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INSTALLATION INSTRUCTIONS
6111 Air Spring Kit
2011+ Ford F250/F-350 Single Wheel 2WD
2011+ Ford F350 Dually 2WD
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING
YOUR INSTALLATION
IMPORTANT NOTES
DO NOT INFLATE ANYAIR SPRINGASSEMBLYUNLESS IT HAS BEEN
PROPERLY INSTALLED ON VEHICLE.
DO NOT INFLATE AIR SPRINGS OVER 100 PSI
AMINIMUM OF 5-10 PSI MUST BE MAINTAINED IN AIR 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.
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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.
1. Park vehicle securely and set parking brake and chock wheels. Jack up
frame of vehicle to allow clearance to install air spring assembly. Rest
frame of vehicle on jack stands before working on or under vehicle.
2. Remove factory bump stops from vehicle by
removing nuts from studs using a 15mm wrench
or socket.
3. Install fitting in port of air spring. Torque fitting to approximately 20 ft-lb.
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3
3/8 X 1” Bolts
torque to 20 ft-lb.
Brake hose bracket—
leave loose to be attached to a new bracket
later.
Axle vent fitting
3/8” X 2”
threaded stud to
be inserted into
hole on frame for
bump stop stud
Heat Shield—
pass side only
3. Disconnect brake hose
bracket from axle by removing vent tube fitting from axle.
Reconnect vent tube fitting
without brake bracket.
Brake bracket will be attached
to a new bracket later.
4. Install frame bracket to air
spring with 3/8 X 1” bolts.
Install heat shield as shown
for passenger side only.
Torque nuts to 20 ft-lb. Install 3/8” X 2” threaded stud
into frame bracket as shown.
Torque Air fitting
4
to 20 ft-lb.
5. Attach axle bracket to bottom of air spring using 3/8” X
1” bolts and washers leave
loose for adjustment later.
5
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Make sure brake relocation
bracket is installed so that
threaded stud and flange
nut can be installed.
Outside of Frame
Front of Vehicle
559-734-7451 800-367-5480 FAX 559-734-7460
Attach axle bracket so that it is located under
frame bracket with exposed slotted holes oriented outboard.
5
DRIVER SIDE ONLY—for single wheel models (not required for dual
wheel applications with single rear brake hose)— Attach brake relocation
bracket as shown with bracket pointing inboard on the rear side of assembly
as shown. Use 3/8” X 1-1/4” bolts and washers. Torque to 20-25 ft-lb.
5. Attach axle bracket to bottom of air spring using 3/8” X 1” bolts and washers
as shown in photos. Axle bracket must be attached so that it is located under the
frame bracket with exposed slotted holes oriented outboard. For single rear
wheel models (not required for dual wheel applications with single rear
brake hose) - Attach brake relocation bracket to driver side as shown in photos. Make sure that threaded stud and flange nut can be installed when brake relocation bracket is installed. Torque bolts to 20-25 ft-lb.
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Remove 8mm bolt before
installing air spring assembly. Replace with
M8-1.25xX40 bolt and
washer included in kit.
3/4” bolt without
washer on inside of
frame.
Driver Side
6a 6b 6c
Driver Side
Passenger Side
6. Driver Side: Before installing air spring assembly, remove 8mm bolt in location shown in
figure 6a. This bolt will be replaced with a M8-1.25xX40 bolt and washer kit after installing
air spring assembly. To install air spring assembly, insert between frame and axle as shown
with the axle bracket resting on axle—note fit of brackets to frame and axle. Stud on frame
bracket will install in hole where bump stops were attached. Fasten stud on frame bracket to
frame rail with 3/8” lock nut and washer. Install 3/4” bolt, washer and nut through hole in
frame rail. No washer will be used between the head of the 3/4” bolt and the inside of the
frame rail on the driver side. After aligning assembly to rail, Tighten M8-1.25 bolt to 15 ftlb. Then tighten nut on stud to 20 ft-lb. Finally tighten 3/4” bolt to 100-125 ft-lb. If bolt is
used by fifth wheel hitch mounting brackets, tighten bolt to hitch manufacturer’s specifications. Special Note: If vehicle has factory installed fifth wheel hitch, do not install 3/4”
bolts. See step 7 for instructions.
Passenger Side : To install air spring assembly, insert between frame and axle as shown with
the axle bracket resting on axle -note fit of brackets to frame and axle. Stud on frame bracket
will install in hole where bump stops were attached. Fasten stud on frame bracket to frame
rail with 3/8” lock nut and washer. Install 3/4” bolt, washer and nut through hole in frame
rail. Then tighten nut on stud to 20 ft-lb. Finally tighten 3/4” bolt to 100-125 ft-lb. If bolt is
used by fifth wheel hitch mounting brackets, tighten bolt to hitch manufacturer’s specifications. Special Note: If vehicle has factory installed fifth wheel hitch, do not install 3/4”
bolts. See step 7 for instructions.
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Factory Installed 5th Wheel Only
3/8” Bolts
7
7. If vehicle has factory installed 5th
wheel, it will cover the mounting holes
for the 3/4” bolt. Do not install 3/4” bolt.
Drill 2 holes in each frame rail using the
frame bracket as a guide and fasten to rail
using 3/8X1-1/4” Grade 8 bolts, washers
and locknuts as shown. BEFORE DRILL-
ING ANY HOLES IN THE RAIL—
RELOCATE AND/OR PROTECT ANY
FUEL, ELECTRICAL OR BRAKE LINES
THAT MAY INTERFERE WITH THE
DRILL BIT OR INSTALLATION.
8. Install threaded rods and flanged
locknuts as shown in picture.
Threaded rods should be installed so
that the threads slightly protrude above
top of axle bracket. Tighten flanged
Flanged Locknut
lock nuts to 20 ft-lb to lock threaded
rods to bracket. Attach saddle
bracket to threaded rods as shown with
Threaded Rod
3/8” locknuts and washers. Reposition
brake lines or cables so that they will
not interfere with the bracket or the
Saddle Bracket
threaded rods. Tighten locknuts to 2025 ft-lb.
Locknut 8
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Dual Brake Line requires relocation
3/8X1” Bolt
10a
Brake Relocation Bracket
Brake hose bracket
Axle Vent
Single Brake Line does
not require relocation
9b
9. Attach brake hose bracket to brake relocation bracket as shown using 3/8X1”
bolts, washers and locknuts. Tighten bolts to 20-25 ft-lb. Reposition brake lines
as required to avoid any contact with shock absorber. Note location of brake
hoses, electrical lines or any other component that may contact air spring assembly
and reposition as required.
10. 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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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. 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. A soapy 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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