559-734-7451 800-367-5480 FAX 559-734-7460
INSTALLATION INSTRUCTIONS
6216Air Spring Kit
2003+ Dodge 2500/3500 2WD & 4WD
2006+ 1500 Mega Cab 2WD & 4WD
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 IN AIR SPRINGS
AFTER INSTALLATION FOR WARRANTY TO 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 VEHICLEWEIGHT RATING.
OVERINFLATIONAND IMPROPER USE MAY RESULT IN PERSONAL
INJURYAND/OR DAMAGETO YOUR VEHICLEAND PROPERTY.
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559-734-7451 800-367-5480 FAX 559-734-7460
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.
4 Wheel Drive2 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. Make sure that fitting is oriented as
shown in photo.
2
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559-734-7451 800-367-5480 FAX 559-734-7460
3
Attach air spring to plate using forward end of slot
3. Lay out base plate as shown in photo. Attach air spring to base plate using 3/8” x
1” bolt as shown in photo. Torque to 20-25 ft-lb.
4. Install heat shield and frame bracket
as shown. (Passenger side shown.
Drivers side heat shield not required)
Torque nuts to 20 ft-lb.
4
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559-734-7451 800-367-5480 FAX 559-734-7460
5. Attach reinforcement strap to frame
bracket as shown. Leave loose for adjustment later.
5
6
6. Insert 3/8 x 1” stud into adapter plate as shown. Make sure thread is fully engaged into plate. Leave 1/2 thread exposed on back side of plate as shown in
photo. Red lock-tite can be added to threads if desired.
4WD Shown
7. Attach adapter plate to frame
rail using supplied M10-1.5 X
30 flat head bolt. Align slotted
hole with existing hole in frame
rail and tighten flat head bolt to
20-25 ft-lb.
7
7
6216 ( R-6216) 11/22/06
559-734-7451 800-367-5480 FAX 559-734-7460
8. Insert assembly between frame
rail and axle and attach frame
bracket using 3/8” flange nut to stud
and supplied M10-1.5 x 30 flange
bolt to existing threaded hole in
frame. Align bracket and torque
bolts to 20-25 ft-lb.
2WD Shown
8
Reinforcement strap
9. Slide reinforcement strap
firmly against frame rail and
tighten fasteners to 25 ft-lb.
Make sure reinforcement strap
fits flush with rail after tightening bolts.
9
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4WD Shown
559-734-7451 800-367-5480 FAX 559-734-7460
10. Insert cap screws into slots in
axle bracket as shown and attach
saddle using supplied washers and
locknuts. Tighten to 20-25 ft-lb.
11
10
4WD Shown
Reinforcement strap
2WD Shown
11. 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 shield is positioned for maximum protection
of air spring.
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559-734-7451 800-367-5480 FAX 559-734-7460
12. Complete passenger and driver’s side installation of air spring assembly.
13.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.
14.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 TUB-
ING, A SQUARE CUT IS REQUIREDAND 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.
15.Inflate air springs to 40 psi and check for leaks. Asoapy water solution can be
used to find slow leaks.
16.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.
17.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 RE-
CEIVES THIS INSTRUCTION SHEET, ALL IMORTANT NOTE CARDS
AND THE WARRANTY FORM.
6216 ( R-6216) 11/22/06
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