTED IF REQUIREDBY PUSHING DOWN ON THE
OUTER RING WHILE PULLING FIRMLY ON THE AIR LINE.
ROUTE AIRLINES AWAY FROM EXHAUST PIPES OR ANY OTHER SOURCESOF HEAT AND ENSURE THAT THE
AIR LINES ARE PROTECTED FROM SHARP EDGES.
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Measure this
distance
1. Prepare vehicle for installation by chocking front tires and setting emergency
brake. Before starting installation, measure the distance from the top of rear
wheel to fender lip as shown. This is the original ride height of the vehicle.
Write this measurement down as this will be used to set the height of the air
springs later in the installation.
2. For ease of installation, position the rear wheels on automotive ramps. Ensure vehicle is
secure and disconnect shock
absorbers from rear axle. Raise
Remove insulators
from frame and axle
vehicle frame until coil springs
are unloaded. Support frame
with jack stands and remove
coil springs and insulators from
vehicle. Do not remove bump
stops from frame.
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7/16UNF x 2-1/4 Bolt
Push Nut Clip
3/8 UNF Nut
Driver Side
1/2 MPT x 3/8
Hose fitting
This side of bracket
faces inboard
3. Prepare driver side air spring
assembly by installing 1/2” MPT
x 3/8 push to connect fitting into
air spring. Torque to 25-30 ft-lb.
The driver side frame bracket
has a full circle cut out for the
air fitting instead of a cut-out on
the edge. Attach frame bracket
to air spring with 3/8” UNF nuts.
Torque to 20 ft-lb. Place 7/1620x2-1/4” bolt through hole in
frame bracket and retain with
push nut clip. Push nut can be
installed on bolt by pushing on
clip with a deep well socket
while holding head of bolt in
place.
7/16UNF x 2-1/4 Bolt
Push Nut Clip
This side of bracket
faces inboard
Passenger Side
3/8 UNF Nuts
1/2 MPT x 3/8
Hose fitting
Heat Shields
4. Prepare passenger side air
spring assembly by installing
1/2” MPT x 3/8 push to connect
fitting into air spring. Torque to
25-30 ft-lb. The passenger side
frame bracket has a cut-out on the
edge of the bracket for the air fitting. Place two (2) heat shields
on top of air spring as shown and
attach frame bracket to air spring
with 3/8” UNF nuts. Torque to
20 ft-lb. Place 7/16-20x2-1/4”
bolt through hole in frame
bracket and retain with push nut
clip. Push nut can be installed on
bolt by pushing on clip with a
deep well socket while holding
head of bolt in place.
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This end inboard This end inboard
3/8-16 x 1” Bolt
3/8-16 x 1-3/4”
Bolt Install 11/4” spacer
tube between
bracket and air
spring
3/8-16 x 1” Bolt
Driver Side
Passenger Side
5. Attach axle bracket to air spring as shown. The reinforcement braces are to be
installed over the coil seat on the axle. Note that the bracket is installed so that
the braces are under the air spring. The section of the axle bracket without
braces will be installed so that it faces inboard toward the center of the axle.
There are differences in how the brackets attach to the air spring for the driver
and passenger assemblies. On the passenger side assembly attach the 3/8-16 x
1-3/4” bolt and 1-1/4” spacer to air spring and axle bracket as shown. Then attach 3/8-16 x 1” bolt to air spring through middle hole of axle bracket as shown.
Snug bolts but do not tighten to allow for adjustment. On the driver side assembly attach the axle bracket to the air spring using the slotted holes as shown using 3/8-16 x1” bolts. Snug bolts but do not tighten to allow for adjustment.
Passenger Side
3/8-16 x 1-3/4” Bolt
Install 1-1/4” spacer
tube between
bracket and air
Coil spring seat—install
bracket so that reinforcement
braces center bracket on seat.
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Place frame bracket over coil spring
seat
6. Compress air spring assembly and install between axle and frame. Place brackets over
coil spring seats so that the cut-out in the frame bracket and the reinforcements in the axle
bracket fit over the raised lip of the seat. Adjust axle brackets so that air springs sit square
and tighten bolts to 20 ft-lb. Heat shields may need to be bent slightly to clear exhaust pipe.
Nut and lock washer
Frame Washer
7. To aid assembly of brackets to frame, lower frame of vehicle slightly so that the air spring
assembly holds itself in place between the axle and frame. While lowering frame, DO NOT
get under vehicle or place hands between axle and frame. Place frame on jack stands before
continuing work. Attach frame bracket by placing frame bracket over coil spring seat so that
the cut-out in the frame bracket fits over the raised lip of the seat. Place frame washer over
bolt and attach bracket with 7/16”nut and lock washer. Tighten 7/16” bolt to 35-40 ft-lb.
Due to the close quarters of the body and frame it is advised to hold the nut in place with a
wrench and tighten the bolt head. To gain additional clearance to tighten the nut, the plastic
inner fender wells can be unbolted.
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Slotted hole
8a. 1999– early 2006 models—Driver side panhard axle bracket has a large slotted hole to
insert bolt through as shown. Place 3/8-16x2-3/4” bolts through slotted holes in axle bracket
as shown and attach qty 2 axle straps per side to axle using washers and 3/8” locknuts.
Tighten nuts until legs of axle straps bend slightly. Relocate brake lines so that they do not
interfere with axle brackets, bolts, straps and air springs.
Thick washers
8b. Late 2006 models on - Driver side panhard axle bracket does not have a large slotted hole.
Place 3/8-16x2-3/4” bolts through slotted holes in axle bracket as shown and attach qty 2 axle
straps to passenger side axle bracket using washers and 3/8” locknuts. Attach 1 axle strap to
outboard side of axle bracket only as shown for early models. Place qty (2) 1/4” thick washers between axle bracket and panhard axle bracket as shown. Shim axle bracket with additional flat washers until bracket is parallel with axle. Insert 3/8-16 x 1-1/2 bolt and tighten
locknut to 20 ft-lb. Tighten nuts on axle straps until legs of axle straps bend slightly. Relocate brake lines so that they do not interfere with axle brackets, bolts, straps and air springs.
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Panhard bolt
10. Recheck all fasteners for proper torque and ensure adequate clearance to all vehicle components – exhaust, brake hoses, brake lines, shocks, differential, etc. Make sure that passenger
side panhard bolt will not contact air spring during use. A minimum of 1/2” clearance is required. If necessary, remove and re-install panhard bolt with bolt head facing air spring to
provide clearance.
11.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.
12.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. A length of heat shielding is provided to protect the air line as
it exits the passenger side air spring.
13. Inflate air springs to 40 psi and check for leaks. A soapy water solution can be used to find
slow leaks.
14.When satisfied with integrity of the system, adjust air pressure to desired level. The air
springs can be inflated to any level between 25 and 100 psi. DO NOT run the air springs
empty or warranty will be void. 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.
15.CHECK AIR PRESSURE IN THE SYSTEM DAILY TO ENSURE SYSTEM PER-
FORMANCE 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 daily basis. Failure to maintain air pressure will result in
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For Best Performance
This suspension system is designed to work with the factory supplied shocks and
suspension components, however, for increased performance, Hellwig Products recommends the following suspension upgrades:
2000-06 Models
Monroe Reflex Shock Absorber p/n 911178 front* / 911166 rear*
Hellwig p/n 7633 1-5/16” front sway bar
Hellwig p/n 7650 1-1/4” rear sway bar
2007-present Models
Monroe Reflex Shock Absorber p/n 941001 front* / 911506 rear*
Hellwig p/n 7685 1-1/2” front sway bar
Hellwig p/n 7686 1-1/4” rear sway bar
*confirm part number to application as part number may change
ATTENTION INSTALLER: BE SURE THAT THE CUSTOMER RE-
CEIVES THIS INSTRUCTION SHEET, ALL IMORTANT NOTE CARDS
AND THE WARRANTY FORM.
6091 ( R-6091) 03/09/07
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