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559-734-7451 800-367-5480 FAX 559-734-7460
INSTALLATION INSTRUCTIONS
6107Air Spring Kit
1999+ Ford F-250/350 Single Wheel 2WD
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 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 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.
1999-2004 Models 2005-2007 Models
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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
559-734-7451 800-367-5480 FAX 559-734-7460
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
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mounting brackets, tighten bolt to hitch manufacturer’s specifications.
6. Insert axle bracket between air
spring and axle The short bracket is
used on driver’s side and the long
bracket is used on the passenger side.
Attach air spring to bracket using 3/8”
x 1” bolt and tighten to 20 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
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3/8” flanged lock nuts and tighten until bracket flexes slightly.
7. Insert carriage bolts into axle bracket as
shown and attach saddle using flat washers
and flanged lock nuts as shown. Reposition
brake line as required to prevent brake line
from contacting carriage bolt. Tighten to 25
ft-lb.
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Driver’s Side
Passenger Side
Heat Shield
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8
8. 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.
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9. Complete passenger and driver’s side installation of air spring assembly.
10.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.
11.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. Alength of heat shielding is provided to protect the air line as it
exits the passenger side air spring.
12. Inflate air springs to 40 psi and check for leaks. Asoapy water solution can
be used to find slow leaks.
13.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.
14.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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