Hellwig Air 6106 User Manual

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INSTALLATION INSTRUCTIONS

6106Air Spring Kit

1999+ Ford F250/350 Single Wheel 4WD

Thank you for purchasing a quality Hellwig Product.

PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING

YOUR INSTALLATION

IMPORTANT NOTES

DO NOT INFLATE ANYAIR 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 AND THE HOSE END
MUST NOT BE DEFORMED OR LEAKAGE MAY RESULT.

1999-2004 Models 2005-2007 Models

1

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

2. Install fitting in port of air spring. Torque fitting to approximately 20 ft-lb.

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3

Use this hole in frame rail

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3. Install lower frame bracket using
long flat head bolt and flanged lock
nut. Leave loose for adjustment later.

4. Locate Large hole in frame rail. Attach
upper frame bracket using supplied 3/4”
bolt, flat washers, lock washer, and nut
with washers on both sides of rail and bolt
head on outside of rail. Leave loose for ad­justment later. Align slotted holes with
holes in lower bracket so that air spring
studs can be inserted through holes in both
upper and lower frame brackets. When
brackets are properly aligned, tighten lower

Align holes in brackets for
air spring studs

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bracket flat head bolt to 20-25 ft-lb.

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5. Place heat shield on top of air spring and insert
air spring through holes in both frame brackets.
Attach using flange head nuts. Driver side shown
uses heat shield to prevent emergency brake cable
from rubbing on air spring. Align passenger side
heat shield to prevent heat from exhaust pipe from
damaging air spring. Tighten nuts to 20 ft-lb. Af­ter tightening air spring nuts, tighten 3/4” bolt to
100-125 ft-lb. If bolt is used by fifth wheel hitch

Emergency Brake Cable

5

mounting brackets, tighten bolt to hitch manufac­turer’s specifications.

Bump Stop Tongue

Install this hole to­ward Front of vehicle.

Low Position High position

6

Front of vehicle.

Use spacer tab if there
is a gap between axle
bracket and top of axle.
If no gap exists, use
bracket without spacer
tab.

6. Insert axle bracket between air spring and axle as shown. The short bracket is used on
driver’s side and the long bracket is used on the passenger side. With the bracket resting
on cast bump stop tongue note fit of bracket to axle. If no gap exists proceed to step 7.
If there is a gap between the axle and the end of bracket, install spacer tab on axle
bracket with holes oriented as shown in photos for high and low position. Note orienta­tion of tab with regard to front of vehicle .

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7

Limiter Tab

8

Air spring bolt

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7. Insert limiter tab over bump stop tongue
as shown.

8. Reinstall axle bracket and attach air
spring to limiter tab and axle bracket using
3/8” x 1” bolt as shown. Tighten bolt to
20-25 ft-lb. Insert legs of U-bolt through
holes in bracket. It is preferred to use the
upper holes, but if U-bolt cannot be in­stalled in upper holes, use the lower holes
as shown. Attach U-bolt using 3/8”
flanged lock nuts and tighten until bracket
flexes slightly.

9. 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. Make sure that heat shields
are positioned for maximum protection of
air spring.

9

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

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 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.

15.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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