Hellwig Air 6102 User Manual

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ALL VEHICLES WILL REQUIRE REMOVAL OF THE REAR TIRES. RAISE THE VEHICLE BY THE FRAME TO

INSTALLATION INSTRUCTIONS

Thank you for purchasing a quality Hellwig Product.

PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING YOUR INSTALLATION

TORQUE TABLE

NOTE : THESE AIR SPRINGS ARE DESIGNED TO MOUNT TO THE AXLE AND THE FRAME , SOME DRILLING

ON THE VEHICLES FRAME MAY BE NECESSARY.

NOTE : IT MAY BE NECESSARY TO JACK THE VEHICLE BY THE FRAME TO MAKE ENOUGH SPACE BETWEEN

THE AXLE AND THE FRAME TO INSTALL THE AIR SPRING. REMOVAL OF THE REAR TIRES MAY BE NEC­ ESSARY TO GAIN ACCESS TO THE AREA ON THE FRAME WHERE THE HOLES ARE TO BE DRILLED. NOT

CHECK FOR ACCESS CLEARANCE.

NOTE : IF THE REAR TIRES ARE TO BE REMOVED SUPPORT THE VEHICLES FRAME BY USING JACK STANDS AND

BLOCKING THE FRONT VEHICLES TIRES.

1. As per the diagrams , attach the air spring to the frame bracket with the locknuts provided. On the air spring that
mounts on the passenger side of the vehicle , install the heat shield between the air spring and the vehicles frame.
Tighten just slightly to allow for adjustment later.

2. Use the 3/8” bolt and lock washer provided attach to the lower axle bracket at the bottom of the air spring. There are a
variety of drilled holes on this bracket. It may be necessary to change holes after mounting for best fit so that the air
spring is properly aligned on your particular vehicle. Leave loose at this time to allow for adjustment later.

3. Install the brass air fitting into the top of the air spring. Tighten the fitting completely so that some of the thread seal­ant gets down inside the threads of the air spring. Align the air fitting so that the air hose points in the direction de­sired for your particular vehicle.

4. Locate the rubber bump stop bracket that is mounted to the bottom of the vehicles frame and directly above the vehi­cles axle. Remove the bump stop brackets , these items will not be reused.

5. Place the air spring assembly on top of the vehicles axle. Place the frame bracket on the outside of the vehicles frame.
The frame bracket needs to be up against the bottom and flat to the outside of the vehicles frame. The frame bracket
should nest into the radius and be up against the bottom of the vehicles frame. The lower holes on the side of the
frame bracket are for clearance over the rivets that are on the vehicles frame. If your vehicle does not have rivets on
the frame these holes will not be used.

6. With the assembled air spring in position, align the brackets so that the air spring is as straight as possible. The frame
bracket should be centered on the reinforced area for the bump stop bracket. With the brackets in the proper position
use the upper holes in the upper frame brackets to mark the locations on the vehicles frame, where the mounting holes
will be drilled for mounting. Before drilling the vehicl es frame make sure and move any wires , hoses or any other
items from inside the frame to avoid any damage when drilling the mounting holes. Do the same on opposite frame.

7. Using a 7/16” drill bit , drill the two holes on the vehicles frame. Place the air spring into position , insert the bolts
with washers provided through the frame brackets and the vehicles frame. The threaded end of the bolts will be on the
inside of the vehicles C-channel frame. The inner frame bracket will mount flush against the inside of the frame and
to the top of the air spring. There are two inner frame brackets per air spring they are bent opposite each other. One
on the front and one on the rear , when properly installed the bent legs of the brackets will be facing each other. The
small corners that are trimmed off on the inner frame brackets will mount towards the brass air line fitting. Remove
the air spring upper lock nut , insert through the frame bracket re-install the lock nut do not over tighten. Leave loose
to allow for adjustment later. The inner frame brackets ar e designed to allow for a tunnel next to the vehicles frame
so any electrical wires , fuel lines or hoses can be placed back against the frame as before. Use the plastic insulator
covers that are supplied for protection as needed.

NOTE : use bracket # 20800247 if extra clearance is required for relocating wires, fuel and brake lines in the

frame rails ( SEE LAST PAGE FOR ILLISTRATION ).

BOLT THREAD DIAMETER : 3/8” = 20-30 ft. lbs. – 7/16” = 35-45 ft. lbs. – ½” = 50-70 ft. lbs. – 9/16” = 70-90 ft. lbs.

6102 ( R-6102 ) 09 -17-07

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

8. Place the carriage bolts into the lower axle brackets so that the threads hang down next to the axles. Mount the
axle clamp brackets under the vehicles axle to align with the carriage bolts. Be sure to move any brake lines or

fuel hoses or other items on the axle to avoid damage during installat ion. Attach the axle brackets with the car­ riage bolts with the locknuts provided. Either set of holes in the lower axle bracket can be used. Choose for best
fit as per your vehicle. Leave loose at this time to allow for adjustment later.

9. Move the frame bracket on the frame and the axle bracket on the axle to align the air springs as straight up

and down as possible. Once the air springs are properly aligned make sure all lines , hoses and wires are out of
the way so that they will not be crushed during installation. Rotate the heat shield to protect the air spring from
the vehicles exhaust. Torque all frame mounting hardware to specified rate. Double check the alignment after
tightening. Torque the top air spring lock nuts to max. 25 ft lbs.

10. Tighten the axle clamp locknuts completely , be careful as to not bend the brackets. The corners of the lower axle

brackets will grip the top of the axle. This will prevent the bracket from rotating on the axle. With the clamp
bracket properly installed at the bottom of the axle it will not rotate.

11. Cut the 1/4” air line into two ( 2 ) equal lengths. Make sure that the air line has a straight clean cut to avoid

air leaks after installation. Connect one end of the air line to the brass air fitting on top of the air spring. See
the air hose fitting diagram for the style of fittings that are supplied in your particular kit. If an air compressor is
being installed on your vehicle follow the mounting instructions for proper hose routing.

12. Route the air line to the desired fill location. Using the supplied plastic tie straps , tie the air line to either existing

wires , lines or hoses. Be careful , and keep the air lines away from the exhaust system to avoid damage. Use the
black hose insulator if needed for extra protecti on. Keep air line and mounting hardware minimum 1-1/2” from
making contacting with any of the exhaust components. Find a location , either on the vehicles frame or bumper
to install the air fill valve. Using a 5/16” drill bit , drill a hole at desired fill location. Your kit is supplied with
( 2 ) schrader air fill valves , one per air spring. NOTE : see page #5 for the style of air fill valve that is supplied
in your installation kit.

13. With the air springs properly mounted and secured to the vehicle , inflate the air springs to approximately 30 lbs

PSI. Using a squirt bottle with a mixture of 30% liquid dish soap and 70% water check the entire system for air
leaks. If an air leak is detected remove the air pressure from the entire system before repairing the leak. Usually
tightening the fittings will repair the leak. Re-inflate and retest the system until no leaks are detected.

14. Keep a minimum of 5-10 lbs PSI in your systems at all times to avoid any damage. For best ride use only

enough air pr essure as required to level the vehicle. If a firmer ride is desired , more pressure can be used.
The air springs can be inflated to any level between 10-100 PSI.

15. Check air pressure in the system regularly to ensure system performance and to maintain the warranty. Just like

tires the air pressure in the system will vary due to temperatur e changes. For your air springs to function properly
they must be checked on a regular basis.

NOTE : NEVER LOAD THE VEHICLE THAT THIS KIT IS BEING INSTALLED ON BEYOND THE

MANUFACTURERS MAXIMUM GROSS VEHICLE WEIGHT RATING

ATTENTION INSTALLER: BE SURE THAT THE CUSTOMER RECEIVES THIS INSTRUCTION

SHEET, ALL IMORTANT NOTE CARDS AND THE WARRANTY FORM

6102 ( R-6102 ) 09-17-07

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IMPORTAN T NOTE

DO NOT ATTEMPT ANY MODIFICATIONS TO THE VEHICLE OTHER THAN
THOSE OUTLINED IN THIS INSTRUCTION SHEET. IF ANY INTERFERENCE
OCCURS WITH GAS TANKS , BRAKE & FUEL LINES , EXHAUST PIPES , ETC.,
STOP YOUR INSTALLATION AND CONTACT HELLWIG PRODUCTS CO. FOR
TECHNICAL ASSISTENCE OR INSTRUCTIONS.

NEVER LOAD THE VEHICLE THIS UNIT IS BEING INSTALLED ON BEYOND
THE MANUFACTURERS MAXIMUM GROSS VEHICLE WEIGHT RATING.

WHEN LIFTING THE VEHICLE WITH A JACK, BE SURE TO SET THE PARKING
BRAKE AND BLOCK THE TIRES. USE SAFETY STANDS AND SUPPORT THE
VEHICLE BY THE AXLE TO KEEP THE SUSPENSION LOADED.

WHEN REINSTALLING THE TIRES ON THE VEHICLE , CHECK THE
MANUFACTURERS SPECIFICATIONS FOR PROPER TORQUE RATINGS.

MOVE ANY ELECTRICAL WIRES , FUEL & BRAKE LINES , OR ANY OTHER
OBJECTS INSIDE THE FRAME RAILS BEFORE DRILLING ANY HOLES TO
AVOID DAMAGE TO ANY OF THE VEHICLES COMPONENTS.

BE SURE THE FLA T PLATES INSIDE THE FRAME RAILS ARE BEHIND ANY
WIRES , LINES , OR HOSES TO AVOID PINCHING OR CRUSHING WHEN THE
MOUNTING HARDWARE IS TORQUED TO THE SPECIFIED RATE.

THIS UNIT MUST BE MOUNTED SECUREL Y TO THE VEHICLE AT THE TOP AND
BOTTOM MOUNTING BRACKETS PRIOR TO ADDING ANY AIR PRESSURE OR
DAMAGE CAN OCCUR.

THE PROPER AIR SPRING SETUP HEIGHT IS BETWEEN FIVE ( 5 ) AND SIX AND
ONE HALF ( 6-1/2 ) INCHES. BETWEEN THE TOP OF AIR SPRING END CAP TO
BOTTOM OF AIR SPRING END CAP.

6102 ( R-6102 ) 09-17-07