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INSTALLATION INSTRUCTIONS
6118Air Spring Kit
2008 F-450 Dual Wheel 2WD/4WD
Accommodates High clearance fifth wheel hitch
Thank you for purchasing a quality Hellwig Product.
PLEASE READ THIS INSTRUCTION SHEET COMPLETELYBEFORE STARTING
YOUR INSTALLATION
IMPORTANT NOTES
DO NOT INFLATEAIR SPRINGASSEMBLYUNLESS IT HAS BEEN
PROPERLY INSTALLED ON VEHICLE.
DO NOT INFLATEAIR 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 LEVEL LOAD 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 TO YOURVEHICLE 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 OR LEAKAGE MAY
RESULT.
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
wrench or socket.
1
2. Install fitting in port of air spring. Torque fitting to approximately 20 ft-lb.
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Use this hole in frame rail
3
3/8” x 2” Bolt
3. Install upper frame bracket and insert 3/8” X 2” bolt with washer, and lock washer
through hole in frame as shown in photo. Align slotted hole in bracket with bolt and
place bracket squarely against bottom of frame rail.
3/4” Fastener
4. Locate Large hole in frame rail.
Attach frame bracket using supplied 3/4” bolt, flat washers, lock
washer, and nut with washers on
both sides of rail and bolt head on
3/8” x 2” Bolt
outside of rail. Leave loose for adjustment later.
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Passenger Side shown—Driver side opposite
Attach air spring to
inboard holes
Forward
5. Orient axle bracket as shown in photo to prepare for attachment of air spring.
When installed on vehicle, the air spring will attach to the inboard holes.
6. Attach air spring as shown in photo using flanged serrated locknuts. Torque to
25 ft-lb.
Forward
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Driver Side
3/4” Fastener
Heat Shield
Passenger Side
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7. Insert air spring assembly between frame and axle as shown. Install heat shield on
passenger side as shown in photo Attach air spring to frame rail with 3/8” X 2” bolt
inserted in step 3 and torque to 25 ft-lb. Torque 3/4” bolt to 100 ft-lb.
Driver Side
Passenger Side
Carriage Bolts
Unclip brake line to allow clearanceto
carriage bolt. Boltthreads must not
Retainer Plate
contact brake line.
8. Insert carriage bolts into slots in axle bracket and attach plate to bottom of axle tube
with locknuts and washers as shown in photo. It may be necessary to reposition brake
lines slightly to allow clearance. The passenger side brake line may be un-clipped
from the axle tube to provide additional clearance to carriage bolts. Make sure that
carriage bolts will not contact brake lines during operation of vehicle. Algin
brackets and torque nuts to 20-25 ft-lb.
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9. Complete passenger and driver’s side installation of air spring assembly.
10. 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 CUTTING AIR BRAKE TUBING, A SQUARE CUT IS RE-
QUIRED 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.
Air lines with shielding
Emergency Brake Cable
Driver Side Frame Rail —Tie off both pass and
driver side air lines with shielding installed to emergency brake cable at frame hanger next to fuel tank.
From this point air lines can be routed as desired.
Emergency Brake Cable
Driver Side—route air
line in gentle arc to
emergencybrake cable.
Tie to cablewith pass
side air line.
Emergency Brake hanger
Driver Side – Place shielding on air hose as it exits
fitting to protect hose from
chafing on brackets and
fittings.
Pass Air Line
Place shielding on pass side air
line and tie to emergency brake
cable at top of axle.
Pass side—route air line
to top of axle with
shielding at top of axle
11. Route air lines as shown along the emergency brake cables. Lines MUST be routed as shown
with shielding and tie straps installed on air lines as shown. Failure to install air lines as shown will
result in excessive flexing of air lines and potential leaks. Air lines can be routed as required after being tie strapped to the emergency brake cable frame hanger on driver side frame rail near fuel tank.
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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. Inflate air springs to 40 psi and check for leaks. Asoapy 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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