Hellwig Air 6212 User Manual

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

INSTALLATION INSTRUCTIONS

6212 Air Spring Kit

Dodge 2500/3500 Single and Dual Rear Wheels

Dodge 1500 Mega Cab

Thank you for purchasing a quality Hellwig Product.

PLEASE READ THIS INSTRUCTION SHEET COMPLETELY BEFORE STARTING

YOUR INSTALLATION

DO NOT

PROPERLY INSTALLED ON VEHICLE.

DO NOT

A MINIMUM OF
AFTER INSTALLATION FOR WARRANTY TO BE VALID. FAILURE TO
KEEP MINIMUM PRESSURE IN AIR SPRINGS WILL VOID WARRANTY.

THIS UNIT IS DESIGNED TO INCREASE THE LEVEL LOAD CARRYING
CAPACITY OF YOUR VEHICLE. NEVER LOAD THE VEHICLE THIS
UNIT IS INSTALLED ON BEYOND THE MANUFACTURER’S MAXIMUM
GROSS VEHICLE WEIGHT RATING.

INFLATE AIR SPRING ASSEMBLY UNLESS IT HAS BEEN

INFLATE AIR SPRINGS OVER 100 PSI

IMPORTANT NOTES

10

PSI MUST BE MAINTAINED IN AIR SPRINGS

OVERINFLATION AND IMPROPER USE MAY RESULT IN PERSONAL
INJURY AND/OR DAMAGE TO YOUR VEHICLE AND PROPERTY.

6212 ( R-6212 ) 08/17/2012

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BEFORE STARTING YOUR 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.

4 Wheel Drive 2 Wheel Drive

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

6212 ( R-6212 ) 08/17/2012

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3/8 x 1” Studs. Apply
locktite to threads
before installation

3. Prepare frame adapter
plates for mounting to vehicle
frame by installing 3/8 x 1”
studs into threaded holes as
shown. Apply locktite to
threads before installation.

4. Attach frame adapter plates to frame rails as shown using M10-1.5 x 30 flat head
cap screws. Torque to 25 ft-lb.

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3/8 x 3/4 Flat Head
Cap Screw

3/8 x 1” Studs. Apply
locktite to threads
before installation

3/8 x 3/4 Flat Head
Cap Screw

Heat Shield.

Passenger Side Driver Side

5. Attach mounting plates to air springs with 3/8 x 3/4” flat head cap screws as shown. In­stall heat shield on passenger side assembly as shown. Note location of fasteners for
driver and passenger side assembly. Torque flat head cap screws to 20-25 ft-lb. Apply

Attach bracket to bottom of air spring
with 3/8 x 1” bolts and washers as shown
using these holes. Torque to 20 ft lb.

Passenger Side

6. Attach axle bracket to bottom of air spring with 3/8 x 1” bolts and washers as shown.

The bracket should be attached so that the bracket is oriented outboard from the centerline
of the air spring as installed on vehicle. Passenger side shown. Torque bolts to 20 ft-lb.

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Driver Side

Fasten plates
together with
flange nuts on
3/8 x 1” studs.

7

7. Place air spring assembly between the axle and the frame rail as shown and in­sert threaded studs through mating holes in plates. Fasten plates together by at­taching 3/8 flanged nuts to 3/8 x 1” studs in frame adapter only. Torque to 20-25
ft-lb.

Slide reinforcement
bracket squarely
against frame rail

8

3/8 x 1-1/2” stud

8. Place reinforcement bracket on 3/8 x 1-1/2” studs and attach with 3/8” flanged
nuts. Slide bracket squarely against frame rail and tighten nuts to 20-25 ft-lb.

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Insert cap screws
into slots in axle
bracket as shown.

Attach saddle with cap
screws and lock nuts.
Torque to 20-25 ft-lb.

9. Insert cap screws into slots in axle bracket as shown and attach saddle using
supplied washers and locknuts. Tighten to 20-25 ft-lb.

6212 ( R-6212 ) 08/17/2012

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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. WHEN CUTTING AIR BRAKE

TUBING, A SQUARE CUT IS REQUIRED AND THE HOSE END
MUST NOT BE DEFORMED OR LEAKAGE MAY RESULT. IF DEF­FORMATION 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. 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 10 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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